Method of dyeing fabric using microorganisms
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Solution Overview
Problem
Conventional fabric dyeing methods rely on toxic chemicals and solvents, generating hazardous waste and consuming significant water, while existing microbial dye production methods do not effectively address dye extraction, deposition, and fixation onto fabrics.
Innovation Solution
A method involving microorganisms that adsorb dye-containing microorganisms onto textile fibers using carbon sources above a threshold concentration, followed by a heat treatment to release and fix dyes onto the fibers, reducing waste and water consumption, and utilizing recombinant and non-recombinant microorganisms for localized dye production and fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional chemical dyeing methods are used, then dyeing efficiency is high, but toxic waste and water consumption increase significantly
Solution Approach 1:
The patent changes the fundamental parameter of the dyeing process by replacing chemical dyes with microbially-produced pigments. This parameter change transforms the harmful chemical substances into biodegradable microbial cells that can be directly adsorbed onto fabric, eliminating toxic waste while maintaining dyeing efficiency
Solution Approach 2:
The patent uses microbial cells as living factories that copy and produce pigment molecules within their cellular structures. These pigment-containing microbial cells then serve as the actual dyeing agent, copying the function of traditional chemical dyes while being environmentally benign and biodegradable
2Object-generated harmful factors
If microbial pigment production is used, then environmental harm is reduced, but dye extraction and deposition efficiency decreases
Solution Approach 1:
The patent extracts the pigment from the microbial cell through a simplified process where the microbial cells are directly applied to the fabric and the pigment is released during heat treatment. This eliminates the need for complex chemical extraction solvents and procedures, improving efficiency while maintaining environmental benefits
Solution Approach 2:
The microbial cells serve multiple functions simultaneously: they produce the pigment, act as the carrier for pigment delivery, and provide the adsorption mechanism for fabric uptake. This self-service approach eliminates the need for separate extraction and deposition steps, significantly improving overall process efficiency
3Quantity of substance
If traditional dye extraction methods are used, then pigment recovery is achieved, but water and energy consumption increase
Solution Approach 1:
The pigment is pre-formed and stored within the microbial cell structure before application. This preliminary action of pigment synthesis within the living cell eliminates the need for energy-intensive post-extraction and purification processes, as the pigment is already in its final usable form within the microbial carrier
Solution Approach 2:
The patent merges the pigment production, carrier formation, and dyeing application into a single integrated process. The microbial cell simultaneously serves as pigment factory, delivery vehicle, and adsorption medium, eliminating multiple separate processing steps that would otherwise consume water and energy
4Reliability
If multiple processing steps are used for microbial dyeing, then dye fixation is improved, but process complexity increases
Solution Approach 1:
The patent combines multiple functions into a single microbial cell: pigment production, carrier function, and adsorption capability. This merging reduces the number of processing steps required while maintaining reliable dye fixation, as the microbial cell naturally adheres to fabric and releases pigment in a controlled manner during heat treatment
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 method significantly reduces waste generation, water consumption, and energy use, achieving high dye incorporation efficiency with biodegradable waste products and eliminating the need for toxic solvents, while allowing for a wide range of textile colors through various microorganism and dye combinations.
Implementation Method 1
the adsorption of dye-containing microorganisms onto textile fibers is improved using carbon sources above a threshold concentration
Implementation Method 2
Dye molecules contained within the microorganism are released from the microorganism and fixed directly and locally to the textile fibers using a heat treatment step
Data Source
AI summary
This invention relates to a method for dyeing fabrics, yarns and fibers using microorganisms whereby the adsorption of dye-containing microorganisms onto textile fibers is improved using carbon sources above a threshold concentration. Dye molecules contained within the microorganism are released from the microorganism and fixed directly and locally to the textile fibers using a heat treatment step. Said heat treatment also deactivates the carrier microorganisms. Single or multiple microorganism species, and single or multiple dyes produced by said single or multiple microorganism species may create a variety of textile colors. Suitable synthetic dyes may also be added before, during or after microorganisms have produced dyes but before the dye-releasing heat treatment step.