Apparatus and method for dyeing textiles

Abstract

A method for improving the color fastness of dyed textiles is provided, the method including the steps of conveying the dyed textile along an automated processing line to a first chamber having a first controllable environment, temporarily storing the dyed textile in the first chamber for a first period of time, conveying the dyed textile to a second chamber having a second controllable environment, and temporarily storing the dyed textile in the second chamber for a second period of time.

Description

[Technical field]

[0001] The present invention relates to improvements in or relating to the dyeing of textiles, and in particular to improvements in the colour fastness of dyed textiles. [Background technology]

[0002] Coating or dyeing textiles can be an environmentally harmful process, primarily due to the large amounts of wastewater that are generated, typically many times the weight of the textile.

[0003] Traditional processes for dyeing applications include bath immersion methods such as exhaust or jet dyeing, and padding using a roller application mechanism. Alternatively, the coating or dye may be applied to the fabric by a roller "padding" process. The applied dye is then dried and heated to fix the dye. For both of these traditional dyeing methods, washing is required to remove excess unbound dye and auxiliary chemicals. Washing generally requires several tanks operated at high temperatures and may introduce additional chemicals in the process of "reduction washing" where a basic pH is used.

[0004] As a result, conventional methods generally result in excessive dye loading on textile materials, which must be removed by repeated high-temperature washing, thereby generating large amounts of polluted wastewater. Polluted wastewater, including water contaminated with dyes, is a significant global environmental problem, requiring large-scale wastewater treatment to avoid environmental damage. Summary of the Invention [Means for solving the problem]

[0005] It is against this background that the present invention arises.

[0006] According to the present invention, there is provided a method for improving the color fastness of dyed textiles, the method comprising the steps of conveying the dyed textile in a first direction along a processing line, flowing a fluid from a reservoir through the dyed textile on the processing line in a second direction substantially opposite to the first direction, then removing at least 50% of the applied fluid from the dyed textile, removing contaminants from the fluid, and returning the fluid to the reservoir.

[0007] Flowing the fluid through the dyed fabric in a direction substantially opposite to the direction of transport allows the cleanest fluid to contact the cleanest portions of the dyed fabric, which prevents any contamination of the clean portions of the dyed fabric with contaminated wastewater. Additionally, flowing the fluid in a direction opposite to the direction of travel of the dyed fabric may aid in the removal of excess dye.

[0008] According to the present invention, there is provided a method for improving the color fastness of a dyed textile, the method comprising the steps of conveying the dyed textile along a processing line, applying a fluid to the dyed textile at a first location on the processing line in a second direction substantially opposite to the first direction, and then removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line.

[0009] The dyed textile may be continuously conveyed along the processing line. For example, the processing line may be a continuous roll-to-roll processing line. The processing line may be automated. The processing line may include a processor configured to digitally control the processing line. The processor may control the speed at which the textile is conveyed along the processing line. In some embodiments, the processing line may be a non-immersion processing line. Conventional dyeing, washing, and / or fixing processes generally include at least one immersion tank. However, a non-immersion processing line is a processing line that does not contain an immersion tank.

[0010] In some embodiments, the dyed fabric may be in a consolidated form, e.g., the dyed fabric may be transported as a roll, or the dyed fabric may be in a non-consolidated form, e.g., the dyed fabric may be transported in a linear form.

[0011] The dyed textile may be at high temperatures. For example, the dyed textile may be at 10°C to 220°C, 15°C to 200°C, 20°C to 180°C, 25°C to 140°C or 30°C to 100°C. The temperature of the dyed textile and / or the processing line may be controlled. This may improve the hand of the dyed textile.

[0012] The first and second locations in the processing line may be substantially the same location. For example, the first and second locations in the processing line may overlap. Alternatively, or in addition, the first and second locations in the processing line may be adjacent to each other. Conversely, in some embodiments, the first and second locations may be different from each other.

[0013] For example, the first location and the second location can be within 1 meter of each other. Alternatively, the first location and the second location can be within 0.75 m, 0.5 m, 0.25 m, or 0.1 m of each other. For example, in a processing line, the first location and the second location can be opposite each other, adjacent to each other, or overlapping each other.

[0014] The fluid may include a liquid. More specifically, the fluid may be a liquid. For example, the fluid may be water. However, any suitable liquid may be used. The fluid may include a fragrance. Alternatively, or in addition, the fluid may include a gas. The gas may be air. However, any suitable gas may be used. The gas may include a solid. For example, the fluid may include air and sand / gravel configured to sandblast the dyed textile.

[0015] Removal of the fluid from the dyed textile may be in the form of a dewatering step. Physically removing the fluid from the textile removes any remaining dyes and / or chemicals that are not fixed to the textile. Conversely, drying the textile leaves behind dyes and / or chemicals that are not fixed to the textile.

[0016] By removing the applied fluid, the fluid can be reused, reducing the overall amount of fluid required. In some embodiments, at least 60%, 70%, 80%, 90%, 95% or 99% of the applied fluid can be removed from the dyed textile. Preferably, at least 75% of the applied fluid is removed from the dyed textile at the second location on the processing line.

[0017] The rate of fluid removal can be greater than 0.5, 1, 1.5, 2, 2.5 or 3 times the mass flow rate of the dyed fabric. Alternatively, or in addition, the mass of fluid retained on the fabric downstream of the second location in the treatment line can be less than 0.5, less than 0.3, less than 0.2, less than 0.1 or less than 0.05 times the mass flow rate of the fabric.

[0018] In this context, mass flow rate may be defined as the mass of dyed fabric passing a given point per unit time. For example, mass flow rate may be defined as the mass of dyed fabric passing a first location in a processing line per unit time.

[0019] The fluid may be removed from the fabric by a vacuum. The vacuum may efficiently remove the fluid without damaging the fabric. Alternatively, or in addition, the fluid may be removed from the fabric by applying a high velocity gas to the fabric. The gas may be air. The high velocity gas may be passed through the fabric. The high velocity gas may be configured to remove excess liquid and loose solids from the dyed fabric.

[0020] The fluid applied to the dyed textile at the first location on the processing line can be a predetermined amount of fluid. More specifically, the fluid applied to the dyed textile at the first location on the processing line can include a predetermined amount of liquid.

[0021] Thus, the method may include applying a predetermined amount of fluid to the dyed textile at a first location on the processing line. For example, fluid may be applied to the dyed textile until the textile reaches a predetermined water content. The application of fluid to the dyed textile may be controlled. Furthermore, the application of fluid to the dyed textile may be regulated.

[0022] Alternatively, or in addition, the fluid applied to the dyed textile at a first location on the processing line may be applied at a predetermined rate.

[0023] The method may further include removing contaminants from the removed fluid and reapplying the fluid to the dyed textile. More specifically, the method may include reapplying the fluid to the dyed textile at a first location on the processing line. Alternatively, or in addition, the method may include reapplying the fluid to the dyed textile at a third location on the processing line. The third location may be upstream of the second location.

[0024] The fluid may be first applied to a first location on the dyed textile and then removed from that location. The fluid may then be cleaned and reapplied to a second location on the dyed textile. The reapplied fluid may then be removed from the second location on the dyed textile at a second location on the processing line.

[0025] The method may further include applying a fluid to the dyed textile at a third location on the treatment line, and then removing at least 50% of the fluid applied at the third location from the dyed textile at a fourth location on the treatment line.

[0026] Thus, the method of claim 1 may be repeated. More specifically, the method may be repeated multiple times. For example, the method may be repeated 1, 2, 3, 4, 5, 8, or 10 or more times.

[0027] The reapplied fluid may be reapplied at a first location and / or a third location on the processing line. The fluid may be applied to the fabric, removed from the fabric, and reapplied at any number of locations on the dyed fabric. For example, the fluid may be applied to the fabric, removed from the fabric, and reapplied at 3, 4, 5, 6, 7, 8, 9, or 10 or more locations on the dyed fabric.

[0028] The method may be continuous. For example, the method may include the steps of continuously conveying a dyed textile along a processing line, continuously applying a fluid to the dyed textile at a first location on the processing line, and then continuously removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line.

[0029] The method may further include continuously removing contaminants from the removed fluid. Still further, the method may include continuously reapplying the removed fluid to the dyed textile. More specifically, the method may include continuously reapplying the removed fluid to the dyed textile at a first location on the processing line. Alternatively, or in addition, the method may include continuously reapplying the removed fluid to the dyed textile at a third location on the processing line. This looping method further reduces water usage.

[0030] The total mass of fluid applied to the dyed textile may be up to 500% of the mass of the dyed textile. More specifically, in some embodiments, the total mass of fluid applied to the dyed textile may be up to 75%, 100%, 150%, 200%, 250% or 300% of the mass of the dyed textile. Alternatively or additionally, the total mass of fluid applied to the dyed textile may be 50% to 350%, 100% to 300%, or 150% to 250% of the mass of the dyed textile. The application rate of fluid may be more than 0.5, 1, 1.5, 2, 2.5 or 3 times the mass flow rate of the dyed textile. However, in some embodiments, the total mass of fluid applied to the dyed textile may be less than 50%, 30%, 20%, 10% or 5% of the mass of the dyed textile.

[0031] At the first location, the fluid may be applied to the dyed fabric at 1-50 liters / min. Alternatively, the fluid may be applied at 1-20 liters / min (L / min). The fabric may be transported at 1-100 meters / min (m / min). More specifically, the fabric may be transported at 5-50 m / min or 10-20 m / min.

[0032] In some embodiments, the fluid removed from the dyed textile at the second location may be less than that applied to the dyed textile at the first location. Removing less fluid than was applied may be desirable, for example, to leave certain chemicals in the fluid on the textile.

[0033] The method may further include heating the fluid to greater than 40° C. More specifically, the fluid may be heated to greater than 50° C., 60° C. or 70° C. Alternatively, or in addition, the fluid may be heated to between 40° C. and 80° C., between 50° C. and 70° C. or to about 60° C. For example, the temperature of the fluid may be adjusted to optimize the cost of the method and the total energy used during the method.

[0034] The method may further include heating the first location in the processing line to between 40 and 95° C. More specifically, the method may include heating the first location in the processing line to between 50 and 70° C. or about 60° C. Increasing the environmental temperature of the first location reduces the cooling effect of the fluid application and therefore reduces the total energy required for the method. In some embodiments, excess heat from the stationary chamber may be used to heat the first location.

[0035] The method may further comprise the steps of determining a range of acceptable flow rates of the applied fluid, monitoring the flow rate of the applied fluid, and adjusting the flow rate of the applied fluid if the flow rate of the applied fluid falls outside the range of acceptable flow rates. As a result, the applied fluid can be accurately monitored and adjusted when in use. This may be used to optimize the method, thus improving the efficiency of the method.

[0036] The fluid may be sprayed onto the dyed textile. The fluid may be sprayed onto the dyed textile by multiple spray nozzles. This may ensure that the entire textile is sprayed. Furthermore, spraying the fluid may agitate the textile, thus removing some of the excess dye and / or unfixed dye from the textile. This may improve the color fastness of the dyed textile. Furthermore, spraying the fluid onto the dyed textile may significantly reduce the water used compared to conventional methods. This is particularly advantageous in terms of cost and environmental impact. The fluid may be sprayed onto the textile at a speed of at least 10 m / s, at least 15 m / s, or most preferably at least 20 m / s.

[0037] However, in some embodiments, the fluid may be applied to the fabric by slot die liquid application or dip application. Alternatively, or in addition, the fluid may be applied to the fabric by a rotary printing application, such as a rotating screw or gravure sprinkler. Still further, in some embodiments, the fluid may be applied to the fabric by a waterfall, weir, sprinkler, or jet.

[0038] The method may further include a step of mechanically agitating the dyed textile. Mechanically agitating the dyed textile may remove some of the excess dye, thus improving the color fastness of the dyed textile. More specifically, the mechanical agitation may be configured to move the fibers of the textile, thus exposing excess unfixed dye.

[0039] The mechanical agitation may apply pressure to the dyed fabric. The mechanical agitation may effectively squeeze fluid out of the fabric. The mechanical agitation may be configured to reduce the mass of water in the fabric to below the fabric mass flow rate.

[0040] For example, the mechanical agitation may include a pair of rollers configured to contact the fabric being transported along the processing line. More specifically, the mechanical agitation may include a pair of nip rollers. The pair of nip rollers may reduce the mass of water in the dyed fabric to less than 60% of the mass flow rate of the dyed fabric.

[0041] The mechanical agitation can occur between the first and second locations on the processing line. Alternatively, or in addition, the mechanical agitation occurs at the first and / or second locations on the processing line. For example, the application of the fluid can also be combined with mechanical agitation by rollers in contact with the textile.

[0042] Furthermore, in some embodiments, mechanical agitation can occur between the third and fourth locations on the processing line.

[0043] Alternatively, or in addition, the applied fluid may be configured to agitate the fabric. For example, the fluid may be forced through the fabric at a first location on the processing line. In such an embodiment, the fluid may be removed on the opposite side of the fluid applicator. The second location on the processing line may be directly opposite the first location on the fluid processing line.

[0044] The fluid may include an additive configured to improve the colorfastness of the textile. In some embodiments, the fluid includes a plurality of additives configured to improve the colorfastness of the textile. For example, the additive may be a finishing chemical. The additive may be configured to allow movement of the fibers of the textile without removing dye from the textile.

[0045] Alternatively, or in addition, the additive may include an anionic or cationic surfactant. Alternatively, the additive may include any detergent species. In some embodiments, the additive may include a polymeric species. The polymeric species may include an aliphatic or silicon-based backbone.

[0046] Alternatively or in addition, the fluid may include lubricating and / or softening additives. The fluid may include additives configured to improve the softness of the fabric. The additive may be a chemical softener. The chemical may be a silicone. The softener may be a biological extract. Alternatively or in addition, the fluid may include a colorless dispersant. Furthermore, the fluid may be water-based and / or mixed with fresh water when in use.

[0047] Alternatively or additionally, a method for improving the color fastness of a dyed textile is also provided, the method comprising the steps of conveying the dyed textile along a processing line to a first chamber having a first controllable environment, temporarily storing the dyed textile in the first chamber for a first period of time, conveying the dyed textile to a second chamber having a second controllable environment, and temporarily storing the dyed textile in the second chamber for a second period of time. The processing line may be automated. The processing line may be the same processing line as previously disclosed.

[0048] The first controllable environment may be different from the second controllable environment. Alternatively, the first controllable environment and the second controllable environment may be the same. More specifically, the first controllable environment may include multiple parameters. For example, the first controllable environment may include a first temperature, humidity, pressure, airflow rate, and / or inert gas. Alternatively, or in addition, the second controllable environment may include multiple parameters. For example, the second controllable environment may include a second temperature, humidity, pressure, airflow rate, and / or inert gas.

[0049] In some embodiments, at least one of the first temperature, humidity, pressure, airflow rate, and inert gas can be the same as the second temperature, humidity, pressure, airflow rate, and inert gas. Alternatively, or in addition, at least one of the first temperature, humidity, pressure, airflow rate, and inert gas can be different from the second temperature, humidity, pressure, airflow rate, and inert gas. Any of the aforementioned parameters can be used to define the controllable environment of each chamber. More specifically, any combination of parameters can be used to define the controllable environment of each chamber.

[0050] In some embodiments, the temperature may include a temperature gradient. Alternatively, or in addition, airflow may be used to keep the temperature uniform in the chamber. For example, heat may be added in the form of hot air in the first and / or second chamber. The velocity of the air introduced into the chamber may ensure that the air circulates throughout the chamber. The air circulation may ensure uniformity of the heat. The humidity may be the relative humidity in the chamber. The relative humidity may be 0% to 100%, more preferably 30 to 70%, and most preferably about 50%. The pressure may be about atmospheric pressure. Alternatively, the pressure may be higher than atmospheric pressure. For example, the pressure may be up to 1.5, 2, 2.5, or 3 times atmospheric pressure. Still further, in some embodiments, the first chamber and / or the second chamber may be filled with an inert gas. For example, the chamber may be filled with a noble gas. Alternatively, or in addition, the chamber may be filled with nitrogen or argon.

[0051] The dyed textile may be continuously conveyed along the processing line. For example, the dyed textile may be continuously conveyed to the first chamber. At least a portion of the processing line may be automated. Alternatively, the entire processing line may be automated. Thus, the dyed textile may be automatically conveyed to the first chamber.

[0052] Furthermore, the dyed textile may be continuously conveyed to the second chamber. The dyed textile may be automatically conveyed to the second chamber. Alternatively, or in addition, the dyed textile may be manually conveyed to the second chamber. The dyed textile may be a textile that includes a dye.

[0053] The method may further include adjusting the first controllable environment and / or the second controllable environment based on the characteristics of the textile to be dyed, the dye used to dye the textile, and / or the dyed textile. When in use, the first environment and / or the second environment may be adjusted. In other words, the first environment and / or the second environment may be adjusted while the processing line is transporting the textile.

[0054] The dye properties may include dye concentration, color, shade, Pantone, reflectance, water content, color index number, and / or molecular weight. For example, a dye with a higher molecular weight may require more energy to fix to the textile. A higher molecular weight dye will result in the dyed textile being stored in the first and / or second chamber for a longer period of time and / or at a higher temperature. Furthermore, the dyed textile and / or textile properties may include textile basis weight, absorbent capacity, reflectance, water content, thickness, diameter, and / or batch code.

[0055] The dyed and / or dyed textile may include polyester, cotton, wool, nylon, elastane, and / or silk. However, other textiles or textile products may be used. Furthermore, the dye may include disperse dyes, pigments, acid dyes, and / or reactive dyes. For example, in some embodiments, the textile may be polyester and the colorant may be a disperse dye. Alternatively, the textile may be cotton and the colorant may be a reactive dye. In some embodiments, the textile may be cotton and the colorant may be a pigment dye. Alternatively, the textile may be nylon and the colorant may be an acid dye.

[0056] Alternatively or additionally, properties of the textile being dyed and / or the dyes used to dye the textile may be determined before, during and / or after dyeing, allowing multiple properties to be measured throughout the dyeing and fixing process.

[0057] Consequently, the method may include determining the properties of the fabric and / or the properties of the dye before, during, and after dyeing of the fabric, and adjusting the first controllable environment and / or the second controllable environment based on the determined properties. Comparisons between the properties measured at various points within the method may also be used to optimize the controllable environment in each chamber. This may enhance the quality of the dyed fabric, more particularly, the color fastness.

[0058] The first chamber may include a first internal temperature. The second chamber may include a second internal temperature that is lower than the first internal temperature. By making the second temperature lower than the first temperature, the energy applied to the textile in the first chamber may be at least partially utilized in the second chamber. This reduces the energy required to heat the textile in the second chamber.

[0059] For example, the method may include temporarily storing the dyed textile in a first chamber having a first internal temperature for a first period of time and temporarily storing the dyed textile in a second chamber for a second period of time, the first internal temperature being greater than the second internal temperature. However, in some embodiments, the second chamber may include a second internal temperature that is substantially greater than or equal to the first internal temperature.

[0060] Storing the dyed textile in a first chamber having a first temperature for a first period of time and in a second chamber having a second temperature for a second period of time may improve the colorfastness and / or flexibility of the dyed textile. For example, the use of two chambers may result in almost complete fixation of the dye on the textile. This may be because the dye molecules that were loosely bound to the surface of the textile fibers are now more strongly bound to the fibers. Therefore, only a very low concentration of the dye molecules may be removed from the textile during colorfastness testing.

[0061] The first internal temperature may be between 140°C and 230°C. Temporary storage of the dyed textile at 140°C to 230°C may result in localized fixation of the dye around individual fibers. This improves the resulting color fastness of the dyed textile. More specifically, the first internal temperature may be between 150°C and 215°C. More specifically, the first internal temperature may be between 160°C and 200°C.

[0062] The second internal temperature may be between 120°C and 200°C. A lower temperature in the second chamber allows the fabric to cool slightly. This cooling effect may be utilized to improve the flexibility of the fabric. Furthermore, a lower temperature in the second chamber may eliminate the need to further heat the fabric, reducing the overall energy used during the process. In some embodiments, the second internal temperature is between 130°C and 190°C or between 140°C and 180°C.

[0063] The second period of time may be longer than the first period of time. The first period of time may be at least 10 minutes. More preferably, the first period of time may be between 30 minutes and 4 hours. Most preferably, the first period of time may be between 45 minutes and 2 hours. However, in some embodiments, the first period of time may be up to 5 hours, 8 hours, 10 hours or 12 hours. For example, the dyed textile may be stored in the first chamber overnight.

[0064] The second period of time may be at least 2 hours. For example, the second period of time may be 5 to 60 minutes, or 10 to 30 minutes. Alternatively, the second period of time may be 4 hours, 6 hours, 8 hours, 12 hours, 24 hours, or up to 48 hours. However, in some embodiments, the second period of time may be longer than 48 hours.

[0065] The method may further include determining a cooling rate of the dyed textile and adjusting the controllable environment of the first chamber and / or the second chamber based on the cooling rate. In this context, the cooling rate may be defined as the time required to cool the textile by 1°C. Furthermore, the cooling rate may be determined based on the characteristics of the textile to be dyed, the dyed textile, and / or the dye. The cooling rate may be calculated prior to the dyeing process of the textile. The cooling rate may be adjusted to improve the flexibility and / or color fastness of the dyed textile.

[0066] The method may further include temporarily storing the dyed textile in a second chamber at a plurality of different temperatures. For example, the second chamber may be configured to subject the dyed textile to a plurality of different temperatures within a temperature gradient. The temperature gradient within the second chamber may define a cooling rate for the dyed textile. In some embodiments, the second chamber may include a plurality of heaters. Each heater may be configured to generate a different temperature. The plurality of heaters may generate a temperature gradient within the second chamber.

[0067] In some embodiments, the dyed textile is temporarily stored at each temperature within the temperature gradient for up to 1 hour. Alternatively, the dyed textile may be temporarily stored at each temperature within the temperature gradient for up to 10 minutes, 20 minutes, 30 minutes, 45 minutes, 1 hour, 2 hours, 3 hours, or 4 hours.

[0068] The method may further include conveying the dyed textile through a plurality of different temperatures in a second chamber. Conveying the textile through the second chamber may include temporarily storing the dyed textile in the second chamber. The plurality of different temperatures in the second chamber may generate a temperature gradient. The thermal energy used to create the temperature gradient in the second chamber may be at least partially received by the dyed textile. The dyed textile may be cooled as it is conveyed through the second chamber.

[0069] The second chamber may comprise a proximal end having a first opening configured to receive the dyed textile. In some embodiments, the first opening is configured to receive a roll of the dyed textile. The second chamber may comprise a distal end having a second opening configured to output the dyed textile. In some embodiments, the second opening is configured to output the roll of the dyed textile. Each of the first opening and the second opening comprises a door and / or a seal. The temperature of the proximal end may be higher than the temperature of the distal end. For example, the proximal end may be about 180° C. and the distal end may be about 140° C. There may be a substantially linear temperature gradient between the proximal end and the distal end. In use, the dyed textile, more specifically the roll of the dyed textile, may move between the proximal end and the distal end. The dyed textile may take at least two hours to move between the proximal end and the distal end.

[0070] The method may further include consolidating the dyed textile into a roll in the first chamber. Alternatively, the textile may be consolidated into some spatially compacted structure. For example, the method may include consolidating the textile into a folded stack, an accordion-like stack, or an unstructured stack. Consolidating the textile in the first chamber increases the amount of dyed textile that can be stored in the second chamber. Furthermore, consolidating the dyed textile eliminates airflow and / or eddy currents in the textile. This improves the dye fixation process and therefore the resulting color fastness.

[0071] The speed at which the dyed textile is conveyed to the first chamber can be varied. For example, the speed at which the dyed textile is conveyed to the first chamber can be faster than the speed at which it is conveyed to the second chamber. This can result in excess dyed textile in the first chamber. The consolidated textile roll can be separated from the processing line and conveyed to the second chamber. At the same time, consolidation of the excess dyed textile can begin, producing a second roll in the first chamber. In addition, the speed at which the dyed textile is conveyed to the first chamber can be reduced until the excess dyed textile is consolidated. This can reduce downtime of the process. Alternatively, in some embodiments, the processing line is paused to remove the roll from the first chamber.

[0072] The length of the roll may be 50 to 3000 m. More specifically, the length of the roll may be 500 to 1500 m or about 1000 m.

[0073] The method may further include temporarily storing the plurality of rolls of dyed textile in the second chamber. Temporarily storing the plurality of dyed textile, more specifically the rolls of dyed textile, in the second chamber increases thermal mass and reduces free space within the chamber. This reduces the energy required to maintain a controllable environment within the chamber.

[0074] Still further, in some embodiments, the method includes conveying a plurality of rolls of dyed fabric through a plurality of different temperatures in the second chamber, Once the rolls of dyed fabric have been conveyed a predetermined distance through the second chamber, a subsequent roll of dyed fabric may be added to the second chamber.

[0075] As previously disclosed, the second chamber may include multiple temperatures and / or temperature gradients. Each dyed fabric roll may be cooled as it is conveyed through the second chamber. Thus, the thermal energy used to create the temperature gradient in the second chamber may be at least partially received by the addition of the subsequently dyed fabric roll. For example, the temperature of the subsequently dyed fabric roll may be about 180° C. when it enters the second chamber. The temperature of the first dyed fabric roll may be less than 180° C. when the subsequently dyed fabric roll enters the second chamber. For example, the temperature of the first dyed fabric roll may have been reduced to about 175° C., 170° C., 165° C., or 160° C.

[0076] Each roll in the second chamber may be rotated. For example, each roll may be rotated about a roll axis. The roll axis may be an axis about which the fabric is wound to produce the roll. More specifically, each roll in the second chamber may be rotated at a constant rate. Additionally, each roll may be transported along a conveyor in the second chamber. More specifically, each roll may be transported along a conveyor in the second chamber as new rolls are added. In some embodiments, new rolls are added every 10 to 30 minutes.

[0077] In some embodiments, the method further comprises monitoring and / or controlling the cooling rate of the dyed textile after it leaves the second chamber. This may further improve colorfastness. For example, the temperature of the dyed textile when it leaves the second chamber may be about 140° C. The roll of dyed textile is cooled slowly during storage. This may further improve colorfastness of the dyed textile compared to a sample removed in a non-consolidated form and cooled immediately.

[0078] The method may further include conveying the dyed textile through a fixing chamber having a third controllable environment. For example, the dyed textile may be conveyed through the fixing chamber and then temporarily stored in the first chamber and / or the second chamber. The fixing chamber may be configured to reduce the water content of the dye-laden textile and simultaneously initiate the fixing process between the dye and the textile. The third controllable environment may have a third internal temperature.

[0079] The temperature in the fixing chamber may be between 180°C and 220°C. The third controllable environment may have a third internal temperature. When the textile is heated in the fixing chamber to between 180°C and 220°C, the dye is fixed to / within the textile. For example, when the dyed textile is heated to between 180°C and 220°C, at least 90% of the dye may diffuse into the textile fibers. However, in some embodiments, when the dyed textile is heated to between 180°C and 220°C, at least 80%, 85%, 90%, 93%, 95%, 96%, 97%, 98% or 99% of the dye may diffuse into the textile fibers.

[0080] The dyed textile is then stored in the first chamber at 160° C.-200° C., whereby the remaining dye may diffuse locally into the textile fibers, for example, at least 85%, 90%, 93%, 95%, 96%, 97%, 98%, 99% or 100% of the dye may diffuse into the textile fibers in the first chamber.

[0081] The fixation chamber can be configured to heat the dyed textile to the third temperature for between 1 and 15 minutes. In some embodiments, the fixation chamber can be configured to heat the dyed textile to the third temperature for between 0 and 20 minutes, between 1 and 15 minutes, between 2 and 10 minutes, between 3 and 8 minutes, or about 5 minutes.

[0082] The method may further include transporting the second chamber, in which the dyed textile is temporarily stored, to a new location. Transporting the dyed textile temporarily stored in the second chamber to the new location reduces the overall time between when the end user requests the dyed textile and when the end user receives the textile, thereby improving the overall efficiency of the process.

[0083] In some embodiments, the method includes applying a dye to an undyed textile. More specifically, the method may include conveying the undyed textile along a processing line to apply the dye to the undyed textile. A single processing line may be used to both apply the dye to the undyed textile and improve the colorfastness of the dyed textile. Alternatively, in some embodiments, at least two separate processing lines may be used. For example, a first processing line may be configured to apply the dye to the undyed textile and a second processing line may be configured to improve the colorfastness of the dyed textile.

[0084] The method may further include applying the dye containing a colorless dispersant to the undyed textile. The colorless dispersant may further improve the color fastness of the result. For example, the use of the colorless dispersant may replace a washing process. This significantly reduces the overall amount of water required to produce the dyed textile.

[0085] The method may further include dispensing dye onto the textile by an array of channel dispensers. The channel dispenser array may be digitally controlled. Digital control of the channel dispenser array may provide versatility such as real-time or near real-time correction of color mismatches and / or provide near instantaneous color changeovers on the same processing line. For example, applying dye onto the textile by an array of channel dispensers allows for precise deposition of the appropriate dose of dye depending on measured parameters of the textile, as opposed to the traditional method of immersing the textile in a disperse dye bath.

[0086] Accordingly, the present invention relates to a method for improving the colorfastness and / or hand feel of dyed textile fabrics, which improves colorfastness and hand feel while allowing for a continuous roll-to-roll dyeing process without the need for additional downstream processing and washing.

[0087] The present invention includes two methods, which can be used individually or in combination. Thus, according to the present invention, a method for improving the color fastness of dyed textiles is also provided, which includes the steps of conveying a dyed textile along a processing line, applying a fluid to the dyed textile at a first position on the processing line, and then removing at least 50% of the applied fluid from the dyed textile at a second position on the processing line, conveying the dyed textile to a first chamber having a first controllable environment, temporarily storing the dyed textile in the first chamber for a first period of time, conveying the dyed textile to a second chamber having a second controllable environment, and temporarily storing the dyed textile in the second chamber for a second period of time.

[0088] The method may further include removing contaminants from the removed fluid and reapplying the fluid to the dyed textile. The fluid may be sprayed onto the dyed textile.

[0089] The method may further include mechanically agitating the dyed textile. The method may further include adjusting the first controllable environment and / or the second controllable environment based on the characteristics of the textile being dyed, the dye used to dye the textile, and / or the dyed textile. The first chamber may include a first internal temperature. The second chamber may include a second internal temperature that is lower than the first internal temperature.

[0090] The method may further include temporarily storing the dyed textile in the second chamber at a plurality of different temperatures. Alternatively or in addition, the method may further include consolidating the dyed textile into a roll in the first chamber. The method may further include conveying the dyed textile through a fixing chamber having a third controllable environment. The method may further include dispensing dye onto the textile by an array of flow-through dispensers.

[0091] As a result, a method for improving the color fastness of a dyed textile is also provided, the method comprising the steps of conveying the textile along a processing line, dispensing dye onto the textile by an array of flow path dispensers, conveying the dyed textile through a fixing chamber having a first controllable environment, applying a fluid to the dyed textile at a first location on the processing line and then removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line, conveying the dyed textile to a first chamber having a first controllable environment, temporarily storing the dyed textile in the first chamber for a first period of time, conveying the dyed textile to a second chamber having a second controllable environment, and temporarily storing the dyed textile in the second chamber for a second period of time.

[0092] In some embodiments, the dye applied to the fabric may include a standard formulation, which may include approximately 5 g / L of Levafix Blue (reactive dye), 5 g / L of soda ash (alkaline buffer), 1 g / L of caustic soda (catalyst), 1 g / L of Meropane DA (sequestering agent), 2 g / L of wetting agent, 5 g / L of humectant, glycerol or PEG400, and 0.5 g / L of sodium alginate (leveling agent). This formulation may be used to dye cotton fabrics, for example.

[0093] According to the present invention there is also provided an apparatus for improving the colour fastness of dyed textile fabrics, the apparatus comprising a treatment line for conveying the textile fabric in a first direction, a reverse osmosis unit including a fluid reservoir for storing fluid and a filtration unit for removing contaminants from the fluid, a fluid applicator configured to apply the fluid to the textile fabric in a second direction substantially opposite to the first direction, and a fluid removal device configured to remove the fluid from the textile fabric and return it to the reverse osmosis unit.

[0094] The application of the fluid acts to allow for fiber movement in the textile and improves the overall colorfastness. Applying the fluid to the textile by a fluid applicator and then removing the fluid from the textile by a fluid removal device may improve the colorfastness of the textile. Furthermore, excess dye in or on the dyed textile may be removed along with the fluid by the fluid removal device.

[0095] The fluid removal device may be downstream of the fluid applicator. Alternatively, or in addition, the fluid removal device may be located opposite the fluid applicator. The fluid may pass through the fabric.

[0096] The contaminants are removed by reverse osmosis in a reverse osmosis unit configured to remove the contaminants by forcing the contaminated fluid through a semi-permeable membrane. The reverse osmosis unit may be configured to remove salts, ions and / or polymers, such as lignin, from the fluid.

[0097] The reverse osmosis unit may include a fluid reservoir in communication with the fluid applicator. The reverse osmosis unit may further include a filtration unit configured to receive fluid from the fluid removal device, remove contaminants from the removed fluid, and return the decontaminated fluid to the fluid reservoir. The filtration unit may be in fluid communication with the fluid reservoir. The fluid applied to and removed from the fabric may be recirculated via the fluid reservoir.

[0098] The reverse osmosis unit may recover more than 60%, more specifically more than 70%, and most specifically more than 80% of the water used inside the device. Alternatively or in addition, the efficiency of the filtration unit may be more than 90%, more preferably more than 95%, and most preferably more than 98%.

[0099] Fluid recirculation and / or regeneration uses significantly less water and energy than alternatives that require large volumes of water rinsing liquid. The filtration unit may include multiple filters that reduce pore size. The filtration unit may be located between the fluid reservoir and the fluid applicator. Alternatively, or in addition, the filtration unit may be located between the fluid removal device and the fluid reservoir. The filtration unit may be located in line with the fluid applicator, the fluid reservoir, and the fluid removal device.

[0100] Alternatively, or in addition, the filtration unit may be disposed in parallel with the fluid reservoir. Fluid exiting the fluid reservoir may return to the fluid reservoir through the filtration unit. The reverse osmosis unit may include multiple filtration units. The filtration units may be configured to remove dye particles from the fluid.

[0101] The fluid reservoir may be at least partially filled with a liquid. Alternatively, or in addition, the fluid reservoir may be at least partially filled with a gas. The liquid may be water. The gas may be air.

[0102] The fluid applicator and the reverse osmosis unit may form a fluid flow loop. The fluid flow loop may be a continuous fluid flow loop.

[0103] Alternatively, or in addition, contaminants may be removed by ozonation. Ozone treatment may be used to remove (oxidize) chemicals from the fluid. The fluid decontamination process may be a combination of filtration, reverse osmosis and / or ozonation.

[0104] The fluid applicator may comprise a spray nozzle. The spray nozzle may distribute the fluid evenly across the fabric. Furthermore, the fluid applicator may comprise a plurality of spray nozzles. The plurality of spray nozzles may be an array of spray nozzles. The array of spray nozzles may ensure that the sprayed fluid is applied entirely to the fabric. In some embodiments, the fluid applicator is a liquid applicator.

[0105] More specifically, in some embodiments, each spray nozzle may be configured to force fluid through the fabric when in use. Alternatively, or in addition, fluid may be sprayed onto, into, and / or through the fabric when in use.

[0106] The fluid removal device may be configured to generate a partial vacuum, which, when in use, may draw fluid onto, into and / or through the fabric, which, when in use, may remove fluid from the fabric without damage and / or contact to the fabric.

[0107] Alternatively, or in addition, the fluid removal device may be configured to generate a high velocity air stream that passes through the dyed fabric, for example, the dyed fabric may be conveyed between the high velocity air stream and a vacuum.

[0108] The apparatus may further comprise a mechanical agitator, which may comprise a roller, and a single roller may be advantageous for more delicate fabrics, as it provides less mechanical agitation than a pair of rollers, allowing excess dye to be removed without damaging the fabric.

[0109] The mechanical agitator may comprise a pair of rollers. At least one of the rollers may be a roller used to transport the dyed textile along the processing line. The rollers may be reciprocating rollers. At least one roller may be configured to reciprocate in a first direction parallel to the movement of the dyed textile to stretch the dyed textile. Alternatively, or in addition, at least one roller may be configured to reciprocate in a second direction transverse to the movement of the dyed textile to shear the dyed textile. The rollers may reciprocate up to 100 mm. More specifically, the rollers may reciprocate up to 75 mm, 50 mm, 30 mm, 20 mm, or 10 mm. For example, the rollers may reciprocate ±10 mm from a starting position. However, in some embodiments, the rollers may reciprocate ±25 mm from a starting position. Alternatively, or in addition, the mechanical agitator may be configured to vibrate. More specifically, the roller(s) may be configured to vibrate. This may improve the mechanical agitation applied to the textile.

[0110] There may be multiple mechanical agitators. Each agitator may be configured to contact the conveying fabric when in use. The mechanical agitators may move the fibers of the fabric when in use.

[0111] The mechanical agitator may comprise an open surface configured to contact the textile fabric when in use. The open surface may be configured to transmit a mechanical force to the textile fabric. This is advantageous because excess dye that would otherwise remain on the textile fabric may be removed by the mechanical force acting on the textile fabric, further improving the colorfastness of the textile fabric.

[0112] The rough surface of the roller may be knurled.

[0113] The rough surface of the roller may be helical.

[0114] Alternatively, or in addition, the mechanical agitator may comprise a brush, which may be configured to contact the fabric when in use.

[0115] The mechanical agitator may include at least one axis relative to which it can move. For example, the mechanical agitator may include a longitudinal axis along its longest length. The agitator may be configured to rotate about its longitudinal axis. Alternatively, or in addition, the agitator may be configured to move along its longitudinal axis.

[0116] For example, a roller contacting the fabric may be configured to rotate about a longitudinal axis that is substantially perpendicular to the fabric being transported, and conversely, a brush contacting the fabric may be configured to move along a longitudinal axis that is substantially perpendicular or parallel to the fabric being transported.

[0117] The mechanical agitator may be configured to move at a speed different from the speed of the transported fabric, thereby enhancing the effectiveness of the mechanical agitation.

[0118] The device may further comprise a heat exchanger. The heat exchange element is configured to remove thermal energy from the decontamination / contaminated fluid and to provide said thermal energy to the fluid applied to the textile. This allows thermal energy that would otherwise be lost to be reused to help heat the applied fluid to a desired temperature. This means that less energy from an external heat source is required to heat the applied fluid to its required temperature.

[0119] Using a reverse osmosis unit and a heat exchanger in series to recycle heat from the first to the last stage of the process reduces water output from the process to less than 10 L / kg at room temperature, more specifically to less than 1 L / kg at room temperature, and also reduces heat loss to less than 30% (i.e., less than 0.20 MJ / kg), more specifically to less than 20% (i.e., less than 0.15 MJ / kg), and most specifically to less than 10% (i.e., less than 0.10 MJ / kg).

[0120] Alternatively, or in addition, there is also provided an apparatus for improving the color fastness of a dyed textile, the apparatus comprising a processing line configured to transport the dyed textile to a first chamber having a first controllable environment, the first chamber configured to temporarily store the dyed textile for a first period of time, and a second chamber having a second controllable environment, the second chamber configured to temporarily store the dyed textile for a second period of time.

[0121] As previously disclosed, each of the predetermined first and second controllable environments may include a first and second temperature, humidity, pressure, air velocity, and / or inert gas, respectively.

[0122] The second chamber may be directly adjacent to the first chamber. Locating the second chamber directly adjacent to the first chamber reduces heat energy lost from the fabric passing therebetween.

[0123] The second chamber may be mobile. The second chamber may be used to transport the dyed textile, thus utilizing the time the textile is in the second chamber to also move and / or deliver the textile to potential users. This increases the overall efficiency of the dyeing process. For example, the second chamber may be an insulated skip or trolley. Alternatively, or in addition, the second chamber may be an actively heated skip or trolley. The second chamber may comprise at least one wheel, roller and / or caster. More specifically, the second chamber may comprise a plurality of wheels, rollers and / or casters.

[0124] The first chamber can be downstream of the second chamber. As previously disclosed, the first chamber can include a first internal temperature and the second chamber can include a second internal temperature that is lower than the first internal temperature. By placing the first chamber downstream of the second chamber, the fabric can be most efficiently heated to the higher of the two temperatures and then cooled slightly as it progresses to and through the second chamber.

[0125] The second chamber may include a temperature gradient. For example, the dyed fabric may be heated to an elevated temperature before entering the second chamber. Thermal energy of the fabric may be provided while in the first chamber and / or the third chamber. Thus, a temperature gradient may be created by natural cooling of the fabric as it is conveyed through the second chamber.

[0126] The first chamber may include a cylindrical core configured to receive the dyed textile in use to form a roll of dyed textile. The cylindrical core may be a circular tube. The core is configured to receive the dyed textile to form a roll that efficiently packages the dyed textile. This integrated form is easier to move, store, and transport. Furthermore, the cylindrical core may be configured to maintain uniform pressure throughout the roll. The core may be cardboard, plastic, or metal.

[0127] The apparatus may include multiple cores, for example, the apparatus may include two cores, each configured to receive the dyed fabric in sequence.

[0128] The first chamber may include a cutting module configured to cut the fabric to generate separate rolls of dyed fabric. The cutting module may include a blade. By cutting the fabric to generate separate rolls of dyed fabric, each roll may include a predetermined length of dyed fabric. This may improve packaging of the rolls.

[0129] The second chamber may be configured to receive multiple individual rolls of dyed fabric. If the second chamber can receive multiple individual rolls of dyed fabric, the efficiency of the apparatus is increased. Multiple rolls of fabric have a greater thermal mass, which reduces the amount of heat required to generate and maintain a given temperature.

[0130] Alternatively or additionally, when used, each individual roll of dyed fabric may travel through the second chamber. Still further, as previously disclosed, the second chamber may include a temperature gradient. The dyed fabric may be cooled as it travels through the second chamber. Thus, the thermal energy used to create a temperature gradient in the second chamber may be at least partially received by adding the roll of subsequently dyed fabric. The roll of subsequently dyed fabric may be about 180° C. when it enters the second chamber. The roll of initially dyed fabric may be less than 180° C. when the roll of subsequently dyed fabric enters the second chamber. For example, the roll of initially dyed fabric may be about 175° C., 170° C., 165° C., or 160° C.

[0131] More specifically, the second chamber may include a proximal end having a first opening configured to receive an individual roll of dyed textile. The second chamber may include a distal end having a second opening configured to output an individual roll of dyed textile. Each of the first opening and the second opening includes a door and / or a seal. The temperature of the proximal end may be higher than the temperature of the distal end. For example, the proximal end may be about 180° C. and the distal end may be about 140° C. There may be a substantially linear temperature gradient between the proximal end and the distal end. In use, the roll of dyed textile may travel between the proximal end and the distal end. The dyed textile may take at least two hours to travel between the proximal end and the distal end. Once the roll of dyed textile has traveled a predetermined distance toward the distal end of the second chamber, a subsequent roll of dyed textile may be added to the second chamber through the first opening.

[0132] The apparatus may further comprise a fixing chamber configured to receive the dyed textile. The fixing chamber may comprise a third controllable environment configured to heat the dyed textile to a third temperature. The fixing chamber may be configured to heat the textile to 150°C to 240°C. Furthermore, the residence time of the textile in the fixing chamber may be up to 10 seconds. Alternatively, the residence time of the textile in the fixing chamber may be up to 20 seconds, 30 seconds, 40 seconds or up to 60 seconds. However, in some embodiments, the residence time of the textile in the fixing chamber may be longer than 60 seconds. The fixing chamber may be configured to reduce the water content of the textile containing the dye and simultaneously initiate the fixing process between the dye and the textile.

[0133] The fixing chamber may be located downstream of the first and second chambers. Alternatively, or in addition, the fixing chamber may be located upstream of the digital dyeing process. Alternatively, or in addition, the first and second chambers may be located upstream of the digital dyeing process. The digital dyeing process may be as described in WO2020 / 208362, the disclosure of which is incorporated herein by reference. However, in some embodiments, the fixing chamber may be located upstream of the analog dyeing process. For example, the fixing chamber may be located upstream of an exhaust dyeing process, a pad dyeing process, a spray deposition process, a hot or cold transfer process and / or a dye bath.

[0134] The fixing chamber may include an infrared (IR) or near infrared (NIR) drying module configured to heat the dyed textile. IR or NIR is an effective way to increase the temperature of the textile and fix the dye thereon without damaging the textile. The energy delivered to the textile by IR or NIR can also be easily handled and optimized. Moreover, the use of digital dyeing and / or infrared drying can further limit the presence of aggregates on the surface of the textile fibers that may adversely affect colorfastness performance.

[0135] Accordingly, the present invention also relates to an apparatus for improving the color fastness and / or hand of dyed textiles. The present invention includes two apparatuses, which can be used individually or in combination. Thus, according to the present invention, an apparatus for improving the color fastness of dyed textiles is also provided, which comprises a processing line for conveying textiles, a fluid applicator configured to apply a fluid to the conveyed textile, a fluid removal device configured to remove the fluid from the conveyed textile, a first chamber configured to receive the conveyed textile, the first chamber having a first controllable environment and configured to temporarily store the dyed textile for a first period of time, and a second chamber having a second controllable environment and configured to temporarily store the dyed textile for a second period of time.

[0136] Each of the aforementioned chamber environments may be digitally controlled. Alternatively or additionally, the fluid applicator and / or the fluid removal device may be digitally controlled. More specifically, the entire processing line may be digitally controlled. For example, the processing line may include a control unit. The control unit may include a processor. The control unit may be configured to control the environment within each chamber, including but not limited to the temperature and / or cooling rate, as appropriate. Alternatively or additionally, the control unit may be configured to control parameters of the processing line, including but not limited to the speed at which the textile is conveyed along the processing line and / or the temperature of the processing line.

[0137] The processing line, chamber environment, fluid applicator, and / or fluid removal device may be digitally controlled when in use. Thus, the processing line, chamber environment, fluid applicator, and / or fluid removal device may be digitally controlled while the processing line is transporting the fabric.

[0138] The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0139] [Figure 1] FIG. 1 illustrates a method for improving the color fastness of dyed textile fabrics according to some embodiments of the present invention. [Diagram 2] FIG. 1 illustrates a method for improving the color fastness of dyed textile fabrics according to some embodiments of the present invention. [Diagram 3] FIG. 1 illustrates a method for improving the color fastness of dyed textile fabrics according to some embodiments of the present invention. [Figure 4] FIG. 1 illustrates an apparatus for improving the color fastness of dyed textile fabrics according to some embodiments of the present invention. [Diagram 5] FIG. 1 illustrates an apparatus for improving the color fastness of dyed textile fabrics according to some embodiments of the present invention. [Figure 6] FIG. 1 illustrates an apparatus for improving the color fastness of dyed textile fabrics according to some embodiments of the present invention. [Figure 7] FIG. 1 illustrates an apparatus for improving the color fastness of dyed textile fabrics according to some embodiments of the present invention. [Figure 8A] FIG. 1 shows a mechanical agitator in the form of a spiral roller. [Figure 8B] FIG. 1 shows a mechanical agitator in the form of a screw roller. [Figure 8C] FIG. 1 shows a mechanical agitator in the form of a shaping roller. [Figure 8D] FIG. 1 shows a mechanical agitator in the form of a knurled roller. [Figure 9A] FIG. 2 is a cross-sectional view of a mechanical agitator in the form of a brush roller. [Figure 9B] FIG. 1 is a cross-sectional view of a mechanical agitator in the form of a geared roller. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0140] 1 shows a method for improving the color fastness of a dyed textile, the method including conveying 110 a dyed textile along a processing line, applying 120 a fluid to the dyed textile at a first location on the processing line, and then removing 130 at least 50% of the applied fluid from the dyed textile at a second location on the processing line.

[0141] More specifically, the method includes applying 120 a predetermined amount of fluid to the dyed fabric at a first location on the treatment line. The predetermined amount is based on a desired water content of the fabric. The predetermined amount of fluid applied to the fabric is calculated based on a mass flow rate of the fabric along the treatment line.

[0142] The total mass of fluid applied to the dyed textile may be 100% to 300% of the mass of the dyed textile. The fluid applied to the dyed textile at the first position is typically applied at 1 to 20 liters per minute. However, the volumetric flow rate of the applied fluid varies depending on the textile and dye used. Again, the textile is transported along the processing line at typically 1 to 100 meters per minute (m / min). However, again, the speed at which the textile is transported along the processing line varies depending on the textile and dye used.

[0143] The fluid to be applied to the dyed textile at a first location on the processing line is sprayed (step 120). The method includes spraying the dyed textile at a first location on the processing line with the fluid (step 120). The fluid may be sprayed onto the dyed textile by a plurality of spray nozzles configured to spray the fluid across the entire width of the transported textile.

[0144] The fluid may be removed from the fabric by a vacuum. More specifically, the method includes a step 130 of removing at least 50% of the applied fluid from the dyed fabric using a vacuum at a second location on the processing line.

[0145] The method further includes a step of decontaminating the fluid 140. Thus, the method includes a step 110 of conveying the dyed textile along a processing line, a step 120 of applying a fluid to the dyed textile at a first location on the processing line, then a step 130 of removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line, a step 140 of removing contaminants from the removed fluid, and a step 150 of reapplying the fluid to the dyed textile.

[0146] The reapplied fluid is reapplied at a first location on the processing line (step 120). However, in other embodiments not shown in the accompanying drawings, the reapplied fluid may be reapplied at a third location on the processing line.

[0147] The method is continuous. Thus, the method includes a step 110 of continuously conveying the dyed textile along the processing line, a step 120 of continuously applying a fluid to the dyed textile at a first position on the processing line, and then a step 130 of continuously removing at least 50% of the applied fluid from the dyed textile at a second position on the processing line. Furthermore, contaminants are continuously removed from the removed fluid (step 140), and the decontaminating fluid is continuously reapplied to the dyed textile (step 150). The fluid continuously reapplied in step 150 is the fluid that was applied to the dyed textile at the first position on the processing line. At least a portion of the decontaminating fluid is the fluid that was applied to the dyed textile at the first position on the processing line in step 120.

[0148] The method further includes the step of heating the fluid to greater than 40° C. Thus, the fluid applied to the dyed textile at a first location on the processing line is heated to greater than 40° C. (Step 120). More specifically, the method includes the step of heating the fluid to greater than 55° C.

[0149] The method further includes heating the first location in the processing line to between 40 and 95° C. More specifically, the temperature of the environment at the first location on the processing line is between 40 and 95° C. (Step 120). Most specifically, the method includes heating the first location in the processing line to between 50 and 70° C. or about 60° C.

[0150] The method further includes the steps of determining a range of acceptable flow rates of the applied fluid, monitoring the flow rate of the applied fluid, and adjusting the flow rate of the applied fluid if the flow rate of the applied fluid falls outside the range of acceptable flow rates. In use, the applied fluid can be accurately monitored and adjusted.

[0151] The method further includes mechanically agitating the dyed textile. Accordingly, the method includes conveying the dyed textile along a processing line 110, applying a fluid to the dyed textile at a first location on the processing line 120, agitating the textile 125, and then removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line 130, removing contaminants from the removed fluid 140, and reapplying fluid to the dyed textile 150.

[0152] The mechanical agitation occurs between the fluid application step 120 and the fluid removal step 130. More specifically, the dyed fabric is mechanically agitated by a pair of rollers configured to contact the fabric as it is transported along the processing line. The rollers are nip rollers. The mechanical agitation occurs between a first location and a second location on the processing line.

[0153] 2 shows a method for improving the color fastness of a dyed textile. The method includes steps 110 of conveying the dyed textile along a processing line, 210 of conveying the dyed textile to a first chamber having a first controllable environment, 220 of temporarily storing the dyed textile in the first chamber for a first period of time, 230 of conveying the dyed textile to a second chamber having a second controllable environment, and 240 of temporarily storing the dyed textile in the second chamber for a second period of time. The first controllable environment is different from the second controllable environment. More specifically, the second controllable environment includes a temperature gradient.

[0154] The dyed fabric is automatically transported to the first chamber, or conversely, the dyed fabric is manually transported to the second chamber.

[0155] The method further includes adjusting 215 the first controllable environment and / or the second controllable environment based on characteristics of the textile to be dyed, the dye used to dye the textile, and / or the dyed textile. The dye characteristics include dye concentration, color, shade, Pantone, reflectance, water content, color index number, and / or molecular weight. Furthermore, the dyed textile and / or dyed textile characteristics include textile basis weight, absorbent capacity, reflectance, water content, thickness, diameter, and / or batch code.

[0156] The first chamber is maintained at a first internal temperature and the second chamber is maintained at a second internal temperature, the second internal temperature being lower than the first internal temperature.

[0157] More specifically, the first internal temperature is 140° C. to 240° C., and the second internal temperature is 120° C. to 220° C. Most specifically, the first internal temperature is 160° C. to 220° C., and the second internal temperature is 140° C. to 200° C.

[0158] The second period of time is longer than the first period of time. More specifically, the first period of time is at least 10 minutes and the second period of time is at least 30 minutes. Most specifically, the first period of time is at least 40 minutes and the second period of time is at least 2 hours.

[0159] The method further includes determining 250 a cooling rate of the dyed textile and adjusting 260 the controllable environment of the first chamber and / or the second chamber based on the cooling rate. The cooling rate is defined as the time required to cool the textile by 1°C. Furthermore, the cooling rate is determined based on the characteristics of the textile to be dyed, the dyed textile and / or the dye. The cooling rate is calculated prior to the textile dyeing process.

[0160] More specifically, the method includes temporarily storing 240 the dyed textile in a second chamber at a plurality of different temperatures for a second period of time. Most specifically, the method includes transporting 240 the dyed textile through a plurality of different temperatures in a second chamber for a second period of time. Thus, the second chamber includes a temperature gradient.

[0161] The method further includes a step 270 of consolidating the dyed textile into a roll in the first chamber. Furthermore, when in use, the speed at which the dyed textile is conveyed to the first chamber is varied. More specifically, the speed at which the dyed textile is conveyed to the first chamber is faster than the speed at which the dyed textile is conveyed to the second chamber. This results in an excess of dyed textile in the first chamber. The consolidated textile roll is then separated from the processing line and conveyed to the second chamber. At the same time, consolidation of the excess of dyed textile begins to generate a second roll in the first chamber. Additionally, the speed at which the dyed textile is conveyed to the first chamber is reduced until the excess of dyed textile is consolidated.

[0162] The roll of integrated fabric comprises 50 to 3000 m of dyed fabric. More specifically, the roll comprises 500 m to 1500 m or about 1000 m of dyed fabric. Furthermore, each roll in the second chamber is rotated about its roll axis, which is the axis about which the fabric is wound to produce the roll.

[0163] More specifically, the method includes the step 240 of temporarily storing a plurality of rolls of dyed fabric in a second chamber. Once the first roll of dyed fabric has been transported a predetermined distance through the second chamber, a subsequent roll of dyed fabric may be added to the second chamber. As previously disclosed, the second chamber includes a temperature gradient. Thus, each roll of dyed fabric is cooled as it is transported through the second chamber.

[0164] The method further includes a step 280 of conveying the dyed textile through a fixing chamber having a third controllable environment. More specifically, the dyed textile is conveyed through the fixing chamber before being temporarily stored in the first chamber and / or the second chamber. The fixing chamber is configured to reduce the water content of the dye-laden textile and simultaneously initiate the fixing process between the dye and the textile.

[0165] The third controllable environment is maintained at a third internal temperature. More specifically, the temperature within the fixation chamber is between 180°C and 220°C. Furthermore, the fixation chamber is configured to heat the dyed fabric to the third temperature for between 1 minute and 15 minutes. More specifically, the fixation chamber is configured to heat the dyed fabric to the third temperature for between 3 minutes and 8 minutes.

[0166] 3 shows a method for improving the color fastness of a dyed textile, which includes steps 110 of conveying a dyed textile along a processing line, 120 of applying a fluid to the dyed textile at a first location on the processing line, and then 130 of removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line, 210 of conveying the dyed textile to a first chamber having a first controllable environment, 220 of temporarily storing the dyed textile in the first chamber for a first period of time, 230 of conveying the dyed textile to a second chamber having a second controllable environment, and 240 of temporarily storing the dyed textile in the second chamber for a second period of time.

[0167] The method further includes removing contaminants from the removed fluid 140 and reapplying the fluid to the dyed fabric 150. The method also includes mechanically agitating the dyed fabric 125 between the fluid applying step 120 and the fluid removing step 130, and between the fluid removing step 130 and the fluid applying step 150.

[0168] In some embodiments not shown in the accompanying drawings, the method may further include dispensing a dye onto the fabric by an array of fluid dispensers. The dye may be dispensed onto the fabric prior to fluid application. Furthermore, the dye may include a colorless dispersant.

[0169] 4 shows an apparatus for improving the color fastness of dyed textiles. The apparatus 400 comprises a treatment line 410 for conveying textiles 420, a fluid applicator 430 configured, in use, to apply a fluid 435 to the conveyed textiles 420, and a fluid removal device 440 configured, in use, to remove the fluid from the conveyed textiles 420. The fluid removal device 440 is downstream of the fluid applicator 430. Furthermore, the fluid removal device 440 is in fluid communication with the fluid applicator 430 via a reverse osmosis unit 445.

[0170] Fluid applicator 430 and fluid removal device 440 are inside chamber 480. The internal environment of chamber 480 is heated. More specifically, the internal environment of chamber 480 is between 40°C and 95°C. Most specifically, the internal environment of chamber 480 is between 50°C and 70°C. Furthermore, fluid 435 is heated. Fluid 435 is heated above 40°C. More specifically, the fluid is heated to between 50°C and 70°C.

[0171] Apparatus 400 further comprises a reverse osmosis unit 445. Reverse osmosis unit 445 comprises a filtration unit 455 and a fluid reservoir 450. Filtration unit 455 is configured to receive fluid from fluid removal device 440, remove contaminants from removed fluid 435, and provide a decontaminate fluid to fluid applicator 430. More specifically, filtration unit 455 is disposed between fluid removal device 440 and fluid reservoir 450 and is in fluid communication with fluid reservoir 450. Filtration unit 455 comprises a plurality of filters, each filter having a different pore size.

[0172] The fluid applicator 430 comprises a spray nozzle. In use, a fluid is sprayed onto the fabric. More specifically, the fluid applicator 430 comprises a first spray head 432 and a second spray head 434. Each spray head comprises a plurality of spray nozzles. Furthermore, the fluid removal device 440 includes a vacuum. The fluid removal device 440 may be configured to generate a partial vacuum in use.

[0173] The apparatus 400 further comprises a mechanical agitator 460. The mechanical agitator 460 comprises a roller 462. More specifically, the mechanical agitator 460 comprises a pair of rollers 462, 464. The rollers 462, 464 are reciprocating rollers. The rollers reciprocate from a starting position over a range of ±10 mm. Each roller 462, 464 is configured to contact the transported fabric 420 when in use. The mechanical agitator 460 is configured to move the fibers of the fabric when in use. More specifically, the mechanical agitator 460 comprises a rough surface. Most specifically, each roller 462, 464 comprises a rough surface. Some examples of rollers with rough surfaces are shown in Figures 8A-8D and 9A-9B.

[0174] 5 shows an apparatus for improving the color fastness of dyed textiles. The apparatus 500 comprises a processing line 410 configured to convey a dyed textile 420 to a first chamber 530 having a first controllable environment. The first chamber 530 is configured to temporarily store the dyed textile for a first period of time. The apparatus 500 further comprises a second chamber 540 having a second controllable environment. The second chamber 540 is configured to temporarily store the dyed textile for a second period of time.

[0175] The first chamber 530 includes a cylindrical core 532 configured to, in use, receive the dyed fabric 420 to form a roll of dyed fabric 534. The first chamber 530 further includes a cutting module 536 configured to cut the fabric 420 to generate the individual rolls of dyed fabric 380. The cutting module 536 may include a blade 538.

[0176] The second chamber 540 is upstream of the first chamber 530. Furthermore, the second chamber 540 includes wheels 542. The second chamber 540 is mobile. Additionally, the second chamber 540 is configured to receive a plurality of individual rolls 380 of dyed fabric.

[0177] The second chamber 540 includes a temperature gradient. More specifically, the second chamber 540 includes a proximal end 544 having a first opening. The first opening 545 is configured to receive the dyed fabric 380. The second chamber 540 includes a distal end 546 having a second opening 547. The second opening 547 is configured to output the roll of dyed fabric 380. Each of the first opening 545 and the second opening 547 includes a door and / or seal. The temperature of the proximal end 544 is higher than the temperature of the distal end 546. More specifically, the proximal end 544 is about 180° C. and the distal end 547 is about 140° C. There is a substantially linear temperature gradient between the proximal end and the distal end. The roll of dyed fabric 380 is transported from the proximal end 544 of the second chamber 540 to the distal end 546 of the second chamber 530. More specifically, roll 380 of dyed fabric is transported by conveyor belt 548 from proximal end 544 of second chamber 540 to distal end 546 of second chamber 530 .

[0178] 6 shows an apparatus for improving the color fastness of dyed textiles. The apparatus 600 comprises a processing line 410 for conveying textiles 420, a fluid applicator 430 configured to apply a fluid 435 to the conveyed textiles 420, a fluid remover 440 configured to remove fluid from the conveyed textiles 420, a first chamber 530 configured to receive the conveyed textiles 420 and comprising a first controllable environment, and a second chamber 540 having a second controllable environment. The first chamber 530 is configured to temporarily store the dyed textiles for a first period of time, and the second chamber 540 is configured to temporarily store the dyed textiles for a second period of time.

[0179] Apparatus 600 further comprises a reverse osmosis unit 445 configured to receive fluid from fluid removal apparatus 440. The reverse osmosis unit comprises a filtration unit 455 and a fluid reservoir 450. The filtration apparatus 455 is configured to remove contaminants from within the removed fluid 435 and provide a decontaminate fluid to the fluid applicator 430. More specifically, the filtration unit 455 is disposed between the fluid removal apparatus 440 and the fluid reservoir 450 and is in fluid communication with the fluid reservoir 450.

[0180] The apparatus 600 also includes a processing line 410 for transporting the textile 420. The processing line 410 is defined by a plurality of rollers 410 configured to define a path for transporting the dyed textile. Any number of rollers 410 may be used. Each of the plurality of rollers 410 is configured to move relative to one another to extend or shorten the length of the processing line. This may be used to control the mass flow rate of the textile at a given location on the processing line.

[0181] The apparatus 600 further comprises a fixing chamber 610 configured to receive the dyed textile 420. The fixing chamber 610 comprises a third controllable environment configured to heat the dyed textile 420 to a third temperature. More specifically, the fixing chamber is configured to heat the textile to between 150° C. and 240° C. Furthermore, the textile remains in the fixing chamber for between 10 and 60 seconds.

[0182] The fixation chamber 610 is located downstream of the fluid applicator 430, the fluid removal device 440, the first chamber 530 and the second chamber 540. Furthermore, the fixation chamber 610 is located upstream of a digital dyeing process, which is not shown in the accompanying drawings. The digital dyeing process is described in WO2020 / 208362.

[0183] The fixing chamber 610 comprises a drying unit 620 arranged above the dyed textile 420. The drying unit 620 is configured to emit energy as electromagnetic waves. The drying unit emits energy between 20 kW and 200 kW. For example, the drying unit is configured to transfer about 50 kW of energy to the dyed textile. Drying units of 90 to 150 kW are used. The energy is emitted in the form of infrared (IR), near infrared (NIR), mid infrared (MIR), microwave and / or ultraviolet (UV). However, in some embodiments not shown in the accompanying drawings, a plasma heater may be used.

[0184] The drying unit 620 further includes an airflow configured to remove steam and / or humidity from the vicinity of the dyed textile 420. The airflow is configured to remove up to 5 liters of water vapor per minute from the vicinity of the textile. More specifically, the textile 420 having a water content of about 25% enters the fixing chamber 610. The textile exits the fixing chamber with a water content between 0% and 10%.

[0185] The fixation chamber 610 further comprises a reflector 630 disposed beneath the dyed textile 420. The reflector 630 is configured to optimize the amount of emitted energy transferred to the dyed textile.

[0186] The fixing chamber 610 further comprises a temperature sensor 640 configured to measure the temperature of the dyed textile. The dyed textile enters the fixing chamber at approximately room temperature, which may be between 5°C and 45°C, more preferably between 10°C and 35°C, and most preferably between 15°C and 30°C. The temperature of the dyed textile 420 in the fixing chamber 610 is raised by between 5°C and 240°C. For example, the textile enters the fixing chamber 610 at about 25°C and leaves the fixing chamber 610 at about 240°C.

[0187] The fixing chamber 610 is configured to allow the dispensed dye to diffuse into the textile substrate and chemically react with and / or thermally fuse with the substrate.

[0188] The internal environment of the bonding chamber 610 is between 100° C. and 300° C. More specifically, the internal environment of the bonding chamber 610 is between 140° C. and 240° C. However, this temperature may be controlled and / or regulated in use.

[0189] Fig. 7 shows an apparatus for improving the color fastness of dyed textiles. The apparatus 700 comprises a processing line 410, 462, 464, 766 for conveying textiles 420, a fluid applicator 430 configured to apply a fluid 435 to the conveyed textiles 420, and a fluid remover 440 configured to remove the fluid from the conveyed textiles 420. The processing lines 410, 462, 464, 766 are driven by a belt drive 730 connected between two rollers 462 and 464. A motor powers the belt drive 730. The dyed textiles 420 move from left to right across Fig. 7.

[0190] The fluid applicator 430 is disposed inside the chamber 480. The internal temperature of the chamber 480 is between 40 and 80°C, for example about 60°C. The fluid applicator 430 comprises 24 nozzles configured to spray fluid onto the dyed textile. The fluid is a liquid. The fluid is sprayed substantially vertically downwards (i.e. in the direction of gravity). The sprayed fluid fans out between the spray nozzles and the dyed textile to generate a cone-shaped spray pattern. The dyed textile is conveyed at an angle of between 30° and 60° relative to the substantially vertical axis. As a result, the sprayed fluid contacts the dyed textile at an angle of between 20° and 70°.

[0191] The fluid being sprayed is heated by a heating element 705 to a temperature of 60° C. or higher, more specifically, about 80° C.-90° C. The heating element 705 is a trace heater. The fluid is sprayed at about 45 L / min. Moreover, the fluid is sprayed at a pressure of about 0.07 MPa (0.7 bar). The apparatus 700 includes a pump 710 configured to generate the required fluid flow rate and pressure.

[0192] In some embodiments, the fluid applicator 430 is configured to rotate. More specifically, the fluid applicator 430 is configured to rotate up to 360 degrees so that the spray nozzle can be used to wash excess dye from the interior of the chamber 480.

[0193] The chamber 480 is partially filled with a fluid. The fluid is a liquid. The fluid includes any excess fluid sprayed by the fluid applicator 430. More specifically, the fluid is primarily water. However, any suitable fluid may be used. The fluid collects at the bottom of the chamber 480 as shown in FIG. 7. The chamber is configured to accommodate up to 28 liters of liquid. The chamber further comprises a drain 720 having an adjustable weir 722. The adjustable weir is configured to control the amount of liquid and therefore the liquid level X in the chamber 480. More specifically, the weir 722 is configured to control whether the dyed textile conveyed along the processing line passes below the liquid level in the chamber 480. In FIG. 7, the liquid level in the chamber 480 is configured such that the dyed textile is submerged in the liquid at position Y. However, in some embodiments, the liquid level Y is lowered by adjusting the weir 722 such that the dyed textile remains above the liquid level at position Y.

[0194] Excess liquid in chamber 480 spills over weir 722 and exits chamber 480 through drain 720. Drain 720 includes a pump 724 configured to pump fluid from the drain to fluid reservoir 450. Pump 724 is configured to pump fluid at a flow rate of 12 L / min. Drain further includes a filtration unit 455 disposed between weir 722 and fluid reservoir 450. Filtration unit 455 is configured to remove contaminants and particles from within the fluid.

[0195] Furthermore, the fluid reservoir 450 is in fluid communication with the chamber 480 via a conduit 736 having a pump 738. The pump 738 is configured to pump liquid from the fluid reservoir 450 to the chamber 480 to maintain a predetermined liquid level X. The pump 738 is configured to pump liquid at approximately 10 L / min.

[0196] In some embodiments not shown in FIG. 7 , the fluid reservoir 450 is operably connected to a reverse osmosis unit configured to draw fluid from the fluid reservoir 450 via a pump, force the fluid through a semi-permeable membrane to remove contaminants, and then return the fluid to the fluid reservoir 450.

[0197] Fluid reservoir 450 is configured to contain up to 10 liters of liquid. Fluid reservoir 450 may also contain a gas, such as air. Fluid reservoir 450 is in fluid communication with bulk fluid source 726 through pump 728. Pump 728 is a bi-directional pump configured to ensure that the fluid reservoir always contains 10 liters of liquid. Pump 728 is configured to pump fluid at a flow rate of 10 L / min.

[0198] The chamber 480 comprises a mechanical agitator in the form of two rollers 462, 464. The first roller 462 is disposed upstream of the fluid applicator 430, and the second roller 464 is disposed downstream of the fluid applicator 430. The two rollers 462, 464 are configured to reciprocate along a first axis substantially parallel to the movement of the dyed textile between the first roller 462 and the second roller 464 to stretch the dyed textile. Moreover, the two rollers 462, 464 are configured to reciprocate along a second axis transverse to the movement of the dyed textile between the first roller 462 and the second roller 464 to shear the dyed textile. These two reciprocating movements agitate the fibers of the dyed textile. Furthermore, the movement of the dyed textile is configured to rub the applied chemicals, such as softeners or fragrances, into the fibers of the dyed textile. The reciprocating motion of the rollers 462 , 464 is controlled by a rotating cam 732 .

[0199] Chamber 480 further comprises a nip roller 766 configured to apply pressure to the dyed fabric passing between nip roller 766 and a second roller, which in this case is roller 464. However, in other embodiments not shown in FIG. 7, another type of second roller may be used. For example, in some embodiments, multiple nip rollers 766 may be used. The pressure applied by nip roller 766 to the dyed fabric is in the range of 148.0 to 345.3 MPa (1500 to 3500 Kg / cm). 2 ), 197.3~296.0MPa (2000~3000Kg / cm 2 ) or approximately 246.7MPa (2500Kg / cm 2 ). This applied pressure squeezes the liquid out of the dyed fabric. This reduces the liquid content in the dyed fabric to less than 50%. More specifically, the pressure applied by nip roller 766 reduces the liquid content of the dyed fabric to less than 45%.

[0200] The fluid removal device 440 comprises a circular tube 770 configured to emit a gas onto the fabric. The gas is air. However, any suitable gas may be used. In some embodiments, the gas includes a fragrance. The gas is also heated to 40-100°C. The gas is more specifically heated to 60-95°C, and most specifically heated to 80-90°C. The gas is heated by a plurality of finned heaters 772. The gas is emitted from the circular tube 770 at a velocity of 50-160 m / s. The gas is more specifically emitted from the circular tube 770 at a velocity of 80-140 m / s, and most specifically at a velocity of 100-120 m / s.

[0201] The fluid removal device 440 further comprises a collection chamber 773 configured to collect fluids, including liquids and gases, and any solids, including but not limited to contaminants and excess dye particles, that pass through or are released from the surface of the dyed textile 420 proximate the tube 770. The collection chamber 773 comprises a knife edge roller 778 configured to contact the dyed textile 420 proximate the fluid removal device 440. More specifically, the collection chamber comprises a plurality of knife edge rollers 778. Each knife edge roller 778 supports the dyed textile 420 to minimize deflection of the dyed textile 420 produced as a result of the fluid removal device 440.

[0202] The collection chamber 773 is in fluid communication with a separation unit 774 configured to separate gas from liquids and solids. The separation unit 774 includes a vortex or cyclone configured to collect liquid and solid particles at a first end 775, such as a bottom, and release gas from a second end 776, such as a top. The first end 775 of the separation unit 774 is in fluid communication with the fluid reservoir 450 via a pump 715. The pump 715 is configured to pump fluid collected at the first end 775 of the separation unit 774 to the fluid reservoir 450 at a flow rate of 3 L / min. The second end 776 of the separation unit 774 is in fluid communication with the circular tube 770 via a plurality of finned heaters 772. The apparatus 700 further includes a fan 781 configured to generate a gas flow in a conduit 782 connecting the circular tube separation unit 774 to the circular tube 770.

[0203] The dyed fabric downstream of the fluid removal device 440 contains less than 15% liquid content, more specifically, between 5-10% liquid content.

[0204] The chamber 480 further comprises an ionizer 771 configured to ionize the air adjacent the dyed textile adjacent to the fluid removal device 440. This reduces the charge and therefore the surface tension of the dyed textile.

[0205] FIG. 8A shows a mechanical agitator in the form of a spiral roller. Mechanical agitator 460 comprises roller 462. Roller 462 comprises a rough surface. More specifically, roller 462 comprises at least one protrusion 466 on its outer surface. Most specifically, roller 462 comprises two protrusions 466, 467 on its outer surface. Each protrusion is helical and thus winds helically around the outer surface of the roller. Each helical protrusion makes four revolutions around the roller, with one revolution being defined by a "loop" that goes completely around the roller (i.e., 360 degrees). Each revolution of the helix is ​​spaced apart. The gap between each revolution is a groove 481. By way of example, a first revolution 471 and a second revolution 472 are labeled. Each helical protrusion extends over substantially half of roller 462. The two helices meet approximately in the middle of the roller.

[0206] FIG. 8B shows a mechanical agitator in the form of a screw roller. A screw roller is similar to a spiral roller, but each projection 466, 467 has more turns per unit length of the roller. The more turns, the higher the density of the spiral around the roller. In fact, the density of the spiral is so high that each turn of the spiral touches the next turn. Thus, the projections completely surround the roller. Again, the first turn 471 and the second turn 472 are labeled as examples.

[0207] FIG. 8C shows a mechanical agitator in the form of a shaped roller. The roller 462 includes a plurality of protrusions 468 on its outer surface. Although sixteen protrusions are shown in FIG. 8C, only three are labeled. However, any number of protrusions may be present. Each protrusion surrounds the roller such that it extends around the entire circumference of the roller. Additionally, each protrusion includes a ridge or point that extends around the entire circumference of the roller 462.

[0208] 8D shows a mechanical agitator in the form of a knurled roller. Roller 462 includes a plurality of overlapping protrusions 473, 474. Consequently, the roller also includes a plurality of overlapping grooves 481 disposed between overlapping protrusions 473, 474.

[0209] 9A shows a cross-sectional view of a mechanical agitator in the form of a brush roller. Roller 462 includes a plurality of protrusions 476 in the form of bristles protruding from the outer surface of the roller. Each protrusion 476 is flexible. Each bristle may be made from, for example, nylon.

[0210] FIG. 9B shows a cross-sectional view of a mechanical agitator in the form of geared rollers. More specifically, the mechanical agitator 460 comprises a pair of intermeshed rollers 462, 464. Each roller 462, 464 is configured to contact the transported fabric 420 in use. More specifically, the fabric is transported between the rollers 462 and 464. Each roller 462, 464 comprises a rough surface. More specifically, each roller comprises a number of protrusions 478. Each protrusion may be solid and / or rigid. Each roller also comprises a number of grooves, each groove 479 being located between two adjacent protrusions 478. The pair of rollers 462, 464 rotates in such a way that the protrusions 478A of one roller 462 are located within the grooves 179B of the other roller. As such, the transported fabric 420 is deformed as it passes between the rollers 462, 464.

[0211] The invention is further illustrated by the following examples, which are for illustrative purposes only and are not intended to limit the above-mentioned invention. Modifications can be made to the provided examples without departing from the scope of the invention. [Example 1] In this example, the use of the continuous digital dyeing process described in WO2020 / 208362 was employed for the roll-to-roll deposition step. Commercially available disperse dyes were applied to 100% polyester fabric with high precision and control over uniformity and wet addition. The digital approach ensures that all deposited dye is essential for the target shade and that no wash steps to remove excess dye are required to achieve excellent color fastness. The resulting wet fabric was passed through an infrared (IR) fixing chamber to remove the carrier water used in the deposition process. The use of IR ensures that dye uniformity is further improved across the web width of the fabric and limits the formation of aggregates while the fabric is wet.

[0212] The resulting roll of dried dyed fabric was then conveyed to the first chamber, which had a set temperature of 200° C. The line speed was then set to allow the fabric to reside in the first chamber for 5 minutes. The heat treated roll was retained in the first chamber to ensure that no heat was lost from the roll and that it was cut to a set size of 100 m in length.

[0213] The 100m individual rolls were then moved to a second chamber for 2 hours for additional processing. In order that the production rate of the fixing unit could be maintained, several rolls were cut and stored in sequence in the second chamber, ensuring that each roll was exposed to identical thermal conditions. The rolls were then removed and stored to cool.

[0214] Further diffusion occurs during the cooling step: due to the low thermal conductivity of the fabric, the substrate closest to the core will maintain a sufficient temperature to allow for further enhanced diffusion.

[0215] The resulting product had improved color fastness and did not affect the hand of the fabric. [Example 2] The dye deposition method is the same as that applied in Example 1.

[0216] The resulting roll of dried dyed fabric was then transported in a roll-to-roll manner to the first chamber with a set temperature of 170°C. Steam was also added to the first chamber to generate a high humidity environment. The line speed was then set to allow the fabric to reside in the heated steam zone for 8 minutes. The treated substrate was then loosely folded onto an insulated drum and cut into specific lengths of 500m. The drum was then heated to 180°C by an external heat source for 1 hour for additional heat treatment. The resulting product had improved color fastness and no effect on the fabric hand.

[0217] The resulting drum of fabric may be kept in an insulated environment, such as a second chamber, to limit cooling of the fabric. This extends the time at a temperature deemed sufficient for thermally enhanced diffusion. The insulated conveying device is also movable to ensure movement of the dyed fabric. [Example 3] Commercially available dyes with high fastness and minimal or no formulation aids were applied in the manner described using the digital dyeing method. A precise amount of dye was applied to achieve the target shade and the loaded fabric was dried using IR heating. The use of minimal or no-color aids such as surfactants or leveling agents can further improve no-wash fastness performance using this method.

[0218] The dried dyed substrate was then processed in a fixing chamber at 220°C for 3 minutes. The resulting hot substrate is re-stretched onto integrated rolls in the first chamber to ensure the fabric retains heat, minimizing additional heating required to maintain the target temperature. The resulting rolls are then moved to the second chamber where one or more rolls are also kept warm and held at temperature steps for a range of different times. The particular temperature profile is dye and / or fabric specific; however, it will generally be 20°C steps from 180°C to 140°C, with each step typically lasting 20 minutes. This will be controlled by the second chamber. [Example 4] The dye deposition method is the same as that applied in Example 1.

[0219] Commercially available disperse dyes were applied with high precision and control over uniformity and wet addition. Digital techniques ensured that nearly all of the deposited dye was required for the target shade, and minimal excess unfixed dye was left on the surface, followed by an initial heat treatment at 200°C for 5 minutes in a fixing chamber, followed by drying by IR heating.

[0220] The resulting stock was then treated by exposure to a recirculated fluid stream, a combination of water and silicone softener. The fluid was applied to the fabric by a spray nozzle at a flow rate of 15 L / min, providing a wet additive of 150% of the initial stock fabric weight. The fabric was then agitated using a coarse roller to create movement between the fibers to expose any excess dye to the fluid. This mechanical agitation process also improved the penetration of the finishing chemicals. Vacuum removal was then used to reduce the wet additive to 20%. This process of application, agitation and removal was repeated to achieve optimal results. The resulting colorfast fabric was then dried until the wet additive was less than 10%, and the fluid removed from the fabric by vacuum was continuously recovered by filtration and reverse osmosis to yield pure water throughout the duration of the process. [Example 5] The dye deposition method is the same as that applied in Examples 1, 2 and 4.

[0221] The resulting dyed stock was then processed by exposure to a recirculating fluid bath. The fabric was dipped through the fluid bath to achieve a wet loading of 300% of the fabric's weight. Following the fluid bath, the wet loading was then reduced to 100% using nip rollers and mechanical agitation was applied by using brushes rotating at a relative speed of 5 times the speed of the textile line to create agitation inside the fabric. The fluid was then removed by vacuum to leave a wet loading of 40%, and the fluid was recovered by filtration and regenerated inside the fluid system. The resulting fabric was dried under heat and finished.

[0222] Various further aspects and embodiments of the present invention will be apparent to those skilled in the art in view of the present disclosure. As used herein, "and / or" shall be interpreted as a specific disclosure of each of the two specified features or components, regardless of the presence or absence of the other feature or component. For example, "A and / or B" shall be interpreted as a specific disclosure of (i) A, (ii) B, (iii) A and B, as if each of them were individually presented herein.

[0223] Unless the context dictates otherwise, the feature descriptions and definitions presented above are not limited to a particular aspect or embodiment of the present invention, but are intended to apply equally to all aspects and embodiments described. Although the present invention has been described by way of example with reference to certain embodiments, those skilled in the art will further appreciate that the present invention is not limited to the disclosed embodiments, and alternative embodiments may be constructed without departing from the scope of the present invention as defined in the appended claims.

Claims

1. Conveying a dyed fabric along an automated processing line to a first chamber having a first controllable environment; Temporarily storing the dyed fabric in the first chamber for a first period of time; Subsequently, conveying the dyed fabric to a second chamber having a second controllable environment; Temporarily storing the dyed fabric in the second chamber for a second period of time comprising wherein the first chamber includes a first internal temperature; the second chamber includes a second internal temperature lower than the first internal temperature, A method for improving the color fastness of a dyed fabric.

2. Adjusting the first controllable environment and / or the second controllable environment based on the characteristics of the fabric to be dyed, the dye used for dyeing the fabric, and / or the dyed fabric further comprising The method according to claim 1.

3. wherein the first internal temperature is 140°C to 230°C, The method according to claim 1.

4. wherein the second internal temperature is 120°C to 200°C, The method according to claim 1.

5. wherein the second period is longer than the first period, The method according to claim 1.

6. wherein the first period is at least 10 minutes, The method according to claim 1.

7. wherein the second period is at least 2 hours, The method according to claim 1.

8. Determining the cooling rate of the dyed fabric; Adjusting the controllable environment of the first chamber and / or the second chamber based on the cooling rate further comprising The method according to claim 1.

9. Temporarily storing the dyed fabric in the second chamber at a plurality of different temperatures further comprising The method according to claim 1.

10. Conveying the dyed fabric through a plurality of different temperatures in the second chamber which further comprising The method according to claim 1.

11. Integrating the dyed fabric into a roll in the first chamber further comprising The method according to claim 1.

12. Temporarily storing a plurality of rolls of dyed fabric in the second chamber further comprising The method according to claim 11.

13. Transferring the second chamber in which the dyed fabric is temporarily stored to a new position further comprising the method according to claim 1.

14. distributing dye to the fabric by an array of flow path dispensers further comprising the method according to claim 1.

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