Method for manufacturing standard carbon black soiled fabrics
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Solution Overview
Problem
Current methods for manufacturing standard carbon black soiled fabrics for washing machine testing lack standardization, leading to unstable reflectivity, high rejection rates, low yield, and environmental pollution due to the use of carbon tetrachloride as a dispersing medium.
Innovation Solution
A method involving the use of gum acacia powder, lecithin, and castor oil to create a stable carbon black soil, processed using a shear emulsifying machine and a continuous rolling-suction tentering and setting machine, eliminating the need for fabric pretreatment and carbon tetrachloride, with automation and high yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If carbon tetrachloride is used as a dispersing medium in the production of soil, then the soil can be produced, but it causes serious pollution to the environment
Solution Approach 1:
The patent introduces water as an intermediary dispersing medium to replace carbon tetrachloride. Water serves as a safe, non-polluting alternative that can still effectively disperse carbon black particles to form soil, thereby eliminating environmental pollution while maintaining the soil production function.
Solution Approach 2:
The patent changes the chemical parameter of the dispersing medium from carbon tetrachloride (organic solvent) to water (inorganic solvent). This parameter change transforms the system from one that produces serious environmental pollution to one that is environmentally friendly, while still achieving the desired soil dispersion and adhesion properties through adjusted formulation ratios.
2Productivity
If existing manufacturing methods are used for standard soiled fabrics, then fabrics can be produced, but they have unstable reflectivity and high rejection rate
Solution Approach 1:
The patent applies preliminary standardized treatment to the original fabrics before soiling, including uniform pretreatment processes and standardized fabric selection criteria. This preliminary action ensures that all fabrics start with consistent properties, which stabilizes the final reflectivity of the soiled fabrics and reduces rejection rates due to variability.
Solution Approach 2:
The patent standardizes key parameters throughout the manufacturing process, including soil formulation composition, soiling process conditions, and fabric treatment parameters. By controlling and standardizing these parameters, the process achieves consistent reflectivity values across batches, improving manufacturing precision while maintaining productivity.
3Productivity
If existing manufacturing methods are used for standard soiled fabrics, then fabrics can be produced, but they have low yield
Solution Approach 1:
The patent applies preliminary standardized treatment to the original fabrics before soiling, including uniform pretreatment processes and standardized fabric selection criteria. This preliminary action ensures that all fabrics start with consistent properties, which stabilizes the final reflectivity of the soiled fabrics and reduces rejection rates due to variability.
Solution Approach 2:
The patent standardizes key parameters throughout the manufacturing process, including soil formulation composition, soiling process conditions, and fabric treatment parameters. By controlling and standardizing these parameters, the process achieves consistent reflectivity values across batches, improving manufacturing precision while maintaining productivity.
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 high reflectivity, low cost, and environmental friendliness, with a yield of 95% or more, significantly improving testing efficiency and accuracy while reducing human intervention and environmental impact.
Implementation Method 1
the gum acacia powder with a thickening effect is one of the key ingredients in the simulated water-soluble soil, which not only ensures the stability of the dispersion, but also forms a thin film with high viscosity and elasticity on the surface of the fabric to improve the adhesion of the soil to the fabric
Implementation Method 2
The castor oil is one of the key ingredients in the simulated oil-soluble soil, but it is insoluble in the water and has a large viscosity, resulting in the formation of large oil droplets in water to cause adverse effects to the uniformity of the soiling. As an amphipathic material, the lecithin is suitable as a surfactant in an oil-containing mixture, so that it can allow the castor oil to disperse uniformly in an aqueous solution
Implementation Method 3
shearing the first reaction mixture by a shear emulsifying machine at 3000-5000 rpm for 15-20 min; shearing the first reaction mixture by the shear emulsifying machine at 3000-5000 rpm for 10-15 min; shearing the second reaction mixture by the shear emulsifying machine at 3000-5000 rpm for 10-15 min; shearing the second reaction mixture by the shear emulsifying machine at 3000-5000 rpm for 10-20 min; shearing the third reaction mixture by the shear emulsifying machine at 3000-5000 rpm for 30-40 min to produce a stable carbon black soil
Implementation Method 4
heating the first reaction mixture in a water bath to 90° C.; heating the second beaker in the water bath to 90° C.; heating the third reaction mixture in the water bath at 90° C.
Implementation Method 5
a drying temperature is 110-150° C.
Data Source
AI summary
The application relates to the production of a soiled fabric, and more particularly to a method of manufacturing a standard carbon black soiled fabric for performance testing of washing machines. Water is adopted herein as the solvent to prepare a soil, which renders this method safe, environmentally friendly and economical. Moreover, this method introduces a fully-automatic continuous rolling-suction tentering and setting machine to control the pressure of the padder, the drying temperature, the air volume of the fan and the speed of chains, which reduces the manual intervention, achieving a highly-automatic printing and dyeing process. The reflectivity at four points on both sides of the standard carbon black soiled fabric according to the invention is 95% or more.