Novel product for energy- and resource-efficient cold dyeing of textile substrates

Abstract

Product use by means of the invention for dyeing and coloring or the like of substrates made of fibers, fiber cables, yarns made of cut and filament fibers, flat structures such as woven fabrics, knitted fabrics, warp-knitted fabrics, non-woven fabrics and ready-made clothing and home textiles and the like, in particular of textiles with 100% or with mixtures thereof. These can be made of plant and animal natural fibers, stem fibers, synthetic fibers of petrochemical or natural origin as well as special fibers such as soy fibers, milk fibers, bamboo fibers or fibers that are difficult to dye such as aramid, polypropylene.

Description

[0001] A significant contribution to the textile industry is made through an unknown, novel, and resource-efficient product and the resulting simplification of existing dyeing processes and machine technology. It is applied in a cold medium, without the use of chemicals, in extremely short times, and can be used for all fiber and dye types. Thus, almost all required criteria such as sustainability, reduced energy consumption, minimal freshwater pollution, and reduced wastewater volumes, as well as microplastics and CO, are met. 2 -reduction, environmental and resource conservation and almost chemical-free process application. Description

[0002] The invention relates to a novel and resource-efficient product for dyeing fibers, yarns, threads, woven and knitted fabrics, 3D and nonwoven fabrics, naturally / synthetically produced leather goods, and ready-made garments. These can be made from vegetative and animal natural fibers, all known synthetic fibers, stem fibers, organically / inorganically produced fibers, and mixtures thereof.

[0003] Global population growth is causing increasing environmental problems, with the textile industry's negative contribution being significant. Non-toxic, energy- and resource-efficient systems, technologies, products, and machinery must be developed and implemented immediately for the textile industry.

[0004] In the textile industry, processes, technologies, systems, products, chemicals, and textile auxiliaries continue to be used according to conventional processes and conditions. Promising changes have not been implemented for a long time. Only small exceptions regarding reductions in the consumption of freshwater, chemicals, and dyes can be observed. However, the textile industry remains the second largest polluter with its dyeing wastewater.

[0005] The most valuable natural resource for human existence, next to air, is water. It consists of approximately 97% salt water and approximately 3% fresh water. Two-thirds of fresh water lies above the Earth as ice and snow, one-third as groundwater, and only 0.3% is surface water. Negative changes caused by climate change and human activity are a cause for concern.

[0006] Fiber consumption is also steadily increasing. In 2023, approximately 125 million tons of fiber were consumed worldwide. The largest share is made up of approximately 75 million tons of PES fibers and approximately 30 million tons of natural fibers, of which approximately 25 million tons are cotton.

[0007] With the introduction of synthetic dyes, especially those with the highest percentage of reactive dyes, the consumption of water and chemicals increased disproportionately, in addition to their considerable economic success. The main reason for this was the high consumer-friendly fastness and vibrant colors of reactive dyes.

[0008] The consumption of 150-200kg of water per 1kg of fabric and large quantities of salt and soda as chemicals in the dyeing process cause significant environmental damage in reactive dyeing.

[0009] Compared to other dye types, reactive dyes consume more water and energy. The main reason is the required up to 6-10 washes after the dyeing process. Washed-out dyes, which contain approximately 30% unfixed dyes and contain chemicals and salt, lead to significant water pollution and correspondingly increase energy consumption.

[0010] Given the threatening environmental impact, more sustainable solutions are urgently needed. Bio-based dyes, chemical-free technologies, and resource-efficient wastewater treatment techniques should be urgently implemented in the textile industry. These should achieve near-matched fastness levels to reactive dyes and significantly reduce energy and water consumption.

[0011] Cotton dyeing has achieved slight improvements in recent years in terms of reducing salt and liquor quantities. Progress in dye production has also been visible. However, these improvements fall far short of expectations. The textile industry remains the second largest polluter after agriculture, accounting for 20% of emissions.

[0012] A CO 2 Although the technology is a water- and wastewater-free method, its use is limited to polyester fibers. Plant operation requires high energy consumption. This technology is currently not applicable to natural fibers. The enormous investment required makes this technology unattractive for the textile industry.

[0013] In addition to cotton production, which accounts for approximately 25% of global demand, the synthetic group, primarily polyester at approximately 57%, plays a more important role than cotton. Disperse dyes are primarily used for this purpose.

[0014] Dyeing with disperse dyes is a flexible process. The good fastness properties for pastel shades are usually achieved in the boiling range, while medium to darker shades in the HT range up to 140°C are usually achieved using the undesirable, toxicologically questionable carrier. The dyeing time, in conjunction with the high energy consumption and carrier use, represents a cost and ecological problem. It is also the only dye class that can be dyed with CO 2 enables water-free dyeing for polyester.

[0015] The obvious desire of the textile industry is sustainability, resource conservation, reduction of environmental impact, energy saving, CO 2 - Reduction, health maintenance, and conservation of potable freshwater reserves. This will likely only be possible with a rethink and, in some cases, a shift in existing uses.

[0016] The dyeing processes are carried out almost exclusively with petrochemical dyes and, in some cases, harmful chemicals and textile auxiliaries. Energy consumption is very high, as the dyeing processes can last up to 12 hours at temperatures ranging from 60 to 140°C, depending on the fiber type and dye.

[0017] Post-dyeing washing processes for excess dyes may be required, both hot and cold. Different dyes, chemicals, and auxiliaries are known to be used for each fiber type. Advances in machine technology now allow for smaller liquor volumes with lower water consumption. However, the wastewater problem remains.

[0018] In the invention, however, the core element is a novel animal and plant-based product, still largely unknown in the textile industry. Petrochemical products, chemicals, and auxiliaries have been almost completely eliminated from the dyeing phase. Textile auxiliaries can only be used in post-treatment when necessary and to improve performance.

[0019] However, it is currently not possible to do without the well-known synthetic dyes and pigments, as the sustainable sources of natural dyes are not sufficient in terms of quantity and cannot completely cover the colour palette.

[0020] The invention is based on an animal- and plant-based product concept that possesses multiple functional properties. The basic substances consist primarily of wild plant, crop, and plant waste extracts, biopolymers derived from animal waste and plant-based biopolymers, food additives, and hydrotopic solvents.

[0021] Today, the textile industry achieves the dyeing properties mainly through petrochemical means using different products, chemicals and appropriate dyeing processes.

[0022] The invention takes into account all natural and synthetic fibers, including difficult-to-dye polypropylene, aramid fibers, glass fibers, and also protein fibers such as soybean fibers, bamboo fibers, grain or corn fibers of vegetable origin, and milk fibers of animal origin.

[0023] The invention takes into account all natural and synthetically produced dyes, including natural, organic, inorganic pigments and also indigo dyes, as well as dyes of vegetarian and animal origin.

[0024] The invention further takes into account dye combinations specifically tailored to the product based on all natural and synthetically produced dyes, including natural, organic, inorganic pigments and also indigo dyes.

[0025] To achieve optimal results, the dyes can be mixed together. The mixture can be in powder, liquid, or combined with each other. Product compatibility with the dyes is crucial. Subsequent addition of the dyes to the residual liquor for reuse is possible.

[0026] The invention product is used with the aforementioned fiber types and all dye types known to the industry, and their combinations. Using one dye class, a company would be able to dye several fiber types in one bath and with good fastness properties in a single pass.

[0027] The only criterion to be tested is the chemical compatibility of the invented product with the dye used and the textile. Dyes are preferably added in dissolved form. Depending on the chemical properties and pretreatment of the textile, different color shades can be produced from the same dye bath.

[0028] Preliminary trials are essential, as the product's application is largely unknown. This ensures a match between the textile, the product, and the dye, and optimizes the process.

[0029] For dyeing processes, proven dyeing methods can only be represented and optimized after preliminary operational tests. The physical / chemical properties of this product in combination with the respective dye differ largely from the known processes and must be taken into account.

[0030] Empirical results with the known dye classes and staining techniques or reproducibility must be established using the in-house conditions.

[0031] The novelty of this product and the resulting and expected technical / technological start-up problems mean that the conservative textile industry can be expected to take a skeptical attitude towards this new product.

[0032] The simplification in practice, through a single product, without the use of chemicals and textile auxiliaries, as well as the limitation of dye classes and finally the use of simpler machine technology, do not encourage dye, textile auxiliaries and machine manufacturers in the slightest.

[0033] The product is manufactured from natural raw materials as a functional product with natural properties. Selected plant extracts, plant and animal biopolymers, food additives, and solvent promoters from the cosmetics and cleaning industries play a special role. pH adjustment is not necessary.

[0034] This resource-efficient product concept largely meets the requirements for sustainability, resource conservation, environmental aspects, energy savings, wastewater and CO 2 Reduction .

[0035] It has been proven that no toxic chemicals or additives are used during the production of this product, apart from plant extracts and biopolymers.

[0036] The goal is to completely utilize the dye liquor without any residual liquor to avoid wastewater. The remaining liquor residues and the wastewater should be reusable through storage.

[0037] All dyes known to modern technology, including organic, inorganic and natural pigments, are used in all textile fibers.

[0038] Individual dyes or their combinations can exhibit significant differences in the final product appearance and in fastness properties. Reproducibility and the ability to dye specific shades are only possible through in-house efforts.

[0039] According to the invention, the textile substrates specified in the description are dyed in pretreated or natural form without pretreatment using known dyeing processes. Absorbency and washed-out substrates contribute to the result.

[0040] A surprising advantage of the product is the improvement of the simultaneous absorption, affinity and dye penetration capacity in a very short time unit of reactive dyes of different substantivity or of other dyes and pigments.

[0041] To ensure quality for conventional dyeing processes, water preparation is crucial. This includes the water source, filtration, (if necessary) desalination, pH adjustment, disinfection, and temperature.

[0042] Water treatment plants are responsible for treating water and can incorporate various technologies such as reverse osmosis, ion exchange, or filtration. These plants are complex and incur significant investment, maintenance, operating, water, and chemical costs.

[0043] The product is robust and does not necessarily require treated process water. Roughly filtered rainwater and even untreated / natural seawater can be used. This advantage is of enormous importance for coastal countries with water problems.

Claims

[1] Product use by means of the invention for dyeing and coloring or the like of substrates made of fibers, fiber cables, yarns made of cut and filament fibers, fabrics such as woven fabrics, knitted fabrics, warp-knitted fabrics, non-wovens and ready-made clothing and home textiles and the like, in particular of textiles with 100% or with mixtures thereof. These can be made of plant and animal natural fibers, stem fibers, synthetic fibers of petrochemical or natural basis as well as special fibers such as soy fibers, milk fibers, bamboo fibers or fibers that are difficult to dye such as aramid, polypropylene. [2] Product insert according to claim 1, characterized by that the dyeing process using the invention product and the known dyes and their combinations is carried out according to the known conventional technology [3] Product insert according to claim 1 and 2, characterized bythat reactive dyes, substantive dyes, acid dyes, sulfur dyes, disperse dyes, direct dyes, VAT dyes, as well as organic, inorganic, natural pigments are used alone and combined with each other as dyes for combining. [4] Product use according to claim 1, 2, 3 characterized by that the appropriate amount of water and, depending on the depth of colour, the appropriate amount of dye is added to the original product, whereby the dye is dissolved and mechanically well dispersed. [5] Product use according to claim 1,2,3,4 characterized by The dyeing medium is introduced into the process as a ready-to-use liquor. For environmental and resource conservation reasons, padding or spray application is recommended. [6] Product use characterized bythat all chemicals known and used in conventional applications, depending on the type of fibre / dye, are completely dispensed with and textile auxiliaries are largely dispensed with. [7] Product use characterized by that dyeing temperatures of 20-60° C can be used in the invention and that this is mainly used in the cold range of 20-25° C without heating. [8] Product use characterized by that in the invention pH adjustment of the dye liquor plays a subordinate role [9] Product use characterized by that in the invention the chemical compatibility of the individual products with the respective dyes is of primary importance. [10] Product use characterized by that the invention contains, depending on the type of color and dye, 0.5-30% wild and cultivated plant extracts and natural waste residues, 1-20% food additives, 1-30% vegetarian and animal biopolymers and 0.5-10% hydrotopic solvent mediators. [11] Dyeing after exhaustion application and continuous application according to claim 1, characterized by that temperatures between 20-60° C and dyeing times of 3-5 minutes are required depending on the desired color depth and fastness. [12] Dyeing according to the exhaust and continuous application according to claim 4, characterized by that by using selected combinations of dyes, the high temperatures and excessively long dyeing times typically required for these dyes are avoided. [13] Colors after the exhaust application according to claims 4 and 5, characterized by that to achieve good fastness, post-treatment and post-washing are not always / occasionally necessary [14] Use of the product in exhaust dyeing according to one of the preceding claims, characterized by that different color depths and shades can be achieved from one dye bath using time and machine settings [15] Product use of the continuous dyeing application according to one of the preceding claims, characterized by that the application conditions according to claims 3, 4, 5 are maintained [16] Product insert according to claim 1, characterized by that the textile material and dyes or dye combinations are immersed / sprayed in the prepared, single-bath dyeing liquor, thereby ensuring rapid and even diffusion of the dye. [17] Product insert according to claim 8, characterized by that the dyeing process is water-reduced and wastewater-free and that one or more washes are not always necessary depending on the dye and color depth [18] Product use according to several of the preceding claims, characterized by that by reducing temperatures, dyeing times and post-treatment, considerable savings in energy, water / waste water and chemicals can be achieved and CO2 emissions can be reduced. [19] Product insert according to claim 2, characterized bythat the textile substrate is presented for dyeing in untreated, boiled, bleached, mercerized or classically pretreated form [20] Product insert according to claim 11, characterized by that the dyeing time and the contact pressure during padding are selected depending on the material and are adjusted mechanically for other systems [21] Product use according to several of the preceding claims, characterized by that the fleet water used does not have to be treated. [22] Product use according to several of the preceding claims, characterized by that due to the insensitive product properties, coarsely filtered rainwater and also seawater in its natural state can be used in addition to process water. [23] Invention product according to the draw-out or continuous application according to claim 10, characterized bythat the product to be used for textile substrate has a composition of at least three of the specified basic substances [24] Product use according to several of the preceding claims, characterized by that by simplifying machine technology, treating textiles more gently and by significantly reducing dyeing times, the mechanical stress on synthetic substrates is minimized and the microplastics remaining in the dye bath and later excreted in household laundry are less likely to enter natural water sources and seawater.