Foamed Indigo Dye Applicator Layout for Low-Waste Textile Dyeing
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Solution Overview
Problem
The existing indigo dyeing process for cellulosic textile materials is complex, expensive, and generates significant waste due to the need for multiple vats and continuous recirculation of dye liquor, leading to environmental concerns and high disposal costs.
Innovation Solution
An apparatus that applies foamed leuco-state dye in a controlled inert atmosphere, allowing partial collapse and oxidation of the dye on the substrate before exposure to ambient air, reducing waste and improving dye affixation on cellulosic fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple sequential dye vats are used to achieve deep indigo color on cellulosic fibers, then the desired deep color and shade are obtained, but the device complexity and process cost increase significantly
Solution Approach 1:
The patent combines multiple sequential dyeing operations into a single continuous chamber where fabric passes through multiple zones. Each zone applies leuco-state dye foam sequentially, and oxidation occurs automatically in the same chamber before fabric exit, eliminating the need for separate vats and intermediate handling.
Solution Approach 2:
The patent applies leuco-state dye foam to the fabric surface before oxidation occurs. This preliminary application in the reduced state allows deep penetration into cellulosic fibers, and subsequent oxidation within the same chamber completes the dyeing process without requiring multiple separate vats.
2Quantity of substance
If leuco-state indigo dye is diluted to low concentration for penetration into cellulosic material, then the dye can penetrate the fabric, but the amount of water and dye required increases
Solution Approach 1:
The patent changes the physical state of the dye application from liquid to foam. The foamed leuco-state dye maintains low concentration for penetration but uses gas bubbles to deliver the dye more efficiently, reducing overall water consumption and waste compared to traditional liquid vat dyeing.
3Reliability
If the substrate is exposed to atmosphere during the dyeing process, then oxidation can occur to set the indigo, but control over the oxidation process is lost
Solution Approach 1:
The patent maintains an inert atmosphere (nitrogen or carbon dioxide) throughout the dyeing chamber, preventing premature oxidation of the leuco-state dye. Oxidation is controlled by introducing oxygen at a specific point in the process, allowing precise control over when and how the dye sets on the fabric.
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
This approach enhances control over the dyeing process, reduces waste and environmental impact, and allows for efficient affixing of indigo dye on textile substrates with less water and dye usage, thereby lowering costs and improving the quality of the dyeing process.
Implementation Method 1
A foam generator generates foam containing the leuco-state dye in the absence of oxygen with the generator communicating with the applicator for supplying the foamed leuco-state dye to the applicator
Implementation Method 2
A supply of inert gas communicates with the chamber to provide an inert environment therein
Implementation Method 3
allowing partial collapse and oxidation of the dye on the substrate before exposure to ambient air
Data Source
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AI summary
An apparatus for dyeing a textile substrate using a plurality of applicators that each apply an increment of a total dye application. In one form a reduced indigo dye in a leuco- state is applied in an inert atmosphere substantially isolated from oxidizing substances. In another form the foamed dye is applied while open to the atmosphere. In both forms holddown rollers or inverted applicators are located between applicators at decreasing depths to minimize increases in tension as the substrate travels over successive applicator faces.