Dry Enzyme Fabric Ageing With Controlled Humidity Activation
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Solution Overview
Problem
Existing fabric treatment methods using aqueous baths for artificial ageing, such as stone washing, are environmentally detrimental due to water usage and enzyme residue contamination, and are limited by temperature sensitivity of enzymes.
Innovation Solution
A dry treatment method involving atomization of an enzyme compound mixture with water and optional surfactants, activated in a controlled humidity, time, and temperature environment within an industrial dryer, reducing water usage and enzyme deactivation through heat and ozone cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If an aqueous bath is used to apply enzyme compounds for fabric ageing, then the enzyme application is effective and uniform, but water consumption increases significantly and enzyme residues contaminate the environment
Solution Approach 1:
The patent extracts the enzyme application process from the traditional aqueous bath environment and implements it in a dry or reduced-water environment within a drum dryer, eliminating the need for large quantities of water while maintaining enzyme effectiveness through controlled humidity and temperature conditions
Solution Approach 2:
The patent changes the physical parameters of the treatment environment by controlling humidity levels and temperature cycles in the drum dryer, allowing enzyme compounds to remain effective without requiring an aqueous bath, thus reducing water consumption while maintaining application reliability
2Productivity
If steam is used in treatments involving enzymes for fabric ageing, then the treatment process is simplified, but enzyme deactivation occurs due to high temperature sensitivity
Solution Approach 1:
The patent applies dynamic temperature control in the drum dryer, using cyclic heating and cooling patterns that allow the fabric to reach temperatures beneficial for ageing effects while ensuring enzymes are deactivated only at specific stages, thus maintaining both process efficiency and enzyme activity where needed
Solution Approach 2:
The patent employs periodic temperature cycles in the drum dryer treatment, alternating between periods that activate desired fabric modifications and periods that control enzyme deactivation, preventing premature enzyme destruction while maintaining productive treatment flow
3Quantity of substance
If an aqueous bath is used for enzyme treatment, then complete fabric coverage is achieved, but significant quantities of contaminated water require draining and environmental disposal
Solution Approach 1:
The patent extracts the treatment process from the aqueous bath system entirely, using a dry environment in the drum dryer that eliminates contaminated water generation while still achieving complete fabric coverage through drum rotation and controlled humidity application
Solution Approach 2:
The patent converts the traditionally harmful aqueous waste stream into a beneficial dry or reduced-water process where no contaminated water is generated, transforming an environmental liability into an environmentally friendly treatment approach
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 water consumption by limiting water use to rinsing steps, maintains enzyme effectiveness, and achieves effective fabric ageing with improved cleaning of dye contamination, while minimizing environmental impact.
Implementation Method 1
the action of the small balls of solid material is integrated or even completely replaced by enzymatic products that impregnate the textile substrate, this way performing their action on the complete fabric; examples of such a treatment are described in PTL 0001: US 4912056 A (ECOLAB INC [US]). 1990-03-27. or in PTL 0002: WO WO 01/57173 A (BAYER AG [DE]). 2001-08-09.
Implementation Method 2
Ozone Cleaning and Bleaching (35) consisting of making the treated fabric pass through an ozone machine
Data Source
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AI summary
A method for the artificial ageing of fabrics by applying an enzyme compound without using an aqueous bath.