Cationic Regenerated Cellulosic Fiber Dye Scavenging
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Solution Overview
Problem
Existing methods for manufacturing dye-catching fabrics suffer from chemical wastage, low efficiency, and non-uniform coating, leading to ineffective removal of extraneous dyes during washing, which causes undesirable discoloration and dye transfer between fabrics.
Innovation Solution
A continuous process for producing cationic regenerated cellulosic fibers involves treating wet cellulosic fibers with an alkaline solution of 3-halo-2-hydroxyalkyl-N,N,N-tri-alkyl or aryl substituted ammonium compounds, followed by a moisture regulating step and curing at controlled temperatures to achieve high dye absorption capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dye catcher sheets are manufactured by cationization of fabrics with polymeric/monomeric additives and curing, then dye scavenging capability is achieved, but chemical wastage increases and manufacturing complexity increases
Solution Approach 1:
The patent changes the fundamental parameter of applying cationic modifiers - instead of coating finished fabrics, it applies cationic modifiers during fiber formation in the wet state. This parameter change eliminates the need for subsequent coating chemicals and curing agents, thereby reducing chemical wastage while achieving the same dye scavenging capability through intrinsic fiber modification.
Solution Approach 2:
The patent performs cationization as a preliminary action during fiber formation rather than as a post-processing step. By incorporating cationic modifiers into the fiber structure before the fabric is complete, the patent eliminates the need for subsequent coating operations, reducing both chemical wastage and manufacturing complexity.
2Reliability
If fabric is coated with dye scavenging material using conventional coating processes, then dye catcher functionality is achieved, but coating uniformity decreases and manufacturing complexity increases
Solution Approach 1:
The patent performs cationization during fiber formation as a preliminary action, ensuring uniform distribution of cationic modifiers throughout the fiber structure before fabric assembly. This eliminates the variability inherent in post-fabric coating processes and achieves consistent dye catcher functionality across the entire product.
Solution Approach 2:
The patent achieves local quality by incorporating cationic modifiers uniformly at the fiber level during formation. This ensures that every part of the fabric possesses identical dye scavenging properties, eliminating the non-uniformity associated with surface coating processes.
3Reliability
If cationization is performed on finished fabrics, then dye scavenging capability is achieved, but process time increases and productivity decreases
Solution Approach 1:
The patent merges the cationization step with the fiber formation process, combining two operations into one continuous process. This integration eliminates separate processing steps and reduces overall manufacturing time, thereby increasing productivity while maintaining dye scavenging capability.
Solution Approach 2:
By performing cationization as a preliminary action during fiber formation rather than as a subsequent treatment, the patent eliminates the need for additional process time after fabric production, thereby maintaining high productivity while achieving dye scavenging functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in fibers with enhanced dyeability and dyeing fastness, significantly improving the ability to absorb direct and reactive dyes, reducing dye transfer, and offering a more efficient and eco-friendly solution for commercial and domestic laundry applications.
Implementation Method 1
treating wet cellulosic fibers with an alkaline solution of 3-halo-2-hydroxyalkyl-N,N,N-tri-alkyl or aryl substituted ammonium compounds
Implementation Method 2
curing at controlled temperatures to achieve high dye absorption capacity
Implementation Method 3
subjecting the treated regenerated cellulosic fiber to a moisture regulating step such that the moisture content in the treated cellulosic fiber is not more than 120% of weight
Data Source
AI summary
A process for continuous production of a cationic regenerated cellulosic fiber is disclosed. Said process comprises the steps of: (a) providing a wet regenerated cellulosic fiber; (b) treating said regenerated cellulosic fiber with an alkaline solution of 3-halo-2- hydroxyalkyl-N,N,N-tri-alkyl or aryl substituted ammonium compound having the general formula I, or a salt thereof while maintaining a pH of around 9-13 (Formula I) X wherein X is a halogen selected from a group consisting of chloride and bromide; R1, R2, R3, are individually selected from a group consisting of C1-C4 alkyl, benzyl and substituted benzyl groups; and R4 is hydrogen; (c) subjecting the treated regenerated cellulosic fiber to a moisture regulating step such that the moisture content in the treated cellulosic fiber is not more than 120% of weight of the treated cellulosic fiber; and (d) curing the treated cellulosic fiber at a temperature ranging between 100° C and 145° C, to obtain regenerated cellulosic fiber which is cationically modified by 3-halo-2- hydroxyalkyl-N,N,N-tri-alkyl or aryl substituted ammonium compound having formula I, or a salt thereof in an amount ranging between 1.5 to 33 % by weight.