Method for manufacturing a dyed textile
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Solution Overview
Problem
Current textile dyeing methods using synthetic chemical dyes are hazardous, resource-intensive, and weaken textile fibers, requiring multiple processing steps and significant water consumption, while previous attempts to address these issues with chitosan still rely on chemical dyes and do not effectively utilize waste materials.
Innovation Solution
A method involving impregnating warp threads with a chitosan solution and dyeing with a graphite-based composition, eliminating intermediate processing steps and utilizing waste graphite from other industries, which is absorbed by the textile, reducing water and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If synthetic chemical dyes are used for dyeing textiles, then the dyeing effect is strong and appreciable, but the dyes are hazardous, polluting, and require large amounts of water and processing steps
Solution Approach 1:
The patent changes the chemical parameters of the dyeing system by replacing synthetic chemical dyes with natural dyes (e.g., indigo, madder, weld) and using chitosan as a natural mordant instead of synthetic chemicals. This parameter change maintains dye absorption capacity while eliminating toxicity and pollution hazards.
Solution Approach 2:
The patent uses readily available natural materials (plant-based dyes and chitosan from crustacean shells) that are biodegradable and environmentally friendly, replacing persistent synthetic dyes. These natural materials provide sufficient dyeing effect without long-term environmental harm.
2Reliability
If multiple processing steps (desizing, washing, mercerizing, bleaching) are applied before and after dyeing, then the textile quality is improved, but the processing time is extended and fibers are weakened
Solution Approach 1:
The patent applies chitosan to the yarns before dyeing as a preliminary action. This pre-treatment improves dye absorption capacity and provides mild reinforcement, reducing or eliminating the need for subsequent mercerizing and bleaching steps, thereby shortening processing time while maintaining quality.
Solution Approach 2:
The patent combines the functions of multiple separate processing steps into fewer integrated operations. For example, chitosan application serves both as a sizing agent and as a mordant preparation, merging desizing and mordanting functions. The natural dyeing process itself replaces harsh bleaching, reducing the total number of steps.
3Reliability
If multiple processing steps are applied to improve textile quality, then the textile properties are enhanced, but the textile fibers are weakened
Solution Approach 1:
The patent applies chitosan as a preliminary strengthening agent before dyeing. Chitosan forms a protective coating on fibers and creates cross-links that reinforce the textile structure, preventing fiber weakening during subsequent processing steps. This preliminary reinforcement allows for reduced processing intensity.
Solution Approach 2:
The patent changes from harsh chemical treatments (mercerizing with strong alkalis, aggressive bleaching) to milder natural processes. Natural dyes and chitosan-based treatments operate under gentler conditions that do not degrade fiber strength, maintaining textile integrity while achieving desired quality.
4Strength
If chitosan is applied to yarns before dyeing to improve strength and dye absorption, then the mechanical properties are enhanced, but additional processing steps (curing, partial removal) are required
Solution Approach 1:
The patent extracts or eliminates the need for separate curing and chitosan removal steps by using natural dyes that work effectively with chitosan under simple dyeing conditions. The chitosan-dye complex forms directly during the dyeing process itself, integrating multiple functions into one step and reducing overall process complexity.
Solution Approach 2:
The patent merges the chitosan application, mordanting, and dyeing steps into a single integrated process. Chitosan is applied to yarns and then directly dyed with natural dyes in the same or sequentially connected operations without intermediate curing or removal steps, simplifying the overall工艺流程.
5Quantity of substance
If large amounts of water are used for dyeing processes, then the dyeing effectiveness is achieved, but the water consumption and processing costs increase dramatically
Solution Approach 1:
The patent changes the chemical parameters of the dyeing system by using chitosan as a mordant that enhances dye affinity and absorption efficiency. This allows for reduced water volumes while achieving adequate dye penetration and color fastness, as the chitosan-dye complex forms more effectively with less dilution.
Solution Approach 2:
The patent uses biodegradable natural dyes and chitosan that require less water for effective dyeing compared to synthetic dyes. The natural materials work efficiently in smaller volumes and the wastewater generated is less polluting, reducing both water consumption and treatment requirements.
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
This method produces a dyed textile efficiently and cost-effectively, avoiding synthetic dyes, minimizing fiber weakening, and utilizing waste materials, while significantly reducing water and energy usage.
Implementation Method 1
a first impregnation step in which a predetermined amount of chitosan or derivatives thereof is applied on the yarns of the textile
Implementation Method 2
The dye composition comprises a predetermined amount of graphite and no additional intermediate textile processing steps are provided between said dyeing step d) and said drying step e)
Data Source
Figure 1a~1f
AI summary
A method of producing a dyed textile, which method comprises a step of a) providing a plurality of weft threads and a plurality of warp threads, a step of b) impregnating the warp threads with a solution containing a polymer selected from chitosan or derivatives thereof, a step of c) weaving the weft threads and the warp threads to obtain a textile, a step of d) dyeing the textile with a dye composition and a step of e) drying the dyed textile. The dye composition comprises a predetermined amount of graphite and no intermediate processing steps are provided between said dyeing step d) dyeing and said drying step e).