Patent Application
20120047665
The following description is provided to assist the understanding of the reader. None of the information provided or references cited is admitted to be prior art.
In traditional textile dyeing processes, large amounts of water are used as a dye solvent, resulting in one of the largest sources of water pollution for industrialized countries. An alternative dye solvent to water is super critical carbon dioxide (sc-CO2). In addition to reducing water pollution, sc-CO2 includes several advantages over water. The lower viscosity of sc-CO2 allows for higher diffusion rates and lower mass transfer resistances than water, resulting in increased penetration of the dye into the fiber and decreased dyeing times. Thus, less energy is required for the dyeing process.
In addition, dye and sc-CO2 can be easily separated and reused. In contrast, in the aqueous system, leftover water and dye cannot be easily separated and reused, resulting in large amounts of unusable, polluted water. The use of sc-CO2 results in a dry dyed fabric, and thus does not require extensive drying time as does the aqueous system. Furthermore, the dyeing process using sc-CO2 does not generate carbon dioxide and thus is not a direct contributor to green house gas emissions. In addition, sc-CO2 can be recycled.
Synthetic fibers, such as polyester, can be easily dyed using a sc-CO2 dyeing process. However, the application of the sc-CO2 dyeing process to natural fibers, such as cotton and wool, has been limited thus far. Sc-CO2 is a hydrophobic solvent, which does not swell hydrophilic cotton or wool fibers. Sc-CO2 is unable to break the hydrogen bonds between adjacent molecular chains to disrupt the structure of the natural fibers in order to facilitate the diffusion of the dye into the fibers. In addition, most commercial cotton dyes are salts, which are insoluble in sc-CO2 without the use of co-solvents. However, the use of co-solvents requires that the fabrics become saturated, thus requiring drying of the fabrics and more complex cleaning of the process chamber and dyeing components.
The present technology provides an illustrative method for dyeing textiles that includes intermixing a dye with super-critical carbon dioxide (sc-CO2) to form a dye solution and immersing a fabric in the dye solution. The method further includes applying an electric field to the dye solution to cause charged particles of the dye solution to separate and cause the dye to diffuse into the fabric.
The present technology further provides an illustrative apparatus for dyeing textiles that includes an intermixing component that intermixes a dye with super-critical carbon dioxide (sc-CO2) to form a dye solution and a fabric immersion component that immerses a fabric in the dye solution. The illustrative apparatus further includes a cathode and an anode that produce an electric field in the dye solution that causes charged particles of the dye solution to separate and cause the dye to diffuse into the fabric.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the following drawings and the detailed description.
The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.
There are several issues associated with traditional dyeing processes that utilize super critical carbon dioxide (sc-CO2) as a dye solvent. These include, but are not limited to, the inability of the sc-CO2 dyeing process to adequately adhere dyes to natural fibers such as, but not limited to, cotton, wool, silk, linen, hemp, and ramie. Sc-CO2 is a hydrophobic solvent, which does not swell hydrophilic cotton fibers, and is unable to break the hydrogen bonds between adjacent molecular chains of the natural fibers. As a result, the structure of the natural fibers prevents the diffusion of the dye into the fibers. Described herein are illustrative systems, device, and methods for implementing an improved dyeing process that utilizes sc-CO2 as a dye solvent. The improved dyeing process utilizes an electric field to enhance the diffusion of dye particles into the natural fibers. The dyeing processes and devices described below allow for the effective use of sc-CO2 as a dye solvent for dyeing textiles made of natural fibers such as, but not limited to, cotton, wool, silk, linen, and ramie.
In an embodiment, dyeing system 100 may be any system known to those of skill in the art that is capable of raising and maintaining an elevated temperature and pressure of CO2 for sc-CO2 extraction/cleaning processes. In illustrative embodiments, dyeing system 100 is configured such that a temperature and pressure within temperature/pressure vessel 110 can be selected to exceed the critical point of CO2, for example, 31.1 degrees Celsius and 7.39 megapascals (MPa).
Dyeing system 100 may include additional components or have alternative configurations as known to those of skill in the art. Temperature/pressure vessels have been commonly used to enable a temperature and pressure of a quantity of CO2 to exceed the critical point of CO2 for a variety of uses. For example, similar temperature/pressure vessels have been used for removing caffeine from coffee beans, for industrial cleaning of parts, and for drug extraction processes. Examples of similar commercial equipment as known to those of skill in the art include supercritical fluid processing/extraction devices as available from Deven Supercriticals PVT, LTD and Ruian Shengtai Pharmaceutical Machinery Co., Ltd. Example laboratory scale equipment, e.g., compressed gas extractors, is produced by Eden Labs.
Accordingly, upon being placed in temperature/pressure vessel 110, the dye is intermixed with sc-CO2 120 using the surfactant to create a dye/sc-CO2 mixture as appropriate. In an embodiment, the dye, sc-CO2, and surfactant are separately placed into temperature/pressure vessel 110 via one or more inlet ports. In an alternative embodiment, the surfactant and the dye may be placed into temperature/pressure vessel 110 together. In another embodiment, the dye, sc-CO2, and surfactant may be placed within temperature/pressure vessel 110 in any manner known to those of skill in the art. Temperature/pressure vessel 110 is configured to raise the temperature and pressure of the dye/solvent mixture to a desired working temperature and a desired working pressure and maintain the desired working temperature and pressure throughout the subsequent dyeing process. In an embodiment, the temperature and pressure are selected such that the CO2 is maintained in a supercritical state. As such, the CO2 is maintained at a temperature greater than 31.3 degrees Celsius and at a pressure greater than 7.39 MPa. Although solubility of dyes and surfactants are not strongly temperature and pressure dependent when used with the appropriate surfactant, the elevated temperature of the dye/sc-CO2 mixture enhances the ability of the dye to diffuse into a textile.
A cathode 130 and an anode 140 are located within temperature/pressure vessel 110 and are configured to generate an electric field within temperature/pressure vessel 110. Upon application of a sufficient electric field to the dye/sc-CO2 mixture, the dye particles become ionized as the electric charges within the dye are separated, thereby forming charged dye particles 150. The electric field is used to enhance the diffusion of charged dye particles 150 into a fabric 160. Fabric 160 may comprise a natural fiber such as cotton, wool, silk, linen, or ramie, a synthetic fiber such as polyester, rayon, acrylic, etc., or a blend of natural and synthetic fibers. The required strength of the electric field depends on the type of dye used and the energy required to dissociate the charges of the dye particles. In an embodiment, an electric field of between 300 kilovolts per meter (kV/m) and 400 kV/m is used, although alternative embodiments may include electric fields having different strengths depending on the dye used and the energy required to dissociate the charges of the dye particles. The high dielectric strength of sc-CO2 (about 450 MV/m) prevents breakdown of the sc-CO2.
The required distance between cathode 130 and anode 140 is a function of the potential between cathode 130 and anode 140. The distance between cathode 130 and anode 140 must be large enough that fabric 160 may be passed between cathode 130 and anode 140. However, a shorter distance between cathode 130 and anode 140 will result in a smaller required potential between cathode 130 and anode 140 to produce an electric field having a given strength. For example, in an embodiment, the distance between cathode 130 and anode 140 is 1 cm. At a distance of 1 cm, a potential of 4 kV between cathode 130 and anode 140 is required to generate an electric field of 400 kV/m. However, at a distance of 5 cm, a potential of 20 kV between cathode 130 and anode 140 is required to generate an electric field of 400 kV/m. As such, the distance between cathode 130 and anode 140 should be minimized as much as possible given the distance required by fabric 160 in order to reduce the required potential between cathode 130 and anode 140. Reducing the required potential between cathode 130 and anode 140, reduces the amount of energy required, is safer than a higher potential, and is less complex than a system requiring high potentials.
During the textile dyeing process, fabric 160 is contacted with the dye/sc-CO2 mixture and passed between cathode 130 and anode 140 which generate an electric field about fabric 160. In an embodiment, fabric 160 is completely immersed within the dye/sc-CO2 mixture within temperature/pressure vessel 110. In an embodiment, fabric 160 is placed within temperature/pressure vessel 110 via an inlet port prior to placement of the dye, the sc-CO2, and the surfactant within temperature/pressure vessel 110. In an alternative embodiment, the dye and the surfactant are placed within temperature/pressure vessel 110 prior to placement of fabric 160 within temperature/pressure vessel 110.
In the embodiment illustrated in
In an alternative embodiment, charged particles 150 may be negatively charged. Negatively charged dye particles would include, but are not limited to, acid dyes such as Anthraquinone type dyes (blue in color) or Triphenylmethane type dyes (yellow or green in color). According to such an embodiment, upon generation of an electric field by cathode 130 and anode 140, the negatively charged dye particles are repelled from cathode 130 (which is also negatively charged) and attracted to anode 140 (which is positively charged).
In an illustrative embodiment, when positively charged particles 150 are used, fabric 160 is held nearer to cathode 130 than to anode 140. Holding fabric 160 nearer cathode 130 increases the volume of the dye/solvent mixture and the corresponding quantity of charged particles 150 between anode 140 and fabric 160. As a result of the electric field, positively charged particles 150 are pulled from the volume of the dye-solvent mixture between anode 140 and fabric 160 into fabric 160. The volume between anode 140 and fabric 160 will be maximized by maintaining fabric 160 as close as possible to cathode 130. The greater the volume between anode 140 and fabric 160, the greater the quantity of charged particles 150 available to be pulled into fabric 160, and thus the greater the quantity of charged particles 150 that may be diffused into fabric 160. In addition, fabric 160 acts as a filter in that it prevents positively charged particles 150 from accumulating on cathode 130. Heavy accumulation of dye particles on cathode 130 would require routine cleaning.
Conversely, in the alternative embodiment where charged particles 150 are negatively charged, fabric 160 is held nearer to anode 140 than to cathode 130. Negatively charged particles will be attracted to anode 140. As a result, the volume between cathode 130 and fabric 160 should be maximized to increase the quantity of negatively charged particles available to be diffused into fabric 160 and to minimize the negatively charged dye particles accumulating on anode 140.
During a dyeing process, sc-CO2, a dye, and a surfactant are placed in temperature/pressure vessel 210 as described above with respect to
Dyeing apparatus 200 also includes a cathode 240 and anodes 250a, 250b. Cathode 240 and anodes 250a, 250b are configured to generate respective electric fields within temperature/pressure vessel 210. For example, a first electric field is created between cathode 240 and anode 250a and a second electric field is created between cathode 240 and anode 250b. In alternative embodiments, any number of cathodes and anodes may be used to generate any number of electric fields.
Upon application of a sufficient electric field to the dye/solvent mixture, the dye particles become ionized as the electric charges within the dye are separated, thereby forming charged dye particles. The electric fields are used to enhance the diffusion of the charged dye particles into a fabric 260 which is immersed in the dye/solvent mixture within temperature/pressure vessel 210.
In the embodiment of
As fabric 260 is passed through the various electric fields positively charged dye particles are repelled from anodes 250a, 250b (which is also positively charged) and attracted to cathode 240 (which is negatively charged). In this way, charged dye particles are more effectively diffused into fabric 260 which is passed between cathode 240 and anodes 250a, 250b. Accordingly, as fabric 260 is passed through the various electric fields, it gradually accumulates more and more dye. In this way, substantial lengths of fabric can be fed through the electric fields and dyed in an efficient and effective manner.
In alternative embodiments, dyeing apparatus 200 may include any number of cathodes, anodes, and pivot reels in order to pass fabric 260 along any desired path and through any number of electric fields.
A fabric is immersed in the dye solution in an operation 410. In an illustrative embodiment, the fabric comprises natural fibers such as, but not limited to, cotton, wool, silk, linen, or ramie. In alternative embodiments, the fabric may comprise a synthetic fiber such as, but not limited to, polyester, rayon, acrylic, etc., or a blend of natural and synthetic fibers.
In an operation 420, the temperature of the dye solution is raised to a desired working temperature and a pressure applied to the dye solution is raised desired working pressure. The temperature and pressure are maintained at an elevated state throughout the subsequent dyeing process in order to maintain the sc-CO2 in its super-critical state and to enhance the ability of the dye to diffuse into a textile.
An electric field is applied to the dye solution in an operation 430. The electric field is used to enhance the diffusion of charged dye particles into the fabric. Upon application of an electric field to the dye solution, electric charges within the dye are separated. In an embodiment, the electric field causes negatively or positively charged groups may be separated from the rest of the dye particle, creating a positively or negatively charged dye particle. In an embodiment, the electric field is generated by a cathode and an anode. In alternative embodiments, any number of electric fields may be generated by any number of cathodes and anodes. Upon generation of the electric field, the positively charged dye particles are repelled from the anode (which is also positively charged) and attracted to the cathode (which is negatively charged). The fabric is situated between the cathode and the anode. In this way, positively charged dye particles as they are moving toward the cathode are diffused into the fabric.
In an alternative embodiment, negatively charged dye particles may be used to dye the fabric. The negatively charged dye particles are repelled from the cathode (which is also negatively charged) and attracted to the anode (which is positively charged).
After the dyeing process has been completed, the temperature and pressure of the dye solution may be lowered. In an embodiment, by lowering the pressure of the dye solution, the sc-CO2 may change to a gaseous state and separates from the dye which may remain in a solid or liquid state. As a result of the separation, the sc-CO2 and the dye may be reused in subsequent dyeing processes. As a result, the dyeing process described above has the advantage that it does not produce large amounts of unusable, polluted solvents such as water.
One or more flow diagrams may have been used herein. The use of flow diagrams is not meant to be limiting with respect to the order of operations performed. The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely illustrative, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “operably connected”, or “operably coupled”, to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable”, to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically mateable and/or physically interacting components and/or wirelessly interactable and/or wirelessly interacting components and/or logically interacting and/or logically interactable components.
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
The foregoing description of illustrative embodiments has been presented for purposes of illustration and of description. It is not intended to be exhaustive or limiting with respect to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the disclosed embodiments. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US10/46943 | 8/27/2010 | WO | 00 | 4/19/2011 |
