Reactive Dyestuff Tanning of Collagen Fibers With Simultaneous Dyeing
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Solution Overview
Problem
Current leather manufacturing processes involve separate steps for tanning and dyeing, which lead to resource wastage and environmental impact due to the use of multiple chemicals and the difficulty in achieving eco-friendly leather production.
Innovation Solution
A process that simultaneously tans and dyes collagen-containing fibrous materials using selected fiber-reactive dyestuffs, which act as both tanning agents and colorants, thereby reducing waste and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate tanning and dyeing steps are used, then each step can be optimized independently, but resource wastage and environmental impact increase due to multiple chemicals and processing steps
Solution Approach 1:
The patent combines two separate leather processing steps (tanning and dyeing) into a single simultaneous operation. The reactive dyestuff serves dual functions: it dyes the collagen-containing fibrous material while simultaneously providing tanning effects through crosslinking. This integration eliminates the need for separate chemical treatments, reducing chemical waste and resource consumption while maintaining quality standards for both tanning and coloring.
Solution Approach 2:
The reactive dyestuff used in this invention performs multiple functions: it acts as a colorant to provide desired coloration, and simultaneously acts as a tanning agent through its crosslinking capability with collagen. This multi-functional approach replaces the need for separate specialized chemicals for each function, thereby reducing overall chemical usage and environmental impact while achieving reliable results in both coloring and preservation.
2Reliability
If multiple chemicals are used in separate processing steps, then specific functions (tanning, dyeing) can be achieved, but environmental impact increases due to chemical discharge
Solution Approach 1:
By merging tanning and dyeing into one simultaneous process using reactive dyestuffs, the patent reduces the total number of chemicals introduced into the system. The reactive dyestuff performs both functions in a single treatment step, minimizing chemical discharge and environmental pollution while maintaining the functional performance required for high-quality leather production.
Solution Approach 2:
The patent improves exhaustion properties of the reactive dyestuff, meaning more of the dye is fixed onto the leather and less is discharged into the environment. This enhanced fixation efficiency reduces harmful chemical discharge while maintaining effective tanning and coloring functions, aligning with environmental sustainability goals.
3Reliability
If traditional separate processing is used, then established methods ensure quality, but productivity decreases due to multiple processing steps
Solution Approach 1:
The patent merges two sequential processing steps (tanning followed by dyeing) into a single simultaneous operation using reactive dyestuffs. This integration maintains quality consistency by ensuring both functions are achieved in one controlled process, while simultaneously improving productivity by eliminating the time and resources required for separate processing steps.
4Loss of substance
If reactive dyestuffs are used for simultaneous tanning and dyeing, then resource consumption is reduced, but achieving good exhaustion and fixation is challenging
Solution Approach 1:
The patent optimizes specific parameters of the reactive dyestuff, particularly the ratio of fiber reactive radicals to chromophore units. By carefully controlling this ratio and selecting appropriate reactive groups (such as halogen, carboxyl, or sulfato groups), the invention achieves both reduced chemical waste and improved exhaustion and fixation properties, resolving the contradiction between resource efficiency and manufacturing precision.
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 achieves good exhaustion, fixation, and washing-off properties of unfixed dyestuffs, resulting in high-quality leather with improved hydrothermal stability, color strength, and fastness, while minimizing the use of restricted substances and reducing energy and water consumption.
Implementation Method 1
wherein (Z1)2-3 is 2 to 3 identical or different fiber reactive radicals, Z2 and Z3 are each independently of the other identical or different fiber reactive radicals
Data Source
AI summary
A process for the simultaneous tanning and dyeing of collagen containing fibrous material, wherein the said material is treated with a liquor containing at least one reactive dyestuff selected from the group of formula (1) and (2)whereinA1, A2 and A3 are each independently of the others the radical of a monoazo, polyazo, metal-complexed azo, anthraquinone, phthalocyanine, formazan or dioxazine chromophore having at least one sulfo group,B is an organic bridge member,Q1, Q2, Q3 and Q4 are each independently of the others hydrogen or unsubstituted or substituted C1-C4alkyl,G1 and G2 are halogen, 3-carboxypyridin-1-yl or 3-carbamoylpyridin-1-yl,(Z1)2-3 is 2 to 3 identical or different fiber reactive radicals,Z2 and Z3 are each independently of the other identical or different fiber reactive radicals, and b is the number 0 or 1,by combining two steps of leather production, tanning and dyeing, into a single step, thus, preserving resources and reducing the environmental impact.