Process for producing dyed mixed fibres, dyed mixed fibre yarns and/or dyed mixed fibre textile fabrics
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Solution Overview
Problem
The existing dyeing processes for mixed fibers, particularly those involving polyester and other fibers like wool or acrylic, are energy- and time-consuming, often requiring high temperatures that can damage non-polyester fibers and necessitate separate dyeing steps, making them costly and inefficient.
Innovation Solution
A process that simultaneously dyes mixed fibers comprising polyester and other fibers using two different dyes at temperatures below 130°C, specifically below 100°C, allowing for the preservation of fiber integrity and enabling a single-step dyeing process for achieving desired colors on multiple fiber types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature dyeing (above 130°C) is used to dye polyester fibers with disperse dyes, then the dyeing efficiency and color fastness are improved, but the further fibers (wool, acrylic, etc.) are thermally decomposed and destroyed
Solution Approach 1:
The patent changes the temperature parameter from conventional high temperature (>130°C) to low temperature (below 130°C, preferably below 100°C) to resolve the contradiction. This temperature parameter change allows simultaneous dyeing of polyester and further fibers without thermal decomposition, while maintaining acceptable dyeing quality through optimized low-temperature dyeing conditions
Solution Approach 2:
The patent introduces a multifunctional additive that acts as an intermediary substance in the dyeing bath. This additive facilitates the dyeing of polyester fibers at low temperatures without requiring high thermal energy, thereby preventing thermal decomposition of further fibers while still achieving good dyeing results
2Object-affected harmful factors
If separate dyeing steps are used for polyester fibers and further fibers, then the fiber integrity is preserved, but the dyeing process becomes very time-consuming and energy-consuming
Solution Approach 1:
The patent merges the dyeing processes for polyester fibers and further fibers into a single simultaneous dyeing step. By using a dyeing bath containing both disperse dyes (for polyester) and direct dyes (for further fibers) along with the multifunctional additive, both fiber types are dyed together at low temperature, eliminating the need for separate dyeing steps and significantly reducing time and energy consumption
3Manufacturing precision
If separate dyeing baths are used for polyester fibers and further fibers, then the desired colors are achieved on each fiber type, but the device complexity and process cost increase
Solution Approach 1:
The patent creates a universal dyeing bath that can simultaneously dye multiple fiber types (polyester and further fibers) with different dye classes (disperse and direct dyes). The multifunctional additive enables this multi-functional dyeing process in a single bath, eliminating the need for multiple separate dyeing baths and processes, thereby reducing device complexity and operational costs while maintaining color accuracy
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 process reduces energy and time consumption, maintains the mechanical properties and softness of the fibers, and achieves high light- and washfastness of the dyed mixed fibers, while being cost-effective and environmentally friendly.
Implementation Method 1
the disperse dyes diffuse into the fibres
Data Source
AI summary
The present invention relates to a process for producing dyed mixed fibres (D-MF), dyed mixed fibre yarns (D-MY) and/or dyed mixed fibre textile fabrics (D-MT) in which mixed fibres (MF), mixed fibre yarns (MY) and/or mixed fibre textile fabrics (MT) comprising at least one polyester fibre (PF) and at least one further fibre (FF) are simultaneously contacted with at least two different dyes (D1) and (D2) at a temperature TD<130° C. The at least one polyester fibre (PF) comprises 80 to 99.5% by weight of at least one terephthalate polyester (A), 0.5 to 20% by weight of at least one aliphatic-aromatic polyester (B) and 0 to 5% by weight of at least one additive (C), wherein the % by weight are based in each case on the total weight of components (A), (B) and optionally (C). Moreover, the present invention relates to the dyed mixed fibres (D-MF), the dyed mixed fibre yarns (D-MY) and/or the dyed mixed fibre textile fabrics (D-MT) obtained by this process.