Concentrated Liquid Dye Injection for Zero-Effluent Garment Dyeing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing garment dyeing processes are wasteful, inefficient, and inflexible, requiring large quantities of dye, water, and other substances, leading to environmental impact and inability to adapt to rapid changes in consumer color preferences.
Innovation Solution
A dyeing apparatus and method using a concentrated liquid dye system that dispenses dyestuff based on garment parameters, eliminating additives like salts and operating at ambient temperature, with a closed-loop system for solvent reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional pre-mixed dye solutions are used in large quantities, then the desired color can be applied to the garment, but excessive water and dye are consumed and must be disposed of
Solution Approach 1:
The patent extracts only the necessary dyestuff from the conventional pre-mixed solution and delivers it in a concentrated form directly to the garment, eliminating the need for large volumes of water and unnecessary dye that would otherwise be consumed and disposed of
Solution Approach 2:
The patent changes the concentration parameter of the dye delivery system, using highly concentrated dyestuff formulations that require minimal volume to achieve the desired color application, thereby reducing both water and dye consumption while maintaining color accuracy
2Reliability
If complex filtering and treatment methods are used post-dyeing, then water quality can be improved, but the process becomes more expensive and time-consuming
Solution Approach 1:
The patent performs preliminary action by ensuring complete dyestuff absorption during the dyeing process itself, preventing contaminants from entering the water stream in the first place, thereby eliminating the need for subsequent filtering and treatment operations
Solution Approach 2:
The patent converts the potential harm of dyestuff contamination into a benefit by designing a system where the dyestuff is completely absorbed by the garment, transforming what would be waste requiring treatment into a useful color application with zero effluent contamination
3Productivity
If large-batch manufacturing processes are used, then production volume can be maintained, but flexibility to adapt to changing consumer color preferences is lost
Solution Approach 1:
The patent introduces dynamics into the dyeing system by enabling rapid adjustment of dyestuff delivery parameters and complete drainage/refill cycles that allow the system to adapt to different color preferences quickly, transforming a static large-batch process into a dynamic system capable of responding to changing consumer demands
Solution Approach 2:
The patent enables discarding of used dyebath fluid through rapid drainage and recovery of the concentrated dyestuff formulation for reuse or adjustment, allowing the system to pivot to new color preferences without being constrained by large batch commitments
4Reliability
If rigid dyeing systems are used, then process control can be maintained, but customization of garment colors and patterns becomes difficult
Solution Approach 1:
The patent applies segmentation by dividing the dyestuff delivery into controllable portions that can be independently adjusted for different garments and patterns, allowing customization while maintaining overall process control through systematic delivery management
Solution Approach 2:
The patent creates a universal dyeing system that can handle both standardized and customized garments through the same concentrated dyestuff delivery mechanism, enabling multi-functionality where the system adapts to different customization requirements without sacrificing process control
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
Minimizes waste and environmental impact, enables on-demand dyeing with reduced resource consumption, and allows for rapid color changes without sacrificing efficiency.
Implementation Method 1
the garment absorbs just a portion of dyestuff present in the dyebath
Implementation Method 2
substantially all of the dyestuff in the dispensed volume of concentrated liquid dye is absorbed by the at least one garment
Data Source
AI summary
Described herein are apparatuses and methods for dyeing garments. An exemplary apparatus comprises a dye injection system configured to dispense concentrated liquid dye; a dyeing machine comprising a dyeing chamber configured for dyeing at least one garment in a dyebath; and a controller in communication with the dye injection system and the dyeing machine, wherein the controller is configured: to receive at least one garment parameter corresponding to the at least one garment; based at least in part on the at least one received garment parameter, cause the dye injection system to dispense a volume of concentrated liquid dye containing an amount of dyestuff that can be substantially absorbed by the at least one garment; and cause the dyeing machine to execute a dye cycle such that substantially all of the dyestuff in the dispensed concentrated liquid dye is absorbed by the at least one garment within the dyeing chamber.