Low-Liquor Textile Dyeing in Closed Containers
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Solution Overview
Problem
Conventional textile dyeing processes consume large volumes of water and auxiliaries, leading to environmental and economic challenges, and existing alternatives like supercritical carbon dioxide and ultrasound technologies are either energy-intensive or not commercially viable.
Innovation Solution
A method involving the treatment of textile substrates with a solid particulate treatment agent in an aqueous system at a liquor-to-substrate ratio of ≤2:1, using a closed container to minimize water usage and eliminate the need for high-energy processes, while achieving comparable dye quality and wash fastness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional aqueous dyeing processes are used, then good dyeing quality is achieved, but water consumption is very high (>95% water used for heating, rinsing, agitation)
Solution Approach 1:
The patent changes the fundamental parameter of liquor-to-substrate ratio from conventional high ratios (typically 10:1 or higher) to a low ratio of ≤2:1. This parameter change enables the process to achieve effective dyeing with minimal water, directly addressing the water consumption problem while maintaining dyeing quality through optimized treatment conditions
Solution Approach 2:
The invention extracts and eliminates the excessive water component from the dyeing process. By using a closed container system with minimal aqueous solution, the process removes the need for large volumes of water used for heating, rinsing, and agitation in conventional processes, thereby reducing environmental impact and wastewater generation
2Quantity of substance
If supercritical carbon dioxide technology is used, then water consumption is reduced, but energy consumption increases significantly
Solution Approach 1:
The patent adopts moderate treatment parameters (temperature ≤100°C, pressure ≤1 atm gauge) rather than the extreme conditions required by supercritical CO2 technology. This parameter selection achieves water reduction goals while avoiding the high energy consumption associated with heating and pressurizing systems to supercritical states
Solution Approach 2:
The invention uses simple, inexpensive equipment (closed container, basic heating/agitation system) compared to complex supercritical fluid systems. The process accepts shorter treatment durations as a trade-off, avoiding the need for expensive, energy-intensive supercritical technology infrastructure
3Productivity
If ultrasound technology is used, then dyeing efficiency is improved, but the process is not commercially viable
Solution Approach 1:
The patent employs conventional, well-established equipment (closed container with heating and agitation) that is already widely available in the textile industry. This self-service approach using existing infrastructure eliminates the need for specialized ultrasound equipment, thereby ensuring commercial viability while maintaining productivity through optimized chemical and physical treatment parameters
Solution Approach 2:
The invention uses a multi-functional closed container system that combines heating, agitation, and containment in a single apparatus. This universal equipment serves multiple process functions simultaneously, avoiding the need for separate ultrasound treatment equipment and ensuring the process can be implemented in conventional manufacturing settings
4Quantity of substance
If liquor-to-substrate ratio is reduced to ≤2:1, then water usage is minimized, but treatment effectiveness must be maintained
Solution Approach 1:
The patent optimizes multiple treatment parameters simultaneously (temperature, time, agitation intensity, treatment agent concentration) to compensate for the reduced water volume. These parameter adjustments ensure that the limited aqueous solution achieves complete and uniform dyeing penetration, maintaining reliability of dyeing quality and wash fastness despite minimal water usage
Solution Approach 2:
The invention applies treatment agents in optimized formulations and concentrations before the actual dyeing process begins. This preliminary preparation ensures that the minimal aqueous solution present in the closed container is highly effective from the start, achieving reliable dyeing results without requiring excess water for multiple rinsing or adjustment steps
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 and auxiliary agent consumption, achieving high-quality dyeings with reduced energy use and fewer procedural steps, while minimizing environmental impact and operational costs.
Implementation Method 1
the aqueous system comprises water which penetrates and swells the substrate, thereby facilitating dissolution of the treatment agent
Data Source
AI summary
The invention provides a method for the application of a treatment agent to a substrate, the method comprising the treatment of the pre-wetted substrate in an aqueous system comprising the solid particulate treatment agent in a closed container, the treatment being carried out at a ratio of liquor to substrate which does not exceed 2:1. Typically, the method is applied to the dyeing of textile fibres at liquor ratios of ≤1:1 and is carried out in the absence of additives conventionally included for the sole purpose of promoting dye uptake by controlling electrical interactions or otherwise enhancing interactions between the substrate and the treatment agent. The invention also provides a method for the removal of surplus treatment agents following application of said treatment agents to a substrate, said method comprising not more than three wash-off treatments of said substrate with water following said application. Said wash off process most particularly comprises a two-stage process comprising performing, in order, the steps of: a first wash-off of the treated substrate with water in a closed container at a ratio of water to substrate which does not exceed 5:1; and a second wash-off of the treated substrate with water in a closed container at a ratio of water to substrate which does not exceed 10:1.