Dry Enzyme Aging of Fabrics With Atomized Application
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Solution Overview
Problem
Existing fabric aging methods using aqueous baths are environmentally detrimental due to water usage and enzyme residue contamination, and are limited by temperature sensitivity of enzymes, which restricts the use of steam and efficiency.
Innovation Solution
A dry 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 enabling enzyme deactivation without rinsing, and optionally incorporating ozone cleaning and abrasive elements for enhanced aging effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an aqueous bath is used to apply enzyme compounds to fabric, then the enzyme application is effective and uniform, but water consumption is high and enzyme residues contaminate the environment
Solution Approach 1:
The invention extracts the essential function of enzyme application from the aqueous bath medium, using atomized spray technology to deliver enzyme compounds directly to the fabric surface without requiring large volumes of water as a carrier medium
Solution Approach 2:
The invention changes the physical state and delivery method of enzyme compounds from liquid bath immersion to atomized spray deposition, transforming the application parameters to achieve both uniform distribution and minimal water usage
2Manufacturing precision
If an aqueous bath is used for enzyme treatment, then enzymes can be applied effectively, but significant quantities of contaminated water must be drained which is dangerous for the environment
Solution Approach 1:
The invention extracts the harmful aqueous waste stream from the process by eliminating the bath system entirely, retaining only the essential enzyme application function through atomized delivery
Solution Approach 2:
The invention discards the contaminated water generation inherent in bath systems by transitioning to a spray application method that uses minimal water and produces no significant waste stream requiring drainage and treatment
3Temperature
If steam is used in treatments involving enzymes, then high temperature processing is achieved, but enzyme activity is lost due to temperature sensitivity
Solution Approach 1:
The invention applies enzyme compounds to the fabric surface first through atomized spray, establishing the enzymatic treatment layer before subsequent steam processing, allowing the enzymes to begin their action at lower temperatures before the steam cycle
Solution Approach 2:
The invention uses periodic or sequential processing where enzyme application occurs in a separate stage before steam treatment, allowing enzyme activity to occur during the application and initial drying phases, then deactivation occurs during the subsequent steam cycle
4Loss of substance
If a dry method with atomization is used, then water consumption is reduced, but the complexity of controlling humidity, time, and temperature increases
Solution Approach 1:
The invention uses an industrial dryer as a multi-functional device that performs both the controlled humidity incubation for enzyme activation and the subsequent drying operation, eliminating the need for separate controlled environment chambers
Solution Approach 2:
The invention uses the natural humidity and temperature conditions within the industrial dryer during its normal operation cycle to provide the controlled environment needed for enzyme activation, rather than requiring additional specialized equipment
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 it to rinsing steps only, maintains enzyme effectiveness, and achieves effective fabric aging with improved cleaning and visual appearance, while minimizing environmental impact.
Implementation Method 1
The action of enzymes depends on size, starches present in raw fabric, and the cellulose fiber of the yarn or on the Indigo colour used in Denim fabrics
Implementation Method 2
Ozone Cleaning and Bleaching
Implementation Method 3
abrasive stones which, by rolling them together with fabric in a washing machines' rotating drum
Data Source
AI summary
A method for the artificial aging of fabrics by applying an enzyme compound without using an aqueous bath.