Dye-Capturing Non-Woven Fabric Using Non-Covalent Binder Composition
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Solution Overview
Problem
Existing dye-capturing non-woven fabrics face issues with reduced strength due to covalent bonding of color catching substances, limited functionalization, and health and safety concerns from alkaline chemical treatments, leading to potential dye bleeding and increased manufacturing time and costs.
Innovation Solution
A composition comprising polyamido-amine epichlorohydrin, a copolymer of vinylimidazole and vinylpyrrolidone, and citric acid is applied to a non-woven substrate to non-covalently bond dye-capturing agents, allowing for complete substrate functionalization and enhanced dye pick-up, while avoiding alkaline conditions and secondary treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If covalent bonding of color catching substances to base sheet is used, then dye capture capability is improved, but base sheet strength is reduced
Solution Approach 1:
The patent uses a binder as an intermediary substance that non-covalently bonds dye-capturing agents to the base sheet. This binder mediates between the base sheet and the dye-capturing agent, providing attachment without the harsh covalent bonding that weakens the base sheet. The binder maintains base sheet integrity while still enabling effective dye capture functionality.
2Reliability
If GMAC chemistry is used for color capture functionalization, then dye capture capability is improved, but health and safety risks increase due to alkaline conditions and carcinogen release
Solution Approach 1:
The patent fundamentally changes the chemical parameters of the functionalization process by replacing alkaline GMAC chemistry with acid-based or neutral binder systems. This parameter change eliminates the need for high pH conditions and hazardous carcinogenic compounds, thereby reducing health and safety risks while maintaining effective dye capture capability through alternative bonding mechanisms.
3Reliability
If GMAC grafting is performed for 24-36 hours, then dye capture capability is improved, but manufacturing time increases
Solution Approach 1:
The patent applies binder and dye-capturing agent in a pre-mixed composition form before application to the base sheet. This preliminary preparation of the composition allows for rapid simultaneous deposition and bonding, eliminating the need for prolonged 24-36 hour grafting processes. The pre-formulated composition enables fast processing while ensuring effective dye capture functionality is achieved.
4Ease of manufacture
If only cellulosic components are functionalized with GMAC, then processing is simplified, but degree of functionalization is limited
Solution Approach 1:
The patent employs a universal binder system that can attach dye-capturing agents to all types of base sheet materials, not just cellulosic components. This multi-functional approach allows the binder to work with various fiber types including synthetics and natural fibers, thereby increasing the overall degree of functionalization across the entire base sheet while maintaining ease of manufacture through a single processing step.
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
The method achieves a dye pick-up increase of over 20% with improved substrate strength and reduced manufacturing time and costs, minimizing health risks through acid-triggered polymerization.
Implementation Method 1
wherein the composition comprises polyamido-amine epichlorohydrin, a copolymer of vinylimidazole and vinylpyrrolidone and citric acid
Implementation Method 2
the dye-capturing non-woven fabric may be capable for capturing dye from a washing liquor
Data Source
Figure 1~3a
Figure 3b~5
Figure 6
AI summary
The present invention relates to a method for producing a dye-capturing non-woven fabric, the method comprising the steps of providing a non-woven substrate and applying a composition to the non-woven substrate, the composition having binding and dye-capturing functionalities. The present invention further relates to a dye-capturing non-woven fabric obtainable by such a method and a dye-capturing non-woven fabric comprising a non-woven substrate comprising cellulose fibers and a dye-capturing agent adhering to the non-woven substrate by means of a binder and/or a dye-capturing agent being absorbed in the non-woven substrate.