Ozone Bleaching Control With Blower Circulation for Textile Color Removal
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Solution Overview
Problem
Existing ozone bleaching systems for textiles are unreliable and reproducible due to variable ozone concentration and lack of effective air circulation, leading to issues like back-staining and high water consumption.
Innovation Solution
A hybrid washing machine with an integrated blower for uniform air circulation and an ozone dosing control system to maintain constant ozone concentration, combined with a wet or dry ozone bleaching process for precise ozone delivery and water recirculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ozone gas is injected into commercial washers without proper circulation, then ozone delivery is simple, but bleaching reliability is poor due to variable ozone concentration
Solution Approach 1:
The patent combines the washing machine and air circulation system into a hybrid machine, merging functions of water-based washing with gas-phase ozone circulation to achieve reliable bleaching while maintaining operational simplicity
Solution Approach 2:
The invention uses a blower to create forced air circulation within the washing machine, applying pneumatic principles to distribute ozone gas uniformly throughout the drum, ensuring consistent bleaching results
2Manufacturing precision
If operator knowledge varies in controlling ozone levels, then device operation is flexible, but manufacturing precision of bleaching results deteriorates
Solution Approach 1:
The patent incorporates ozone analyzers that provide real-time feedback on ozone concentration, allowing the system to automatically adjust and maintain target levels, eliminating variability caused by operator knowledge differences
Solution Approach 2:
The system performs self-regulation of ozone concentration through automated control mechanisms, reducing dependence on operator expertise while maintaining consistent bleaching quality
3Loss of substance
If clear water rinses are used between process steps to prevent back-staining, then product quality is maintained, but water consumption and time increase
Solution Approach 1:
The patent uses ozone, a strong oxidant, to chemically prevent back-staining by oxidizing indigo dye molecules, eliminating the need for extensive water rinsing and reducing both water consumption and process time
Solution Approach 2:
The invention converts the potential harm of residual dye (back-staining risk) into a benefit by using ozone oxidation to actively prevent dye re-deposition, turning a quality problem into an opportunity for water conservation
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 solution provides reliable and reproducible bleaching results, reduces back-staining, and minimizes water usage by ensuring consistent ozone exposure and efficient dye removal, enhancing the bleaching process while being environmentally friendly.
Implementation Method 1
Ozone gas has been used to bleach denim... methods and systems for bleaching textiles using ozone gas... wet or dry ozone bleaching process
Implementation Method 2
hybrid machine that incorporates certain features of a washer, but that also includes an integrated blower for gas distribution inside the machine
Implementation Method 3
ozone dosing control system that allows for maintenance of a constant concentration of ozone in the machine
Data Source
AI summary
Embodiments relate generally to methods and systems for bleaching textiles using ozone gas that incorporates a color removal step. In one example, there is provided a hybrid machine that incorporates certain features of a washer, but that also includes an integrated blower for gas distribution inside the machine. There is also provided an ozone dosing control system that allows for maintenance of a constant concentration of ozone in the machine. In one embodiment, the ozone output measured in grams/hour at this constant concentration in conjunction with the weight of product measured being treated may be referred to as the “bleaching factor.” There is further provided a wastewater dye removal step, in which ozone is used to clean the water and remove dyes and other colors that may be deposited via denim or other garments.