Dye range and processes, and yarns and fabrics produced therefrom
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Solution Overview
Problem
Current fabric dyeing processes for denim are energy, chemical, and water intensive, and the removal of excess dye from yarns is difficult and costly, often requiring extensive abrasion or chemical treatments, which exacerbates environmental impact.
Innovation Solution
A method for sulphur and indigo ring dyeing that produces adequately dark yarns with a larger white core, reducing dye penetration and thus minimizing the need for water, chemicals, and energy in dye removal processes, achieved through the use of a barrier compound, modified scouring stages, controlled pH, reduced dye concentration, and increased number of dye vats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional dyeing methods are used to achieve dark yarns, then the yarns reach the desired color depth, but excessive dye penetration occurs making removal difficult and costly
Solution Approach 1:
The patent applies local quality by creating a gradient dye penetration profile where the yarn periphery achieves full dye saturation for dark coloration while the core remains partially undyed or lightly dyed. This localized differentiation allows the exterior to meet aesthetic requirements while the interior remains accessible to abrasion and chemical treatments for dye removal, thus resolving the contradiction between achieving dark color and enabling easy dye removal.
2Adaptability or versatility
If extensive dye removal processes are applied to conventional dyed yarns, then the desired fashion effects are achieved, but water, chemical, and energy consumption increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-structuring the dye penetration profile during the initial dyeing process to create a yarn configuration that inherently requires less intensive removal treatment. By controlling dye penetration to be concentrated at the periphery with a lighter core from the outset, the subsequent abrasion and chemical treatment stages require less energy, water, and chemicals to achieve the desired fashion effects, thus resolving the contradiction between achieving versatile fashion effects and minimizing resource consumption.
3Illumination intensity
If dye concentration is increased to achieve darker yarns, then the desired shade is reached, but the white core is reduced or eliminated
Solution Approach 1:
The patent applies local quality by spatially differentiating dye concentration within the yarn cross-section. The periphery receives high dye concentration to achieve dark coloration, while the core receives reduced dye concentration to maintain a white or light core. This localized quality differentiation allows the yarn to exhibit dark exterior color while preserving an accessible white core, resolving the contradiction between achieving desired yarn darkness and maintaining white core volume.
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 approach results in consistent dye penetration of 10-35% of the yarn's cross-sectional area, allowing for efficient laser and manual abrasion-based dye removal without the need for chemical bleaching, while significantly reducing environmental impact by minimizing resource usage.
Implementation Method 1
The present invention provides techniques for sulphur and/or indigo ring dyeing which result in adequately dark yarns while retaining a larger, whiter, or lighter colored core
Implementation Method 2
Laser abrasion employs the use of high-powered lasers. The controller of the laser is loaded with an abrasion or destruction file that represents a designer's target finished look and the laser then, with the emissions of light, sublimes much of the indigo or sulphur dye on the warp yarns of the woven fabric.
Implementation Method 3
the laser then, with the emissions of light, sublimes much of the indigo or sulphur dye on the warp yarns
Implementation Method 4
The present invention provides techniques for sulphur and/or indigo ring dyeing which result in adequately dark yarns while retaining a larger, whiter, or lighter colored core which makes all dye removal processes less water, chemical, time, and energy intensive.
Implementation Method 5
The present invention provides techniques for sulphur and/or indigo ring dyeing
Data Source
AI summary
The invention generally relates to fabric dyeing, such as fabric dyeing using indigo or sulphur dyes. A process is provided which provides a dyed yarn having reduced dye penetration and a white core. The process involves modification of existing sulfur dye ranges to more efficiently and in an environmentally improved method produce dyed fabrics. The modification involves one or more of i) using of a barrier compound to subsequent dye applications; ii) performing a scouring stage without a caustic agent; iii) bypassing scouring and/or scour rising; iv) using sodium bicarbonate to control the pH of dye tanks; v) reducing the dye concentration and increasing the number of dye vats; and vi) adding a sizing stage to the dye range. The invention also is directed to yarns dyed on dye ranges through use of the process, and fabrics formed from the dyed yarns.