Supercritical fluid material finishing
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Solution Overview
Problem
Traditional dyeing processes using water are inefficient and harmful due to high water consumption and chemical discharge, and existing supercritical fluid (SCF) dyeing methods face challenges with dye material solubility, introduction, dispersion, and interaction, increasing process complexity.
Innovation Solution
Manipulating variables such as time, pressure, heat, and internal flow rate in a supercritical fluid carbon dioxide environment to enhance the transfer of material finishes to target materials, maintaining temperature above threshold values as pressure decreases, and using sacrificial materials to achieve desired dye profiles with reduced residual finish deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional water-based dyeing is used, then dyeing effectiveness is achieved, but water consumption increases and chemical discharge harms the environment
Solution Approach 1:
The patent changes the physical-chemical parameters of the dyeing medium from liquid water to supercritical carbon dioxide by adjusting temperature and pressure parameters. This transformation eliminates water consumption and chemical discharge problems while maintaining effective dyeing capability through the unique properties of supercritical fluids.
Solution Approach 2:
The patent utilizes phase transition of carbon dioxide between supercritical and gaseous states to achieve dyeing. By controlling pressure and temperature, CO2 transitions to supercritical state for dyeing, then returns to gaseous state for easy removal, eliminating the need for water evaporation and reducing environmental impact.
2Quantity of substance
If supercritical fluid is used for dyeing, then water consumption is reduced, but process complexity increases due to challenges with dye material solubility, introduction, and dispersion
Solution Approach 1:
The patent introduces sacrificial material as an intermediary carrier that holds dye materials in a form compatible with supercritical fluid. This mediator solves the solubility and dispersion problems by allowing dye to be transferred from the sacrificial material to the target material through the supercritical fluid medium, simplifying the overall process.
Solution Approach 2:
The patent performs preliminary preparation by pre-loading dye materials onto sacrificial materials before the supercritical fluid dyeing process. This preliminary action ensures that dye materials are in the appropriate form and location for efficient transfer during the actual dyeing process, reducing complexity during the main operation.
3Ease of operation
If pressure is decreased from operating pressure to transition pressure, then CO2 transitions from supercritical to gaseous state, but dye material may deposit on system surfaces instead of being absorbed by target material
Solution Approach 1:
The patent employs periodic or sequential manipulation of process variables during pressure transition. By controlling the timing and sequence of pressure reduction, temperature adjustment, and fluid flow, the system ensures dye materials are deposited on target material during the transition phase rather than on system surfaces, achieving both easy operation and precise control.
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 enables a more efficient and environmentally friendly dyeing process with improved uptake of material finishes by the target material and reduced residual deposits, potentially eliminating the need for cleaning processes between dyeing cycles.
Implementation Method 1
the exchange of the working substance (e.g., CO2) and/or the manipulation of one or more variables may allow for the material finish to favor adhering/bonding/coating the intended target material as opposed to the pressure vessel itself
Implementation Method 2
finishing a target material with a material finish in a supercritical fluid carbon dioxide environment
Implementation Method 3
The sequencing of variable manipulation allows for a greater uptake of material finish by the target material and less residual material finish deposited on surfaces of the system
Data Source
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.