Textile Dyeing Fluid Recirculation to Reduce Wastewater Contamination

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Solution Overview

Problem

Conventional textile dyeing methods generate significant volumes of wastewater due to excess dyestuff and chemicals, leading to environmental contamination and the need for extensive wastewater treatment.

Innovation Solution

A method involving a processing line where a dyed textile is conveyed and a fluid is applied in one direction, with at least 50% of the fluid being removed and reused, allowing for the removal of excess dyestuff and contaminants, and the fluid is recirculated and re-applied, reducing the overall water usage and environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional bath immersion methods or padding processes are used for dyeing, then the textile can be dyed, but significant volumes of wastewater are generated due to excess dyestuff and chemicals

Engineering Contradiction:

Improvewater consumptionVSAvoidwastewater contamination

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent applies the discarding and recovering principle by collecting wastewater from the dyeing process and reusing it for subsequent dyeing batches. The system includes a water recovery tank that stores used dyeing water, which is then reused in the next dyeing cycle, thereby reducing overall water consumption and wastewater generation while maintaining effective dyeing performance

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The patent implements self-service through an automated control system that manages the entire dyeing process including water circulation, heating, and dye application. The microprocessor-controlled system automatically regulates water flow between the tank and spray nozzles, controls heater operation based on temperature sensors, and manages the dyeing cycle without manual intervention, reducing the need for additional chemicals and water

Inventive Principle:

Principle #25Self-service

2Reliability

If multiple high temperature washes are performed to remove excess dyestuff, then colourfastness is improved, but energy consumption increases and more wastewater is generated

Engineering Contradiction:

ImprovecolourfastnessVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies preliminary action by thoroughly removing excess dyestuff during the initial dyeing process through controlled spray application and extended contact time. This preliminary removal action eliminates the need for subsequent high-temperature washing operations, as the dyestuff is already properly fixed to the textile before the drying phase begins

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the mechanical/thermal washing system with a chemical-spray based dyeing system. Instead of using high-temperature water baths and mechanical agitation to remove excess dyestuff, the system uses controlled spray application of dye solutions followed by low-temperature drying, substituting thermal-mechanical removal with a chemical deposition approach

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If excess dyestuff is applied to ensure adequate colour coverage, then colour uniformity is improved, but more contaminants are present in the wastewater

Engineering Contradiction:

Improvecolour uniformityVSAvoiddyestuff contamination

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent implements feedback through microprocessor-controlled spray nozzles that monitor and adjust dye application in real-time. The system uses sensors to detect colour uniformity during the dyeing process and automatically adjusts spray duration and intensity to achieve consistent colour coverage without applying excess dyestuff, preventing contamination while ensuring quality

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent applies partial action by using spray nozzles that deliver dye solution only to specific areas of the textile that require it, rather than immersing the entire textile in a dye bath. This targeted application ensures adequate colour coverage in needed areas while minimizing overall dyestuff usage and preventing excessive contamination

Inventive Principle:

Principle #16Partial or excessive action

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 improves colourfastness by efficiently removing excess dyestuff and chemicals, significantly reducing wastewater generation and environmental harm, while optimizing water and energy usage.

Implementation Method 1

flowing a fluid from a reservoir through the dyed textile on the processing line in a second direction substantially opposite to the first direction

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

a filtration unit for removing contaminants from the fluid

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS20240309570A1Apparatus and method relating to textile dyeing

Publication Date: 2024.09.19 ALCHEM TECH LTD

AI summary

A method for improving the colourfastness of a dyed textile is provided. The method comprises the steps of: conveying the dyed textile along an automated processing line and into a first chamber having a first controllable environment; temporarily storing the dyed textile in the first chamber for a first time period; conveying the dyed textile into a second chamber having a second controllable environment; and temporarily storing the dyed textile in the second chamber for a second time period.