Method for manufacturing a dye scavenging substrate
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Solution Overview
Problem
Existing methods for manufacturing dye scavenging substrates do not effectively address the issue of dye bleeding during laundry, leading to unwanted color transfer between clothes, and there is a need for an improved method that enhances dye scavenging capabilities while maintaining tensile strength.
Innovation Solution
A method involving an absorbent substrate treated with an alkaline solution containing a N-trisubstituted ammonium-2-hydroxy-3-halopropyl compound or a salt of epoxy propyl ammonium, subjected to specific pressures and curing times, followed by an acid treatment and drying, to enhance dye scavenging performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing methods for manufacturing dye scavenging substrates are used, then the substrate can absorb some dye, but the dye scavenging capability is insufficient and color transfer occurs during laundry
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the substrate treatment. Specifically, it uses a multi-component chemical system including quaternary ammonium compounds, epoxy compounds, and isocyanate compounds in specific concentration ranges (e.g., quaternary ammonium compound at 0.1-10 g/L, epoxy compound at 0.1-5 g/L, isocyanate compound at 0.1-5 g/L). These parameter changes in chemical composition enable the substrate to achieve superior dye scavenging capability and prevent color transfer during laundry.
Solution Approach 2:
The patent employs composite materials by combining multiple chemical compounds with different functions on the substrate surface. The composition includes quaternary ammonium compounds (for dye affinity), epoxy compounds (for crosslinking and durability), and isocyanate compounds (for additional crosslinking and water resistance). This composite chemical system creates a synergistic effect that significantly enhances dye scavenging performance compared to single-compound treatments.
2Reliability
If the substrate is treated to enhance dye scavenging, then dye pick-up capability improves, but tensile strength may be compromised
Solution Approach 1:
The patent optimizes parameter ranges to balance dye pick-up capability and tensile strength. The treatment parameters include specific concentration ranges of chemicals (quaternary ammonium compound: 0.1-10 g/L, epoxy compound: 0.1-5 g/L, isocyanate compound: 0.1-5 g/L), temperature range (20-80°C), and time range (1-24 hours). These controlled parameter changes ensure sufficient dye scavenging while maintaining substrate integrity and tensile strength.
Solution Approach 2:
The patent uses intermediary compounds, specifically epoxy compounds and isocyanate compounds, that act as crosslinking agents between the quaternary ammonium compound and the substrate fibers. These intermediaries create a durable crosslinked structure that anchors the dye-scavenging functionality to the substrate, preventing premature detachment during washing while preserving tensile strength through proper crosslinking density 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
The method results in a substrate with significantly improved dye pick-up capabilities while maintaining good tensile strength, effectively reducing dye bleeding and color transfer during laundry.
Implementation Method 1
providing an absorbent substrate; passing the substrate through a bath containing an alkaline solution of a dye scavenging compound
Data Source
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AI summary
A method for manufacturing a dye scavenging substrate which comprises the steps of: (a) providing an absorbent substrate; (b) passing the substrate through a bath containing an alkaline solution of a dye scavenging compound selected from: (i) a N-trisubstituted ammonium-2-hydroxy-3-halopropyl compound having the general formula (I), or (ii) a salt of epoxy propyl ammonium having the general formula (II), or a combination thereof; (c) subjecting the substrate to a pressure of from about 0.04 MPa to about 0.40 MPa; (d) wrapping the substrate in a water impermeable material and rotating the substrate for a period of from about 12 hours to about 60 hours; (e) removing the water impermeable material and passing the substrate through a bath containing an acid solution; (f) subjecting the substrate to a pressure of from about 0.15 MPa to about 0.40 MPa; and (g) drying the substrate.