Supercritical fluid material finishing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional dyeing processes using water are inefficient and harmful to freshwater supplies, and the implementation of supercritical fluid carbon dioxide (SCF CO2) in dyeing processes faces challenges such as solubility, introduction, dispersion, and deposition of dye materials, which complicates industrial-scale dyeing.
Innovation Solution
Manipulating variables like time, pressure, heat, and internal flow rate within a pressure vessel to achieve efficient transfer of material finishes to target materials in a SCF CO2 environment, maintaining temperature above threshold values as pressure decreases, and using sacrificial materials to achieve desired dye profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a separate preparation vessel is used to introduce dye to SCF before transferring to the textile treatment system, then the solubility and dispersion of dye materials are improved, but the device complexity and process complexity increase
Solution Approach 1:
The patent combines the dye introduction function directly into the textile treatment system's pressure vessel, eliminating the separate preparation vessel. The dye material is introduced directly into the vessel containing both the SCF and the textile material, merging multiple functions (dye preparation, SCF treatment, and textile processing) into a single integrated system, thereby reducing device complexity while maintaining effective dye transfer
2Loss of substance
If pressure is decreased from operating pressure to transition pressure during the dyeing process, then the deposition of residual material finish on system surfaces is reduced, but the manufacturing precision of dye profile control may be compromised
Solution Approach 1:
The patent applies preliminary action by carefully controlling the pressure reduction process and maintaining temperature above threshold values during the transition from operating pressure to transition pressure. This preliminary control of pressure and temperature variables ensures that the dye material is properly deposited on the textile material before pressure reduction occurs, preventing premature precipitation that would compromise dye profile control while still minimizing residual deposition on system surfaces
3Quantity of substance
If temperature is maintained above threshold values as pressure decreases, then the uptake of material finish by target material is enhanced, but the energy consumption increases
Solution Approach 1:
The patent utilizes phase transition principles by maintaining temperature above the critical temperature threshold during pressure reduction. This ensures the SCF remains in a state that allows continued dissolution and transport of dye material to the textile, maximizing uptake efficiency. The energy input is strategically applied during the critical phase transition period rather than continuously, optimizing energy consumption while maintaining enhanced material finish uptake
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 enhances the uptake of material finishes by target materials while minimizing residual finishes on the system, offering a more efficient and environmentally friendly dyeing process with improved dye profile control and reduced waste.
Implementation Method 1
carbon dioxide ('CO2'), in a dyeing process
Implementation Method 2
the interaction of dye materials with a SCF, including the solubility, introduction, dispersion
Implementation Method 3
circulation, deposition, and characterization of the interaction
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Methods are directed to the use of a supercritical fluid for finishing a target material with a finishing material. One or more variables selected from temperature, pressure, flow rate, and time are manipulated to increase efficiencies in the finishing process. As temperature or pressure are decreased causing a change in the density of a supercritical fluid carbon dioxide, which in turn causes a precipitation of dissolved material finish with the carbon dioxide, other variables are maintained above threshold values to increase the uptake of the material finish by the target material. This improvement reduces time by limiting cleaning processes of the system, saves materials used in the cleaning process, and saves energy used to achieve cycles of the process, in aspects.