Beaker type dyeing machine

Abstract

A dyeing machine includes a beaker and a carrier within the beaker. The carrier includes a perforation and supports a sample. A pump assembly circulates a processing solution to a first side of the carrier. The processing solution passes through the perforation for dyeing the sample from the inside-out. The carrier is substantially a cylinder.

Description

[0002] This application claims the benefit of U.S. Provisional Application No. 60/327,223, filed Oct. 5, 2001.

BACKGROUND OF THE INVENTION

[0003] The present invention relates to a beaker type dyeing machine. It finds particular application in conjunction with controlled dyeing of fabrics and other materials in a laboratory setting and will be described with particular reference thereto. It will be appreciated, however, that the invention is also amenable to other like applications.

[0004] Many processes for dyeing fabrics on an industrial scale require that liquids, dyes, and other chemicals be added periodically or intermittently according to some predetermined pattern or sequence. In addition, the dye bath should be suitably agitated to assure uniform dye application. The uniformity of results obtained from batch to batch often depends on the precision with which the liquids, dyes, and chemicals are added, both in terms of amounts as well as timing, as well as the level of agitation received.

[0005] New dyeing processes are constantly being developed. To facilitate this work, laboratory-scale dyeing machines are available for carrying out test dyeing protocols in a laboratory setting.

[0006] In one such conventional laboratory-scale dyeing machine, a dyeing beaker is mounted on a rotating disc. A spool of a sample (e.g., fabric) is completely submerged in a liquid/dye/chemical solution (“the solution”). A flow of the solution is established so that the sample is dyed starting from the outside of the sample spool and moving toward the inner core (i.e., from the outside-in).

[0007] Several disadvantages exist for the conventional laboratory-scale dyeing machine described above. For example, substantially uniform and even dyeing is typically only achieved for relatively small samples (e.g., less than about 70 grams). Furthermore, in part because the sample is completely submerged in the solution, the solution/sample ratio for achieving desirable dyeing results is relatively high (e.g., ≧about 10 milliliters/1 gram). In other words, relatively large amounts of dye and chemical solution is needed to dye relatively smaller samples. Since the solution and sample are typically heated and agitated during the dyeing process, the time and cost of the dyeing process is a function of the amount of dye and chemical solution used. Therefore, the conventional laboratory-scale dyeing machine is time consuming and costly.

[0008] Additionally, conventional laboratory-scale dyeing machines do not replicate the flow of the solution through the sample. More specifically, as discussed above, the flow of the solution in conventional laboratory-scale dyeing machines is from the outside-in. Because commercial dyeing systems typically dye a sample starting from the inside of the sample spool and moving toward the outer edge (i.e., inside-out), the conventional laboratory-scale dyeing machines do not provide an accurate representation of how a sample is dyed in commercial dyeing systems.

[0009] The present invention provides a new and improved apparatus and method which addresses the above-referenced problems.

SUMMARY OF THE INVENTION

[0010] In one embodiment of the present invention, a dyeing machine includes a beaker and a carrier within the beaker. The carrier includes a perforation and supports a sample. A pump assembly circulates a processing solution to a first side of the carrier. The processing solution passes through the perforation for dyeing the sample.

[0011] In one aspect, the carrier defines an interior volume. The first side is an interior side of the carrier and the second side is an exterior side of the carrier. The sample is supported on the exterior side of the carrier.

[0012] In another aspect, the carrier is substantially a cylinder.

[0013] In another aspect, a flow guide element has an input flow port, which receives the processing solution from the storage device, and an output flow port, which transmits the processing solution to the first side of the carrier.

[0014] In another aspect, centrifugal forces cause the processing solution transmitted from the output flow port to coat the first side of the carrier.

[0015] In another aspect, a portion of the carrier is submerged in the processing solution within the storage device.

[0016] In another aspect, a displacement body is within a volume of space defined by the carrier. The pump circulates the processing solution within a gap between the first side of the carrier and the displacement body.

[0017] In another aspect, a storage device houses the processing solution.

[0018] In another embodiment, a dyeing machine includes a dyeing beaker and a support assembly mounting the beaker. A carrier, within the beaker, includes an aperture and supports a sample. A means for circulating circulates a processing fluid to a first side of the carrier. The processing fluid passes through the aperture for dyeing the sample.

[0019] In another embodiment, a method for dyeing a sample includes securing a sample to a sample side of a carrier including a perforation. The carrier is secured within a beaker. A processing solution is circulated to a processing side of the carrier. The processing solution passes through the perforation for dyeing the sample.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to exemplify the embodiments of this invention.

[0021] FIG. 1 illustrates a cross-sectional view of a beaker dyeing machine in accordance with one embodiment of the present invention;

[0022] FIG. 2 illustrates a front view of the carrier partially covered by a sample in one embodiment of the present invention;

[0023] FIG. 3 illustrates a top view of a flow guide element in accordance with one embodiment of the present invention;

[0024] FIG. 4 illustrates a cross-sectional view of the flow guide element of FIG. 3 taken along the lines A-A in accordance with one embodiment of the present invention; and

[0025] FIG. 5 illustrates a cross-sectional view of the flow guide element of FIG. 4 taken along the lines B-B in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENT

[0026] Illustrated in FIG. 1 is a cross-sectional view of a beaker dyeing machine 10 in accordance with one embodiment of the present invention. The machine 10 includes a beaker 12. A permanent magnetic flange 14 is positioned near a bottom of the beaker 12. The beaker 12 is positioned such that the magnetic flange 14 is in an operative engagement with a magnetic drive 16. In the illustrated embodiment, the magnetic drive 16 is external to the beaker 12. However, other embodiments, in which the magnetic drive 16 is included in the beaker 12, are also contemplated.

[0027] A fluid pump 20, impeller 22, and drive shaft 24 are secured to the magnetic flange 14. The flange 14, shaft 24, and impeller 22 are recessed within a flow guide element 26, which rests on the bottom of the beaker 12. The magnet 16 drives the magnetic flange 14 which, in turn, drives the fluid pump 20, impeller 22, and drive shaft 24.

[0028] In one embodiment, the pump 20, magnet flange 14, drive shaft 24, impeller 22, and flow guide element 26 are referred to as a pump assembly. As discussed below, the pump assembly is used as a means for agitating and circulating a processing fluid 30 through the dyeing machine 10.

[0029] A displacement body 32 is positioned above the flow guide element 26 and substantially along a central axis 34 relative to the pump assembly. A material (sample) carrier 36 is positioned around the displacement body 32 and also shares the central axis 34. The carrier 36 defines an interior volume 40 in which the displacement body 32 is positioned. In one embodiment, the carrier 36 and displacement body 32 are substantially cylindrically shaped and are coaxial relative to each other. However, other embodiments, in which the carrier 36 and displacement body 32 are shaped as other objects and/or not coaxially positioned relative to each other, are also contemplated.

[0030] In one embodiment, the sample is a fabric to be dyed. However, other embodiments, in which the sample includes other materials (e.g., polymers, etc.), are also contemplated.

[0031] With reference to FIG. 2, the carrier 36 includes apertures 42 that perforate from a first side (a processing side) 44 (see FIG. 1), which is along an inner surface of the carrier 36, to a second side 46 (a sample side), which is along an outer surface of the carrier 36. A sample 50 is secured to the sample side of the carrier 36.

[0032] A pressure ring 52 fits inside the inner surface 44 of the carrier 36 to maintain the shape of the carrier 36. An inner annular gap 54, having a predetermined width, is define between the inner surface 44 of the perforated carrier 36 and the displacement body 32. In one embodiment, the gap 54 ranges from about 2 mm to about 4 mm. However, other embodiments, in which the gap 54 has other predetermined widths, are also contemplated.

[0033] In one embodiment, a portion of the carrier 36 and sample 50 are submerged in the processing fluid 30. However, other embodiments, in which the processing fluid is stored remote from the beaker are also contemplated. In these alternate embodiments, neither the carrier nor the sample is submerged in the processing fluid.

[0034] FIG. 3 illustrates a top view of the flow guide element 26 including input and output flow guide ports 60, 62, respectively.

[0035] FIG. 4 illustrates a cross-sectional view of the flow guide element 26 of FIG. 3 taken along the lines A-A. As discussed below, the input and output flow guide ports 60, 62, respectively, are angled to facilitate the circulation of the processing fluid through the pump 20.

[0036] FIG. 5 illustrates a cross-sectional view of the flow guide element 26 of FIG. 4 taken along the lines B-B. With reference to FIGS. 1 and 4, the impeller 22 includes cross blades 64. The cross blades 64 agitate the processing fluid 30 when the impeller 22 rotates.

[0037] With reference to FIGS. 1 and 5, when the magnetic drive 16 is started, the magnetic flange 14 and blades 64 of the impeller 22 begin to rotate for agitating the processing fluid 30. Furthermore, the rotation of the flange 14 and blades 64 create a flow of the processing fluid 30 in the direction of the arrows through the input and output flow guide ports 60, 62, respectively. More specifically, the processing fluid 30 is drawn into the input flow guide port 60 by a suction created by the rotation of the flange 14 and the impeller 22. Furthermore, the fluid is pumped into the volume 40 below the displacement body 32 via the output flow guide port 62. It is to be understood that, according to commonly accepted practice, the processing fluid 30 is heated to a predetermined temperature by a temperature controller (e.g., heating element) (not shown).

[0038] The angles of the input and output flow guide ports 60, 62 are set for optimizing the circulation of the processing fluid 30. In other words, the angle of the input flow guide port 60 is set to optimize the flow of the fluid 30 into the flow guide element 26. Additionally, the angle of the output flow guide port 62 is set to optimize the flow of the fluid 30 from the flow guide element 26 to the gap 54. More specifically, the angle of the output flow guide port 62 is set to aim the fluid 30 exiting the port 62 into the gap 54.

[0039] The drive shaft 24 rotates the carrier 36 and displacement body 32 (e.g., at about 1200 rpm) to create a centrifugal force, which acts upon the fluid entering the gap. In other words, the centrifugal force causes the fluid entering the gap to come into contact with the inner surface 44 of the carrier 36. In this manner, the processing fluid 30 coats (sprays) the inner surface 44 of the carrier 36.

[0040] After the processing fluid begins to coat the inner surface of the carrier 36, the fluid 30 seeps through the apertures (perforations) 42 until contacting the sample material 50. Although only a single layer of the sample material 50 is illustrated in FIG. 2, it is to be understood that additional layers of the sample material are contemplated to be wrapped around the carrier 36. In one embodiment, up to about 350 grams of the sample material 50 are wrapped around the carrier 36 in one or more layers.

[0041] If multiple layers of the sample material are wrapped around the carrier, the inner-most layer (i.e., the layer against the outer wall 46 of the carrier 36) is dyed first. Then, the additional layers are dyed until the outer-most layer (i.e., the layer farthest from the outer wall of the carrier) is dyed. In this manner, the beaker dyeing machine creates a flow of processing fluid so that samples are dyed from the inside-out.

[0042] It has been found that the beaker dyeing machine 10 described above works well with solution/sample ratios less than about 10 milliliters/1 gram (and even as low as about 5 milliliters/1 gram).

[0043] While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.

Claims

1. A dyeing machine, comprising: a beaker; a carrier within the beaker, the carrier including a perforation and supporting a sample; and a pump assembly for circulating a processing solution to a first side of the carrier, the processing solution passing through the perforation for dyeing the sample.

2. The dyeing machine as set forth in claim 1, wherein: the carrier defines an interior volume, the first side being an interior side of the carrier and the second side being an exterior side of the carrier; and the sample is supported on the exterior side of the carrier.

3. The dyeing machine as set forth in claim 2, wherein: the carrier is substantially a cylinder.

4. The dyeing machine as set forth in claim 1, further including: a flow guide element having: an input flow port which receives the processing solution from the storage device; and an output flow port which transmits the processing solution to the first side of the carrier.

5. The dyeing machine as set forth in claim 4, wherein centrifugal forces cause the processing solution transmitted from the output flow port to coat the first side of the carrier.

6. The dyeing machine as set forth in claim 1, wherein a portion of the carrier is submerged in the processing solution within the storage device.

7. The dyeing machine as set forth in claim 1, further including: a displacement body within a volume of space defined by the carrier, the pump circulating the processing solution within a gap between the first side of the carrier and the displacement body.

8. The dyeing machine as set forth in claim 1, further including: a storage device housing the processing solution.

9. A dyeing machine, comprising: a dyeing beaker; a support assembly mounting the beaker; a carrier, within the beaker, including an aperture and supporting a sample; and means for circulating a processing fluid to a first side of the carrier, the processing fluid passing through the aperture for dyeing the sample.

10. The dyeing machine as set forth in claim 9, further including: an input flow port which receives the processing fluid into a flow guide element; and an output flow port which transmits the processing fluid from the flow guide element to the first side of the carrier at a predetermined angle.

11. The dyeing machine as set forth in claim 10, wherein the support includes: a magnet; and an impeller, the magnet and the impeller cooperating to circulate the processing fluid through the flow ports.

12. The dyeing machine as set forth in claim 11, wherein the impeller generates a centrifugal force for causing the processing fluid from the output flow port to spray the first side of the carrier.

13. The dyeing machine as set forth in claim 10, wherein the output flow port is set at a predetermined angle for causing the processing fluid to coat the first side of the carrier.

14. The dyeing machine as set forth in claim 9, wherein the carrier surrounds a volume of space in the beaker, the dyeing machine further including: a displacement body within the volume of space surrounded by the carrier, the processing fluid being circulated within a gap between the first side of the carrier and the displacement body.

15. The dyeing machine as set forth in claim 9, wherein the carrier causes a portion of the sample to be submerged in the processing fluid.

16. A method for dyeing a sample, the method comprising: securing a sample to a sample side of a carrier including a perforation; securing the carrier within a beaker; circulating a processing solution to a processing side of the carrier; and passing the processing solution through the perforation for dyeing the sample.

17. The method for dyeing a sample as set forth in claim 16, wherein: the step of securing the sample includes: securing a plurality of layers of the sample to the carrier, the layer of the sample closest to the carrier being dyed before the layer of the sample farthest from the carrier.

18. The method for dyeing a sample as set forth in claim 16, wherein the step of circulating includes: receiving the processing fluid in an input flow port of a flow guide element; and transmitting the processing fluid to the processing side of the carrier via an output flow port of the flow guide element.

19. The method for dyeing a sample as set forth in claim 18, wherein the step of transmitting includes: transmitting the processing fluid between a displacement body and the processing side of the carrier; and drawing the processing fluid to the processing side of the carrier via a centrifugal force.

20. The method for dyeing a sample as set forth in claim 16, wherein the carrier is substantially cylindrically shaped, the method including: wrapping the sample around the carrier.

21. The method for dyeing a sample as set forth in claim 16, wherein the step of securing the carrier within the beaker includes: submerging a portion of the sample in the processing solution.