Reactive dye moisture fixation continuous dyeing method
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Solution Overview
Problem
Conventional reactive dyeing processes for cellulose fibers are energy-intensive, highly polluting, and suffer from poor reproducibility and quality fluctuations due to the use of large amounts of inorganic salts and complex procedures.
Innovation Solution
A continuous dyeing method using reactive dyes in wet conditions, involving a one-bath-one-step process with an activated dye liquor and color-fixation alkali, preheating, and controlled rolling and batching to reduce energy consumption and salt usage, while maintaining optimal moisture content to prevent dye migration and enhance color fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pad-dry-pad-steam dyeing process is used, then dye fixation is achieved, but energy consumption increases and inorganic salt usage increases
Solution Approach 1:
The patent changes the fundamental parameters of the dyeing process by eliminating the dry and steam steps, performing dye fixation in wet conditions at lower temperatures (20-50°C) using a one-bath-one-step method that combines dyeing and fixation, thereby dramatically reducing energy consumption while maintaining dye fixation effectiveness
Solution Approach 2:
The patent extracts and eliminates the energy-intensive drying and steaming steps from the conventional dyeing process, retaining only the essential dyeing and fixation functions through a simplified wet-process approach
2Reliability
If conventional pad-dry-pad-steam dyeing process is used, then dye fixation is achieved, but inorganic salt consumption increases and pollution increases
Solution Approach 1:
The patent merges the dyeing and fixation steps into a single one-bath-one-step process, eliminating the need for separate treatment steps and reducing overall inorganic salt consumption by performing both functions simultaneously in wet conditions
Solution Approach 2:
By changing the process parameters to wet conditions with lower temperature and combined dyeing-fixation steps, the patent reduces the quantity of inorganic salts required compared to conventional multi-step processes
3Use of energy by moving object
If cold pad-batch process is used, then energy consumption is reduced, but quality reproducibility decreases due to multiple alkali components
Solution Approach 1:
The patent simplifies the chemical composition by using a single alkali type with controlled concentration (pH 8-10) instead of multiple alkali components, improving quality reproducibility while maintaining the energy-efficient wet-process approach
Solution Approach 2:
The patent applies precise local control of alkali concentration and pH levels in the dyeing bath to ensure consistent dye fixation and color quality across different production batches
4Reliability
If conventional rolling-drying-steaming process is used, then dye fixation is achieved, but process duration increases and production efficiency decreases
Solution Approach 1:
The patent combines multiple sequential steps (dyeing, drying, steaming, fixation) into a single wet-process dyeing and fixation step, dramatically shortening process duration and improving production efficiency while achieving equivalent dye fixation
Solution Approach 2:
The patent segments the conventional multi-step process into a simplified one-bath-one-step approach, eliminating unnecessary intermediate steps and reducing overall process time
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 shortens the dyeing process, reduces steam consumption, improves dye fixation rates, and achieves consistent quality with increased color yield and fastness, while being adaptable to varying temperature conditions and suitable for different production orders.
Implementation Method 1
immersing the fabric pretreated in 1) in a padding liquor with an air film horizontal pad dyeing machine
Implementation Method 2
preheating the fabric after being treated in 2) at a temperature of 50-90°C
Implementation Method 3
adding fabric to a mixture of a dye liquor and an alkali through a one-bath-one-step method; the dye liquor is an activated dye liquor, and the alkali is a color-fixation alkali
Data Source
Figure 1
AI summary
A reactive dye moisture fixation continuous dyeing method, comprising steps of pretreatment, dye liquor padding, pre-drying, rolling and stacking. Compared with a conventional pad-drying pad-steaming process, processes of reactive material steam, solid, liquid padding and steaming are removed during operation, the process is short, the operation is simple, and the working efficiency is improved; the use amount of inorganic salt is low, reactive dye low-salt dyeing is achieved, and environmental pollution is reduced. Compared with a cold pad-batch process, in this method, a color sample is pre-dried after being padded by a dye working liquor, the moisture content is controlled within a certain range, hydrolysis of the dye is reduced, and the fixation rate is increased. The fabric obtained by using the method is full in cloth cover and deep in color yield, and the color fastness comprehensively satisfies the standard requirements.