WATERLESS YARN DYEING SYSTEM, SPRAY DEVICE THEREOF, AND COLOR DEVELOPMENT AND DYE FIXATION EQUIPMENT THEREOF

Abstract

A waterless yarn dyeing system is adapted for outputting a liquid to a plurality of yarns. The waterless yarn dyeing system includes a piece of dyeing equipment, and a piece of color development and dye fixation equipment. The dyeing equipment includes a liquid supply device, and a spray device. The spray device includes a lower body that communicates with the liquid supply device, and an upper body that communicates with the liquid supply device and that is connected to an upper side of the lower body. The color development and dye fixation equipment includes a dye fixation device that includes a body unit, a heater unit, and a circulation unit. The body unit has a heating space that is adapted for the plurality of yarns to pass therethough, a lower vent that is located below the heating space, and an upper intake that is located above the heating space.

Claims

1. A waterless yarn dyeing system adapted for outputting a liquid to a plurality of yarns, the waterless yarn dyeing system comprising: a piece of dyeing equipment including a liquid supply device, and a spray device that includes a lower body which communicates with the liquid supply device, and an upper body which communicates with the liquid supply device and which is connected to an upper side of the lower body in an up-down direction, the lower body and the upper body cooperatively defining a plurality of passages that extend in a first direction which is perpendicular to the up-down direction, and that are spaced apart from each other in a second direction which is perpendicular to the first direction and the up-down direction, the plurality of passages communicating with the liquid supply device and being adapted for the plurality of yarns to respectively pass therethrough; and a piece of color development and dye fixation equipment including a dye fixation device, the dye fixation device including a body unit that has a heating space which is adapted for the plurality of yarns to pass therethough, a lower vent which is located below the heating space, and an upper intake which is located above the heating space, a heater unit that is disposed on the body unit and that is located between the heating space and the upper intake, the heater unit being adapted for outputting a hot air flow to the plurality of yarns in the heating space, and a circulation unit that includes a circulation plumbing which is disposed on an outside of the body unit, a blower which is disposed on the circulation plumbing, and a filter which is disposed between the lower vent and the heating space, the circulation plumbing having two opposite ends that respectively communicate with the lower vent and the upper intake, the blower being operable to transfer air from the heating space sequentially through the filter, the lower vent, and the circulation plumbing to the upper intake.

2. The waterless yarn dyeing system as claimed in claim 1, further comprising a piece of yarn winding equipment connected downstream of the piece of color development and dye fixation equipment, the piece of yarn winding equipment having a plurality of yarn pass eyelets that are adapted for the plurality of yarns to pass therethrough, and a winder unit, the winder unit having a winder frame, a plurality of frame eyelets that are disposed on the winder frame, a plurality of yarn winders that are disposed on the winder frame, and an electric motor subunit that is disposed on the winder frame, the plurality of yarn winders being driven by the electric motor subunit to rotate so as to wind the plurality of yarns.

3. A spray device adapted for communicating with a liquid supply device and outputting a liquid from the liquid supply device to a plurality of yarns, the spray device comprising: a lower body adapted for communicating with the liquid supply device; and an upper body adapted for communicating with the liquid supply device, and connected to an upper side of the lower body in an up-down direction, the lower body and the upper body cooperatively defining a plurality of passages that extend in a first direction which is perpendicular to the up-down direction, and that are spaced apart from each other in a second direction which is perpendicular to the first direction and the up-down direction, each of the plurality of passages communicating with the liquid supply device and being adapted for a respective one of the plurality of yarns to pass therethrough.

4. The spray device as claimed in claim 3, wherein: the lower body has a first inner surface that faces the upper body, a first outer surface that is opposite to the upper body, and a plurality of lower channel units that are spaced apart from each other in the first direction, each of the plurality of lower channel units having a plurality of lower channels each of which extends from a respective one of the plurality of passages and is adapted for communicating with the liquid supply device; and the upper body has a second inner surface that abuts against the first inner surface of the lower body, a second outer surface that is opposite to the lower body, and a plurality of upper channel units that are spaced apart from each other in the first direction, each of the plurality of upper channel units having a plurality of upper channels each of which extends from a respective one of the plurality of passages and is adapted for communicating with the liquid supply device.

5. The spray device as claimed in claim 4, further comprising a plurality of nozzles that are respectively disposed on the plurality of upper channels of the plurality of upper channel units and the plurality of lower channels of the plurality of lower channel units.

6. The spray device as claimed in claim 4, wherein the plurality of upper channels of the plurality of upper channel units respectively face the plurality of lower channels of the plurality of lower channel units in the up-down direction.

7. The spray device as claimed in claim 4, wherein the lower body further has a plurality of lower grooves that extend in the first direction, that are spaced apart from each other in the second direction, and that are formed in the first inner surface, the upper body further having a plurality of upper grooves that extend in the first direction, that are spaced apart from each other in the second direction, and that are formed in the second inner surface, each of the plurality of lower grooves cooperating with a respective one of the plurality of upper grooves to form a respective one of the plurality of passages.

8. The spray device as claimed in claim 4, wherein: the lower body further has a plurality of lower passage surfaces, the upper body further having a plurality of upper passage surfaces, each of the plurality of lower passage surfaces having two lower sloping surfaces and a lower concave surface that interconnects the lower sloping surfaces, each of the plurality of upper passage surfaces having two upper sloping surfaces that are respectively adjacent to the lower sloping surfaces of a respective one of the plurality of lower passage surfaces, and an upper concave surface that interconnects the upper sloping surfaces and that is located above the lower concave surface of the respective one of the plurality of lower passage surfaces, the upper sloping surfaces and the upper concave surface of each of the plurality of upper passage surfaces cooperating with the lower sloping surfaces and the lower concave surface of the respective one of the plurality of lower passage surfaces to define a respective one of the plurality of passages; for each of the plurality of lower passage surfaces, a distance between the lower sloping surfaces increases as the lower sloping surfaces extend away from the lower concave surface, and the lower concave surface is curved; and for each of the plurality of upper passage surfaces, a distance between the upper sloping surfaces increases as the upper sloping surfaces extend away from the upper concave surface, and the upper concave surface is curved.

9. The spray device as claimed in claim 4, wherein the first outer surface of the lower body is formed with a plurality of lower installation grooves that respectively communicate with the plurality of lower channel units, the second outer surface of the upper body being formed with a plurality of upper installation grooves that respectively communicate with the plurality of upper channel units, the spray device further comprising a plurality of spray modules that are respectively disposed on the plurality of lower installation grooves and the plurality of upper installation grooves, each of the plurality of spray modules having a plurality of spray channels, the plurality of spray channels of the plurality of spray modules being adapted for communicating with the liquid supply device, and respectively communicating with the plurality of upper channels of the plurality of upper channel units and the plurality of lower channels of the plurality of lower channel units.

10. The spray device as claimed in claim 3, wherein the lower body has a plurality of drainage channels that respectively communicate with the plurality of passages, each of the plurality of drainage channels being adapted for draining the liquid in the respective one of the plurality of passages when there is the liquid in the respective one of the plurality of passages.

11. A piece of color development and dye fixation equipment adapted for heating a plurality of yarns that are moistened by a liquid and fixing the liquid to the plurality of yarns, the piece of color development and dye fixation equipment comprising: a dye fixation device including a body unit that has a heating space which is adapted for the plurality of yarns to pass therethough, a lower vent which is located below the heating space, and an upper intake which is located above the heating space, a heater unit that is disposed on the body unit and that is located between the heating space and the upper intake, the heater unit being adapted for outputting a hot air flow to the plurality of yarns in the heating space, and a circulation unit that includes a circulation plumbing which is disposed on an outside of the body unit, a blower which is disposed on the circulation plumbing, and a filter which is disposed between the lower vent and the heating space, the circulation plumbing having two opposite ends that respectively communicate with the lower vent and the upper intake, the blower being operable to transfer air from the heating space sequentially through the filter, the lower vent, and the circulation plumbing to the upper intake.

12. The piece of color development and dye fixation equipment as claimed in claim 11, wherein the dye fixation device further includes a yarn separation unit, the yarn separation unit including a plurality of first yarn separation rollers that are rotatably disposed in the heating space, and a plurality of second yarn separation rollers that are rotatably disposed in the heating space, the plurality of first yarn separation rollers and the plurality of second yarn separation rollers being disposed in an alternating arrangement, each of the plurality of first yarn separation rollers and the plurality of second yarn separation rollers having a plurality of annular grooves that are adapted for the plurality of yarns to be spaced apart from each other and be disposed thereon.

13. The piece of color development and dye fixation equipment as claimed in claim 12, wherein the yarn separation unit further includes a synchronization belt that passes over the plurality of first yarn separation rollers, an actuation motor that is disposed on the body unit and that is operable to drive one of the plurality of first yarn separation rollers to rotate, and a controller that is electrically coupled to the actuation motor, the one of the plurality of first yarn separation rollers driving remaining ones of the plurality of first yarn separation rollers to rotate via the synchronization belt when the one of the plurality of first yarn separation rollers rotates, the controller being operable to receive data of a conveying speed of the plurality of yarns and to control a rotational speed of the actuation motor according to the data of the conveying speed of the plurality of yarns so that each of the plurality of first yarn separation rollers rotates at a speed that matches the conveying speed of the plurality of yarns.

14. The piece of color development and dye fixation equipment as claimed in claim 12, wherein the plurality of second yarn separation rollers are movably disposed on the body unit, and movable relative to the body unit in an up-down direction, the yarn separation unit further including a base seat that is disposed on the body unit and at least one lift member that is disposed on the body unit, the plurality of second yarn separation rollers being mounted to the base seat, the at least one lift member being operable to drive the base seat to move in the up-down direction.

15. The piece of color development and dye fixation equipment as claimed in claim 11, further comprising a dryer device that is connected upstream of the dye fixation device, the dryer device including a machine base and a dryer unit, the machine base having a dryer space that is adapted for the plurality of yarns to pass therethrough, the dryer unit being disposed on the machine base and being adapted for heating the plurality of yarns that are in the dryer space.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Other features and advantages of the disclosure will become apparent in the following detailed description of the embodiment(s) with reference to the accompanying drawings. It is noted that various features may not be drawn to scale.

[0015] FIG. 1 is a schematic view illustrating an embodiment of a waterless yarn dyeing system according to the disclosure.

[0016] FIG. 2 is a block diagram illustrating an ink mixture control unit, an ink temperature control unit, and a plurality of pump units of a piece of dyeing equipment of the embodiment.

[0017] FIG. 3 is a fragmentary system schematic diagram illustrating a spray device of the dyeing equipment outputting an ink to a plurality of yarns.

[0018] FIG. 4 is a partly exploded perspective view of the spray device.

[0019] FIG. 5 is a fragmentary system schematic diagram illustrating the spray device outputting the ink to one of the yarns.

[0020] FIG. 6 is a schematic view of a piece of color development and dye fixation equipment of the embodiment.

[0021] FIG. 7 is a fragmentary perspective view illustrating the yarns winding around one of a plurality of first yarn separation rollers and one of a plurality of second yarn separation rollers of the color development and dye fixation equipment.

[0022] FIG. 8 is a fragmentary, enlarged side view of the one of the first yarn separation rollers.

[0023] FIG. 9 is a fragmentary schematic view illustrating a modification of the spray device.

[0024] FIG. 10 is a fragmentary schematic view illustrating the modification of the spray device from another viewing angle.

[0025] FIG. 11 is a fragmentary schematic view illustrating a piece of yarn winding equipment of the embodiment.

DETAILED DESCRIPTION

[0026] Before the disclosure is described in greater detail, it should be noted that where considered appropriate, reference numerals or terminal portions of reference numerals have been repeated among the figures to indicate corresponding or analogous elements, which may optionally have similar characteristics.

[0027] It should be noted herein that for clarity of description, spatially relative terms such as top, bottom, upper, lower, on, above, over, downwardly, upwardly and the like may be used throughout the disclosure while making reference to the features as illustrated in the drawings. The features may be oriented differently (e.g., rotated 90 degrees or at other orientations) and the spatially relative terms used herein may be interpreted accordingly.

[0028] Referring to FIGS. 1 to 3, an embodiment of a waterless yarn dyeing system according to the disclosure is adapted for outputting a liquid to a plurality of yarns (S). In this embodiment, the liquid is configured to be an ink. The waterless yarn dyeing system includes a piece of yarn feeding equipment 100, a piece of yarn separation equipment 200, a piece of dyeing equipment 300, a piece of color development and dye fixation equipment 400, and a piece of yarn winding equipment 800. It is noted that, in this embodiment, the ink may be a dye, or a combination of a dye, water, and a textile auxiliary.

[0029] The yarn feeding equipment 100 includes a yarn feeding roller 101 that is wound around by the yarns (S). The yarn feeding roller 101 is operable to rotate so as to output the yarns (S).

[0030] The yarn separation equipment 200 is connected downstream of the yarn feeding equipment 100. The yarn separation equipment 200 includes a yarn separation base 11, a yarn separation reed 12 that is disposed on the yarn separation base 11, a yarn separation roller 13, and a yarn separation plate 14.

[0031] The yarn separation reed 12 has a plurality of reed gaps (not shown) that are adapted for separating the yarns (S). The yarn separation roller 13 is formed with a plurality of annular grooves (not shown) that are adapted for the yarns (S) to be spaced apart from each other and to be disposed thereon, and is operable to rotate at a speed that matches a conveying speed of the yarns (S). Therefore, tension of the yarns (S) is kept stable, and a risk that the yarns (S) may break is reduced. The yarn separation plate 14 has a plurality of separation grooves (not shown) that are adapted for the yarns (S) to be spaced apart from each other and to be disposed thereon so that the yarns (S) may enter the dyeing equipment 300 while being spaced apart from each other and in alignment. When the yarns (S) are dyed, a textile auxiliary or solvent that is required before dyeing the yarns (S) may be poured into the separation grooves to increase ink absorbency of the yarns (S).

[0032] The dyeing equipment 300 includes a liquid supply device 2, a spray device 3 that is connected downstream of the yarn separation equipment 200, a suction device 4, a plurality of pump units 5, and an ink mixture control unit 6.

[0033] Referring to FIGS. 1 to 4, the liquid supply device 2 includes a plurality of ink containers 21, a plurality of ink supply tubes 22 that are respectively connected to the ink containers 21, an ink tank 23 that is connected downstream of the ink containers 21 and that is connected to the ink supply tubes 22, a stir unit 24 that is disposed in the ink tank 23, an ink temperature control unit 25 that is disposed in the ink tank 23, and a duct module 26 that interconnects the ink tank 23 and the spray device 3. The ink containers 21 are adapted for holding the ink. It is noted that the meaning of the term the ink as used throughout the disclosure may be different based on the context, and may be, for example, a colored/uncolored ink in one/each of the ink containers 21, or a mixture of colored/uncolored inks (i.e., a mixed ink).

[0034] In this embodiment, a number of the ink containers 21 is five. Four of the ink containers 21 respectively hold four different colored inks that correspond to four colors of the CMYK color model, and the remaining one of the ink containers 21 holds a clear ink. The four colors of the CMYK color model are cyan, magenta, yellow, and black. The ink containers 21 are operable to output the different colored inks to the ink tank 23 for mixing the different colored inks. In some embodiments, the number of the ink containers 21 and the colors of the inks are not limited. For example, a user may use three ink containers 21 to hold three different colored inks that correspond to three colors of the RGB color model, in which R represents red, G represents green, and B represents blue.

[0035] The stir unit 24 includes an impeller 241 that is disposed in the ink tank 23, and a motor 242 that is disposed in the ink tank 23 and that is operable for driving the impeller 241 to rotate. The ink temperature control unit 25 includes an ink heater 251 that is disposed in the ink tank 23 and that is adapted for heating the ink which flows into the ink tank 23, and an ink temperature sensor 252 that is disposed in the ink tank 23. The ink heater 251 is configured to be an electric tubular heater or an electric heating plate. The ink temperature sensor 252 is adapted for measuring a temperature of the ink in the ink tank 23.

[0036] The duct module 26 includes a plurality of ink output ducts 261 that interconnect the ink tank 23 and the spray device 3.

[0037] The spray device 3 communicates with the liquid supply device 2, and is adapted for outputting the liquid from the liquid supply device 2 to the yarns (S). The spray device 3 includes a lower body 31, an upper body 32 that is separably connected to an upper side of the lower body 31 in an up-down direction (Z), and a plurality of nozzles 33 that are disposed on the lower body 31 and the upper body 32.

[0038] The lower body 31 communicates with the liquid supply device 2, and has a first inner surface 311 that faces the upper body 32, a first outer surface 312 that is opposite to the upper body 32 in the up-down direction (Z), a plurality of lower grooves 313 that extend in a first direction (X) perpendicular to the up-down direction (Z), that are spaced apart from each other in a second direction (Y) perpendicular to the up-down direction (Z) and the first direction (X), and that are formed in the first inner surface 311, two lower channel units 314 that are spaced apart from each other in the first direction (X), a plurality of drainage channels 316, and a plurality of lower passage surfaces 341. Each of the drainage channels 316 extends from the first outer surface 312 to a respective one of the lower grooves 313. Each of the lower channel units 314 has a plurality of lower channels 315, each of which extends from the first outer surface 312 to a respective one of the lower grooves 313.

[0039] Each of the lower passage surfaces 341 has two lower sloping surfaces 317, and a lower concave surface 318 that interconnects the lower sloping surfaces 317. Each of the lower passage surfaces 341 defines a respective one of the lower grooves 313. The drainage channels 316 are disposed upstream of the lower channels 315.

[0040] The upper body 32 communicates with the liquid supply device 2, and has a second inner surface 321 that abuts against the first inner surface 311 of the lower body 31, a second outer surface 322 that is opposite to the lower body 31 in the up-down direction (Z), a plurality of upper grooves 323 that extend in the first direction (X), that are spaced apart from each other in the second direction (Y), and that are formed in the second inner surface 321, two upper channel units 324 that are spaced apart from each other in the first direction (X), and a plurality of upper passage surfaces 342. Each of the upper channel units 324 has a plurality of upper channels 325, each of which extends from the second outer surface 322 to a respective one of the upper grooves 323. The upper channel units 324 respectively correspond in position to the lower channel units 314. The upper channels 325 of the upper channel units 324 respectively face the lower channels 315 of the lower channel units 314 in the up-down direction (Z).

[0041] Referring further to FIG. 5, each of the upper passage surfaces 342 has two upper sloping surfaces 326 that are respectively adjacent to the lower sloping surfaces 317 of a respective one of the lower passage surfaces 341, and an upper concave surface 327 that interconnects the upper sloping surfaces 326 and that is located above the lower concave surface 318 of the respective one of the lower passage surfaces 341. Each of the upper passage surfaces 342 defines a respective one of the upper grooves 323. The upper grooves 323 respectively face the lower grooves 313. The lower body 31 and the upper body 32 cooperatively define a plurality of passages 34 that extend in the first direction (X), and that are spaced apart from each other in the second direction (Y). Specifically, each of the lower grooves 313 cooperates with the respective one of the upper grooves 323 to form a respective one of the passages 34. More specifically, the upper sloping surfaces 326 and the upper concave surface 327 of each of the upper passage surfaces 342 cooperate with the lower sloping surfaces 317 and the lower concave surface 318 of the respective one of the lower passage surfaces 341 to define a respective one of the passages 34. Each of the passages 34 communicates with the liquid supply device 2, and is adapted for a respective one of the yarns (S) to pass therethrough. Each of the passages 34 communicates with a respective one of the upper channels 325 of each of the upper channel units 324, and with a respective one of the lower channels 315 of each of the lower channel units 314. In this embodiment, for each of the lower channel units 314, each of the lower channels 315 extends from the first outer surface 312 to the respective one of the passages 34, and communicates with the liquid supply device 2. For each of the upper channel units 324, each of the upper channels 325 extends from the second outer surface 322 to the respective one of the passages 34, and communicates with the liquid supply device 2.

[0042] For each of the lower passage surfaces 341, a distance between the lower sloping surfaces 317 increases as the lower sloping surfaces 317 extend away from the lower concave surface 318, and the lower concave surface 318 is curved. For each of the upper passage surfaces 342, a distance between the upper sloping surfaces 326 increases as the upper sloping surfaces 326 extend away from the upper concave surface 327, and the upper concave surface 327 is curved.

[0043] The nozzles 33 are respectively disposed on the upper channels 325 of the upper channel units 324 and the lower channels 315 of the lower channel units 314, and are respectively connected to the ink output ducts 261. Each of the nozzles 33 extends in the up-down direction (Z), is threadedly connected to the lower body 31 or the upper body 32, and is adapted for outputting the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to one of the yarns (S) that are in the passages 34. Specifically, in this embodiment, for the nozzles 33 that are respectively disposed on the upper channels 325 of one of the upper channel units 324, each of the nozzles 33 outputs the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to a respective one of the yarns (S) in the respective one of the passages 34. For the nozzles 33 that are respectively disposed on the upper channels 325 of another one of the upper channel units 324, each of the nozzles 33 outputs the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to a respective one of the yarns (S) in the respective one of the passages 34. For the nozzles 33 that are respectively disposed on the lower channels 315 of one of the lower channel units 314, each of the nozzles 33 outputs the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to a respective one of the yarns (S) in the respective one of the passages 34. For the nozzles 33 that are respectively disposed on the lower channels 315 of another one of the lower channel units 314, each of the nozzles 33 outputs the ink that flows from the ink tank 23 to the respective one of the ink output ducts 261 to a respective one of the yarns (S) in the respective one of the passages 34. In this embodiment, each of the passages 34 corresponds in position to four of the nozzles 33.

[0044] Referring to FIGS. 1, 4 and 5, the suction device 4 includes a suction member 41, and a plurality of drainage ducts 42 (only one of the drainage ducts 42 is shown in each of FIGS. 1 and 5 due to a viewing angle). The suction member 41 is configured to be a pump. Each of the drainage ducts 42 communicates with the suction member 41 and a respective one of the drainage channels 316. The drainage channels 316 respectively communicate with the passages 34. Each of the drainage channels 316 is adapted for draining the liquid in the respective one of the passages 34 when there is the liquid in the respective one of the passages 34.

[0045] It is noted that, in one embodiment, the nozzles 33 that correspond in position to different passages 34 may be respectively connected to the ink containers 21 that respectively hold the different colored inks so as to output the different colored inks from the ink containers 21 to the yarns (S) respectively. Therefore, the spray device 3 may dye the yarns (S) with different colors separately at the same time.

[0046] Referring to FIGS. 1 and 3, the pump units 5 are respectively disposed on the

[0047] ink supply tubes 22 and the ink output ducts 261. Each of the pump units 5 includes an input pump 51, a temporary storage box 52 that communicates with the input pump 51, and an output pump 53 that communicates with the temporary storage box 52. For each of the pump units 5, the input pump 51, the temporary storage box 52, and the output pump 53 are adapted for the ink to flow therethrough in sequence. Each of the pump units 5 further includes a liquid level indicator 54 that is disposed on the temporary storage box 52 thereof, and a scale 55 that is disposed on the temporary storage box 52 thereof.

[0048] Referring to FIGS. 2 and 3, in this embodiment, the ink mixture control unit 6 may be a programmable logic controller (PLC), or other types of controllers. The ink mixture control unit 6 is electrically coupled to the ink heater 251, the ink temperature sensor 252, the input pumps 51, and the output pumps 53. The ink mixture control unit 6 is operable to control the ink heater 251 to heat the ink in the ink tank 23 to a target temperature according to the temperature of the ink in the ink tank 23 that is measured by the ink temperature sensor 252. Moreover, the ink mixture control unit 6 is operable to control a flow rate of the ink that flows through the input pump 51 and the output pump 53 of each of the pump units 5 (i.e., the input pump 51 and the output pump 53 of each of the pump units 5 are operable to adjust the flow rate of the ink) so that a liquid level of the ink in the temporary storage box 52 of each of the pump units 5 is kept at a fixed value. Therefore, an ink pressure of the ink that flows into the output pump 53 of each of the pump units 5 is standardized.

[0049] Referring to FIGS. 1, and 6 to 8, the color development and dye fixation equipment 400 is adapted for heating the yarns (S) that are moistened by the liquid and fixing the liquid to the yarns (S), and includes a dryer device 20, and a dye fixation device 30 that is connected downstream of the dryer device 20. The dryer device 20 includes a machine base 201 that defines a dryer space 202, and a dryer unit 203 that is disposed on the machine base 201. The dryer space 202 is adapted for the yarns (S) (only one of the yarns (S) is shown in FIG. 6 due to the viewing angle) to pass therethrough.

[0050] The dryer unit 203 is adapted for heating the yarns (S) that are in the dryer space 202 so as to dry the ink that is absorbed by the yarns (S). The dryer unit 203 includes a plurality of fans 204 that are disposed on the machine base 201 and that are located above the dryer space 202, and a tubular heater 205 that is disposed on the machine base 201 and that is located between the dryer space 202 and the fans 204. The fans 204 are operable to generate air flows. The air flows that are generated by the fans 204 of the dryer unit 203 flow through the tubular heater 205 of the dryer unit 203 and are heated by the tubular heater 205, and then flow to the dryer space 202. The temperature of the heated air flows that are generated by the dryer unit 203 ranges from about 60 degrees Celsius to about 180 degrees Celsius.

[0051] The dye fixation device 30 includes a body unit 40, and a heater unit 50, a yarn separation unit 60, and a circulation unit 70 that are disposed on the body unit 40.

[0052] The body unit 40 has a heating space 401 that is adapted for the yarns (S) to pass therethrough, a lower vent 402 that is located below the heating space 401, and an upper intake 403 that is located above the heating space 401. The body unit 40 is formed with a plurality of rails 404, each of which extends in the up-down direction (Z).

[0053] The heater unit 50 is located between the heating space 401 and the upper intake 403. The heater unit 50 is adapted for outputting a hot air flow to the yarns (S) in the heating space 401 so as to heat the yarns (S). The heater unit 50 includes a plurality of fans 501 that are disposed below the upper intake 403 of the body unit 40, and a tubular heater 502 that is disposed between the heating space 401 and the fans 501. The fans 501 are operable to generate air flows. The air flows that are generated by the fans 501 of the heater unit 50 flow through the tubular heater 502 of the heater unit 50 and are heated by the tubular heater 502, and then flow to the heating space 401. The temperature of the heated air flows that are generated by the heater unit 50 ranges from about 80 degrees Celsius to about 210 degrees Celsius.

[0054] A temperature that the yarns (S) have to be heated up to differs among different types of the yarns (S). For a cotton yarn, the temperature is about 80 degrees Celsius. For a nylon yarn, the temperature is about 100 degrees Celsius to about 120 degrees Celsius. For a polyester yarn, the temperature is about 140 degrees Celsius to about 210 degrees Celsius.

[0055] The yarn separation unit 60 includes a plurality of first yarn separation rollers 601 that are rotatably disposed in the heating space 401, a plurality of second yarn separation rollers 601 that are rotatably disposed in the heating space 401, a base seat 603 that is disposed on the body unit 40, a plurality of lift members 604 that are disposed on the body unit 40, a synchronization belt 605 that passes over the first yarn separation rollers 601, an actuation motor 606 that is disposed on the body unit 40, and a controller 607 that is electrically coupled to the actuation motor 606. The first yarn separation rollers 601 and the second yarn separation rollers 602 are disposed in an alternating arrangement. The second yarn separation rollers 602 are mounted to the base seat 603. The lift members 604 are operable to drive the base seat 603 to move in the up-down direction (Z).

[0056] Each of the first yarn separation rollers 601 has a plurality of annular grooves 6011 that are adapted for the yarns (S) to be spaced apart from each other and be disposed thereon (i.e., the yarns (S) pass over the first yarn separation rollers 601). A structure of each of the second yarn separation rollers 602 is similar to a structure of any one of the first yarn separation rollers 601. Each of the second yarn separation rollers 602 has a plurality of annular grooves 6021 that are adapted for the yarns (S) to be spaced apart from each other and be disposed thereon (i.e., the yarns (S) pass over the second yarn separation rollers 602).

[0057] The second yarn separation rollers 602 are respectively and movably disposed on the rails 404 of the body unit 40, and each of the second yarn separation rollers 602 is movable relative to the respective one of the rails 404 in the up-down direction (Z). Each of the lift members 604 includes a screw motor 6041 that is disposed on the body unit 40, and a screw rod 6042 that is disposed between the screw motor 6041 and the base seat 603. For each of the lift members 604, the screw motor 6041 is operable to drive the screw rod 6042 to move in the up-down direction (Z) so that the screw rod 6042 drives the base seat 603 to move in the up-down direction (Z). When the base seat 603 is driven to move in the up-down direction (Z), the base seat 603 drives the second yarn separation rollers 602 to move relative to the first yarn separation rollers 601 in the up-down direction (Z). It is noted that in some embodiments, a type or a number of the lift member(s) 604 may not be limited. For example, there may be only one lift member 604, and the lift member 604 may be a piston device that is operable to control the base seat 603 to move in the up-down direction (Z).

[0058] The actuation motor 606 is operable to drive one of the first yarn separation rollers 601 to rotate via a transmission belt (not shown). When the one of the first yarn separation rollers 601 rotates, the one of the first yarn separation rollers 601 drives remaining ones of the first yarn separation rollers 601 to rotate via the synchronization belt 605.

[0059] The yarn winding equipment 800 is connected downstream of the color development and dye fixation equipment 400, and includes a yarn winding roller 801. The controller 607 is operable to receive data of a conveying speed of the yarns (S) from a sensor (not shown) that is disposed on the yarn feeding roller 101 or the yarn winding roller 801, and to control a rotational speed of the actuation motor 606 according to the data of the conveying speed of the yarns (S) so that each of the first yarn separation rollers 601 rotates at a speed that matches the conveying speed of the yarns (S). Therefore, the tension of the yarns (S) is kept stable, and the risk that the yarns (S) may break is reduced. In this embodiment, the controller 607 may be a programmable logic controller (PLC), or other types of controllers.

[0060] The circulation unit 70 includes a circulation plumbing 701 that is disposed on an outside of the body unit 40, a blower 702 that is disposed on the circulation plumbing 701, and a filter 703 that is disposed between the lower vent 402 and the heating space 401. The circulation plumbing 701 has two opposite ends that respectively communicate with the lower vent 402 and the upper intake 403. The blower 702 is operable to transfer air from the heating space 401 sequentially through the filter 703, the lower vent 402, and the circulation plumbing 701 to the upper intake 403. The filter 703 may be a filter net, or a waste gas treatment device.

[0061] A detailed description of a dyeing process of the waterless yarn dyeing system is given below.

[0062] The yarn feeding roller 101 rotates so as to output the yarns (S).

[0063] The yarns (S) pass through the yarn separation reed 12, the yarn separation roller 13, and the yarn separation plate 14 sequentially, and then respectively enter the passages 34 of the spray device 3.

[0064] The ink mixture control unit 6 controls the flow rate of the ink that flows through the input pump 51 and the output pump 53 of each of the pump units 5 which are respectively disposed on the ink supply tubes 22 so that the liquid level of the ink in the temporary storage box 52 of each of the pump units 5 that are respectively disposed on the ink supply tubes 22 is kept at a fixed value. The ink mixture control unit 6 controls the pump units 5 that are respectively disposed on the ink supply tubes 22 so that the four different colored inks in the ink containers 21 are outputted to the ink tank 23 according to color values of the four colors of the CYMK color model of a desired color for ink mixture.

[0065] The ink mixture control unit 6 controls the flow rate of the mixed ink that flows through the input pump 51 and the output pump 53 of each of the pump units 5 which are disposed on the ink output ducts 261 so that the liquid level of the mixed ink in the temporary storage box 52 of each of the pump units 5 that are disposed on the ink output ducts 261 is kept at a fixed value. The ink mixture control unit 6 calculates an amount of the mixed ink that is needed for dyeing each of the yarns (S), and controls the pump units 5 that are disposed on the ink output ducts 261 so that the mixed ink in the ink tank 23 is outputted, through the lower channels 315 or the upper channels 325, to the yarns (S) in the passages 34. For each of the passages 34, the user may choose the nozzles 33 that are disposed on the respective one of the upper channels 325 of one of the upper channel units 324 and a corresponding one of the lower channels 315 which faces the respective one of the upper channels 325 of the one of the upper channel units 324 (i.e., two of the nozzles 33 for each of the passages 34) to output the mixed ink for dyeing the respective one of the yarns (S), or may choose the nozzles 33 that are disposed on the respective one of the upper channels 325 of each of the upper channel units 324 and the respective one of the lower channels 315 of each of the lower channel units 314 (i.e., all of the four nozzles 33 for each of the passages 34) to output the mixed ink for dyeing the respective one of the yarns (S) more completely and evenly.

[0066] In this embodiment, each of the passages 34 communicates with two of the upper channels 325 and with two of the lower channels 315, but is not limited thereto. Because the nozzles 33 that are disposed on the upper channels 325 output the mixed ink by dripping the mixed ink, when the user wants to enhance color evenness of the yarns (S) and prevent the color of the yarns (S) from being discontinuous, each of the passages 34 may be arranged to communicate with more than two of the upper channels 325 or more than two of the lower channels 315 (i.e., the upper body 32 may have more than two upper channel units 324, or the lower body 31 may have more than two lower channel units 314) and additional nozzles 33 may be disposed on the additional upper channels 325/lower channels 315 according to actual requirements to output more mixed ink.

[0067] Superfluous mixed ink in the passages 34 is drawn out by the suction member 41 through the drainage channels 316 and the drainage ducts 42.

[0068] The yarns (S) enter the color development and dye fixation equipment 400 after passing through and being dyed in the spray device 3.

[0069] The dryer unit 203 outputs the heated air flows to dry the mixed ink that is absorbed by the yarns (S) to prevent the first yarn separation rollers 601 or the second yarn separation rollers 602 of the yarn separation unit 60 of the dye fixation device 30 from being stained with the mixed ink, thereby preventing the yarns (S) from ink cross-contamination. In some embodiments, the dryer unit 203 may heat and dry the mixed ink that is absorbed by the yarns (S) by thermal radiation or by microwaves. The heating and drying means may not be limited to the description above.

[0070] Afterwards, the yarns (S) enter the dye fixation device 30, and are conveyed by rotation of each of the first yarn separation rollers 601 and the second yarn separation rollers 602. The heater unit 50 outputs the hot air flow to heat the yarns (S) so that the mixed ink that is absorbed by the yarns (S) is firmly fixed to the yarns (S), thereby achieving the color development of the mixed ink on the yarns (S) and the dye fixation.

[0071] The yarn winding roller 801 of the yarn winding equipment 800 winds the yarns (S) that pass through the color development and dye fixation equipment 400 so that the yarns (S) wind around the yarn winding roller 801 and are collected by the yarn winding roller 801.

[0072] Referring to FIGS. 9 and 10, a modification of the spray device 3 (hereinafter the spray device 3) further has a plurality of installation grooves. Specifically, the first outer surface 312 of the lower body 31 of the spray device 3 is formed with two lower installation grooves 319 that respectively communicate with the lower channel units 314. The second outer surface 322 of the upper body 32 of the spray device 3 is formed with two upper installation grooves 328 that respectively communicate with the upper channel units 324. Each of the lower installation grooves 319 communicates with the lower channels 315 of a respective one of the lower channel units 314, and each of the passages 34 communicates with the respective one of the lower channels 315 of each of the lower channel units 314. Each of the upper installation grooves 328 communicates with the upper channels 325 of a respective one of the upper channel units 324, and each of the passages 34 communicates with the respective one of the upper channels 325 of each of the upper channel units 324.

[0073] The spray device 3 further includes four spray modules 35 that are respectively disposed on the lower installation grooves 319 and the upper installation grooves 328, and a piezo switch module (not shown) that is connected to the spray modules 35. Each of the spray modules 35 has a plurality of spray channels 351. The spray channels 351 communicate with the duct module 26 of the liquid supply device 2, and respectively communicate with the upper channels 325 of the upper channel units 324 and the lower channels 315 of the lower channel units 314. The piezo switch module is operable to output the mixed ink from the ink tank 23 through the ink output ducts 261 and the spray channels 351 to the yarns (S) that are in the passages 34. Thus, the pump units 5 that are disposed on the ink output ducts 261 (i.e., the pump units 5 between the ink tank 23 and the spray device 3) may be omitted.

[0074] It is noted that in some embodiments, the spray device 3 may not be limited to spraying/outputting the ink, and may be adapted for use at different worksites of processing so as to spray/output different types of the liquid.

[0075] For example, an additional spray device 3 may be disposed on the yarn separation equipment 200 so as to output relevant processing liquid, such as equalizing agents, penetrating agents, pH control agents, dye-fixing agents, oil removal agents, etc., to the yarns (S) before the dyeing process of the yarns (S). In addition, the additional spray device 3 may be heated up so that the yarns (S) absorb the relevant processing liquid completely, thereby improving performances of subsequent dyeing and finishing processes.

[0076] Moreover, another additional spray device 3 may be disposed downstream of the color development and dye fixation equipment 400 so as to output another relevant processing liquid, such as anti-phenolic yellowing agents, anti-yellowing agents, water repellents, non-wicking agents, dye-fixing agents, antimicrobial agents, wear-resistant agents, etc., to the yarns (S) after the dye fixation process of the yarns (S). Consequently, evenness of color and luster of the yarns (S) is improved. Furthermore, properties of the yarns (S) are adjustable according to actual requirements of different clients.

[0077] Referring to FIG. 11, a modification of the yarn winding equipment 800 (hereinafter the yarn winding equipment 800) is operable for evenly separating the yarns (S). The yarn winding equipment 800 has a plurality of yarn pass eyelets 801 that are adapted for the yarns (S) to pass therethrough and that are configured to be ceramic eyelets, and a winder unit 802.

[0078] The winder unit 802 has a winder frame 803, a plurality of frame eyelets 804 that are disposed on the winder frame 803, a plurality of yarn winders 805 that are disposed on the winder frame 803, and an electric motor subunit 806 that is disposed on the winder frame 803. The frame eyelets 804 are configured to be ceramic eyelets. The yarn winders 805 are driven by the electric motor subunit 806 to rotate so as to wind the yarns (S).

[0079] Therefore, the yarn winding equipment 800 is capable of separating the yarns (S) evenly and collecting the evenly-separated yarns (S) with the yarn winders 805 thereof. A conventional process in which yarns that randomly wind around yarn winders have to be transported to another yarn separation device to be evenly separated may be omitted. Intricacy of equipment in a waterless dyeing system and space that all equipment in the waterless dyeing system has to occupy are greatly reduced, thereby increasing land use efficiency and reducing cost of the equipment.

[0080] Advantages of the waterless yarn dyeing system according to the present disclosure can be summarized as follows. [0081] 1. By virtue of each of the passages 34 confining the respective one of the yarns (S) to a limited space thereof, and by virtue of the nozzles 33 outputting the ink to both a top side and a bottom side of each of the yarns (S), evenness of spray of the ink is greatly enhanced, and the ink is prevented from spreading to an external environment. Therefore, even though the yarns (S) may rotate or vibrate when they are conveyed, each of the yarns (S) is ensured to be soaked in the ink in the respective one of the passages 34, and absorption of the ink is ensured to be optimized, thereby preventing waste of the ink and improving quality of dyeing. [0082] 2. By virtue of the lower body 31 and the upper body 32 of the spray device 3 being separably connected to each other, the yarns (S) may first be respectively disposed on the lower grooves 313 and then the upper body 32 is connected to the lower body 32. Thus, arrangements of the yarns (S) are simple and may be completed fast. [0083] 3. By virtue of each of the passages 34 communicating with the respective one of the upper channels 325 of each of the upper channel units 324, and with the respective one of the lower channels 315 of each of the lower channel units 314, and by virtue of the nozzles 33 being respectively disposed on the upper channels 325 of the upper channel units 324 and the lower channels 315 of the lower channel units 314, the ink that is sprayed on the yarns (S) is evenly separated. Compared with a structure of a conventional spray device that outputs the ink through a single nozzle, when the yarns (S) are conveyed at a same conveying speed, the spray device 3 according to the disclosure may only need to output a less amount of the ink to allow each of the yarns (S) to absorb a required amount of the ink. Thus, cost of the ink is reduced, and an efficiency of dyeing is increased. [0084] 4. By virtue of a contour of each of the passages 34 that is defined by the upper sloping surfaces 326 and the upper concave surface 327 of the respective one of the upper passage surfaces 342 and the lower sloping surfaces 317 and the lower concave surface 318 of the respective one of the lower passage surfaces 341 being substantially smooth, each of the yarns (S) is prevented from rubbing against the upper sloping surfaces 326 or the upper concave surface 327 of the respective one of the upper passage surfaces 342, or the lower sloping surfaces 317 or the lower concave surface 318 of the respective one of the lower passage surfaces 341 and pilling when the yarn(S) is in contact with the upper sloping surfaces 326 or the upper concave surface 327 of the upper passage surface 342, or the lower sloping surfaces 317 or the lower concave surface 318 of the lower passage surface 341 due to vibration or rotation. Thus, the yarns (S) are prevented from damage or breaking. [0085] 5. By virtue of each of the nozzles 33 extending in the up-down direction (Z), the ink is ensured to be smoothly conveyed to the passages 34 via a shortest path, thereby reducing friction loss when the ink flows. [0086] 6. By virtue of the spray modules 35, a structure of the spray device 3 is simplified, thereby reducing space that the spray device 3 has to occupy. [0087] 7. By virtue of the drainage channels 316, the superfluous ink in the passages 34 may be drawn out, thereby preventing the yarns (S) from absorbing excess ink. [0088] 8. The spray device 3 allows the user to choose different nozzles 33 to output the ink. Thus, the ink may be outputted to only the top sides of the yarns (S) (or only the top side of one of the yarns (S)), only the bottom sides of the yarns (S) (or only the bottom side of one of the yarns (S)), both the top sides and bottom sides of the yarns (S) (or both the top and bottom sides of one of the yarns (S)), or different sides of the yarns (S) (or different sides of one of the yarns (S)). The spray device 3 may provide the user different ink-outputting ways that suit different types of the yarns (S). [0089] 9. By virtue of the spray device 3 evenly coloring/dyeing the yarns (S) by spraying, compared with a conventional dyeing process in which the yarns (S) are impregnated with dyes, water consumption of the waterless yarn dyeing system is greatly reduced. Equipment for water treatment is thus omitted, thereby reducing the cost of the equipment and manufacturing costs. [0090] 10. By virtue of the blower 702 transferring the heated air that has been filtered by the filter 703 from the lower vent 402 through the circulation plumbing 701 to the upper intake 403, the air around the upper intake 403 is kept hot/warm, thereby reducing consumption of energy that the tubular heater 502 requires for heating the air. Moreover, by virtue of the filter 703 filtering the air in the heating space 401, when the ink that is absorbed by the yarns (S) is heated and released into the air, the vaporized ink is prevented from staining the body unit 40, the first yarn separation rollers 601, or the second yarn separation rollers 602, which makes maintenance of the heating space 401 easy and reduces frequency of cleaning and the maintenance of the heating space 401. When the yarns (S) are respectively dyed with different colors, the different colored inks that are released into the air are prevented from staining the yarns (S), thereby preventing the yarns (S) from the ink cross-contamination. [0091] 11. By virtue of the annular grooves 6011 of each of the first yarn separation rollers 601 separating and carrying the yarns (S), by virtue of the annular grooves 6021 of each of the second yarn separation rollers 602 separating and carrying the yarns (S), and by virtue of the yarns (S) being conveyed by the rotation of each of the first yarn separation rollers 601 and the second yarn separation rollers 602, movements of the yarns (S) synchronize with the rotation of each of the first yarn separation rollers 601 and the second yarn separation rollers 602, thereby preventing the yarns (S) from rubbing against the first yarn separation rollers 601 and the second yarn separation rollers 602 when the yarns (S) are conveyed. The tension of the yarns (S) are kept even and stable, and the yarns (S) are prevented from breaking. [0092] 12. By virtue of the yarns (S) passing over the first yarn separation rollers 601 and the second yarn separation rollers 602 (i.e., each of the yarns (S) at least partially surrounding the first yarn separation rollers 601 and the second yarn separation rollers 602), and by virtue of the first yarn separation rollers 601 and the second yarn separation rollers 602 being disposed in the alternating arrangement, the yarns (S) are conveyed along a zigzag path in the up-down direction (Z). Therefore, a conveying path of the yarns (S) in a space with predefined dimensions can be greatly extended, which efficiently saves space of the body unit 40, and extends time that the yarns (S) stay in the heating space 401. Consequently, an effect of the color development and dye fixation is improved. [0093] 13. By virtue of the lift members 604 being operable to drive the base seat 603, and by virtue of the second yarn separation rollers 602 being mounted to the base seat 603, the lift members 604 are operable to drive the second yarn separation rollers 602 to move in the up-down direction (Z) so as to adjust a length of each of the yarns (S) in the heating space 401. Thus, the time that the yarns (S) stay in the heating space 401 is adjustable according to different heating times that different types (i.e., different materials) of the yarns (S) require. Furthermore, it is convenient for the user to remove the yarns (S) from or dispose the yarns (S) to the first yarn separation rollers 601 and the second yarn separation rollers 602 when the second yarn separation rollers 602 are driven to be adjacent to the first yarn separation rollers 601. [0094] 14. By virtue of the controller 607 being operable to control the rotational speed of the actuation motor 606, by virtue of the actuation motor 606 being operable to drive the one of the first yarn separation rollers 601 to rotate, and by virtue of the synchronization belt 605 synchronizing the rotations of the first yarn separation rollers 601, each of the first yarn separation rollers 601 rotates at the speed that matches the conveying speed of the yarns (S). Therefore, the tension of the yarns (S) is kept even and stable, and the risk that the yarns (S) may break is reduced. [0095] 15. By virtue of the dryer device 20 heating and drying the ink that is absorbed by the yarns (S) before the yarns (S) enter the dye fixation device 30, the first yarn separation rollers 601 and the second yarn separation rollers 602 are prevented from being stained with the ink that is absorbed by the yarns (S). Thus, the yarns (S) may not lose color(S), and the first yarn separation rollers 601 and the second yarn separation rollers 602 may not be polluted. In addition, the yarns (S) that are going to subsequently enter the dye fixation device 30 are prevented from the ink cross-contamination, which improves quality of the color development and dye fixation. [0096] 16. By virtue of the yarn winding equipment 800, the yarns (S) that have been heated for the dye fixation may be evenly separated and collected by the yarn winders 805, and may be directly supplied to small equipment or retailers for subsequent uses. The intricacy of the equipment and the space that all equipment has to occupy are reduced, thereby increasing the land use efficiency and reducing the cost of the equipment.

[0097] In the description above, for the purposes of explanation, numerous specific details have been set forth in order to provide a thorough understanding of the embodiment(s). It will be apparent, however, to one skilled in the art, that one or more other embodiments may be practiced without some of these specific details. It should also be appreciated that reference throughout this specification to one embodiment, an embodiment, an embodiment with an indication of an ordinal number and so forth means that a particular feature, structure, or characteristic may be included in the practice of the disclosure. It should be further appreciated that in the description, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of various inventive aspects; such does not mean that every one of these features needs to be practiced with the presence of all the other features. In other words, in any described embodiment, when implementation of one or more features or specific details does not affect implementation of another one or more features or specific details, said one or more features may be singled out and practiced alone without said another one or more features or specific details. It should be further noted that one or more features or specific details from one embodiment may be practiced together with one or more features or specific details from another embodiment, where appropriate, in the practice of the disclosure.

[0098] While the disclosure has been described in connection with what is (are) considered the exemplary embodiment(s), it is understood that this disclosure is not limited to the disclosed embodiment(s) but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.