Colored Yarn Production With Self-Eluting Additives for Low-Wastewater Dyeing
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Solution Overview
Problem
The textile dyeing process generates large quantities of wastewater contaminated with colorants and chemicals, posing environmental and health hazards, and existing dope-dyeing processes still require significant water and chemical use.
Innovation Solution
A method for producing colored yarns and fabrics using a self-elutable and water-soluble spinning additive that is added during the dope-dyeing process, allowing for easy removal with water without detergents, reducing chemical usage and wastewater generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional aqueous color solutions and auxiliary chemicals are used for coloring textiles and yarns, then the coloring process can be supported and completed, but large quantities of contaminated wastewater are generated requiring expensive cleaning
Solution Approach 1:
The patent extracts and eliminates auxiliary chemicals from the coloring process by using a spinning additive that performs multiple functions (spinning support, coloring, and self-removal) without requiring separate auxiliary chemical agents. This extraction of harmful chemicals directly reduces wastewater contamination while maintaining the coloring process reliability.
Solution Approach 2:
The spinning additive is designed to be self-elutable and self-sluicing, meaning it automatically removes itself from the yarn during the washing process without requiring additional detergents or chemicals. This self-service property eliminates the need for separate auxiliary chemicals and reduces wastewater contamination while supporting the coloring process.
2Object-generated harmful factors
If the dope-dyeing process is used to reduce environmental impact, then chemical usage is reduced, but water consumption remains high and environmental burden persists
Solution Approach 1:
The patent changes the parameters of the spinning additive to be water-soluble and self-elutable, allowing it to be removed through simple water washing without requiring large quantities of water for multiple washing cycles. This parameter change enables reduced water consumption while maintaining the environmental benefits of the dope-dyeing process.
Solution Approach 2:
The self-removing property of the spinning additive allows for easier and more efficient water removal during the washing process. The additive automatically detaches and is flushed away with minimal water, reducing the total water consumption compared to conventional processes that require extensive washing to remove auxiliary chemicals.
3Strength
If spinning additives are added during dope-dyeing to prevent fiber breakage, then fiber integrity is maintained, but environmental impact and water consumption increase
Solution Approach 1:
The spinning additive is designed to automatically remove itself during the washing process, eliminating the need for separate removal steps and reducing environmental impact. The self-elutable property allows the additive to maintain fiber integrity during spinning while automatically detaching to be removed with minimal water, reducing overall environmental burden.
Solution Approach 2:
The patent modifies the spinning additive to have water-soluble and self-elutable parameters, allowing it to be easily removed through water washing. This parameter change reduces the environmental impact by enabling simple water-based removal without requiring additional chemicals or extensive water consumption, while still providing the necessary fiber protection during spinning.
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
Significantly reduces environmental impact by minimizing wastewater contamination and enabling water reuse, thus lowering water consumption and chemical demand in textile production.
Implementation Method 1
the spinning additive is self-elutable and/or self-sluicing upon washing the yarn with an aqueous solution and/or the spinning additive is water-soluble
Data Source
AI summary
This invention relates to a method for producing a colored yarn based on synthetic fibers, wherein the method comprises the addition of a spinning additive. The spinning additive is self-elutable and/or self-sluicing upon washing the yarn and/or a fabric spun from the yarn with an aqueous solution and/or the spinning additive is water-soluble. The spinning additive can therefore be easily removed from the yarn and/or fabric produced of the yarn by washing with water.