TREA

Process for treating textile substrates

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Information

  • Patent Grant
  • 6676710
  • Patent Number
    6,676,710
  • Date Filed
    Monday, December 4, 2000
    24 years ago
  • Date Issued
    Tuesday, January 13, 2004
    20 years ago
Information
Abstract
A process for treating a textile substrate, the process including the steps of providing a textile substrate; providing a treatment bath; entraining a transport material in the treatment bath wherein the transport material further comprises a treatment material dissolved or suspended therein and wherein the transport material is substantially immiscible with the treatment bath; and contacting the textile substrate with the transport material in the treatment bath to thereby treat the textile substrate with the treatment material in the transport material.
Description




TECHNICAL FIELD




The present invention relates generally a process for treating textile substrates, and more particularly to a process for treating a textile substrate in treatment bath having a transport material entrained therein, the transport material having a treatment material dissolved, dispersed or suspended therein. In a preferred embodiment, the process comprises treating a textile substrate in supercritical fluid carbon dioxide (SCF—CO


2


).




BACKGROUND ART




It will be appreciated by those having ordinary skill in the art that conventional aqueous dyeing processes for textile substrates generally provide for effective dyeing, but possess many economic and environmental drawbacks. Particularly, aqueous dye baths that include organic dyes and co-solvents must be disposed of according to arduous environmental standards. Compliance with environmental regulations and process heating requirements thus drive up the costs of aqueous textile dyeing to both industry and the consuming public alike. Accordingly, there is a substantial need in the art for an alternative dyeing process wherein such problems are avoided.




One alternative to aqueous dyeing that has been proposed in the art is the dyeing of textile substrates in a supercritical fluid. Particularly, textile dyeing processes using supercritical fluid carbon dioxide (SCF—CO


2


) have been explored.




However, those in the art who have attempted to treat textile substrates in SCF—CO


2


have encountered a variety of problems. These problems include, but are not limited to, “crocking” (i.e. tendency of a dye to smudge when a dyed article is touched) of a dye on a dyed textile article; unwanted deposition of the dye onto the article and/or onto the dyeing apparatus during process termination; difficulty in characterizing solubility of the dyes in SCF—CO


2


; insolubility of many dyes and other treatment materials in CO


2


; difficulty introducing the dyes into the SCF—CO


2


flow; difficulty in preparing the dyes for introduction into the dyeing process; high pressure and temperature requirements for solubility; and trimer (cyclic oligomer) extraction from polyester at high temperature. These problems are exacerbated when attempts to extrapolate from a laboratory process to a plant-suitable process are made.




Poulakis et al.,


Chemiefasern/Textilindustrie


, Vol. 43-93, February 1991, pages 142-147 discuss the phase dynamics of supercritical carbon dioxide. An experimental section describing an apparatus and process for dyeing polyester in supercritical carbon dioxide in a laboratory setting is also presented. Thus, this reference only generally describes the dyeing of polyester with supercritical carbon dioxide in the laboratory setting and is therefore believed to be limited in practical application.




U.S. Pat. No. 5,199,956 issued to Schlenker et al. on Apr. 6, 1993 describes a process for dyeing hydrophobic textile substrate with disperse dyes by heating the disperse dyes and textile substrate in SCF—CO


2


with an azo dye having a variety of chemical structures. The patent thus attempts to provide an improved SCF—CO


2


dyeing process by providing a variety of dyes for use in such a process.




U.S. Pat. No. 5,250,078 issued to Saus et al. on Oct. 5, 1993 describes a process for dyeing hydrophobic textile substrate with disperse dyes by heating the disperse dyes and textile substrate in SCF—CO


2


under a pressure of 73 to 400 bar at a temperature in the range from 80° C. to 300° C. Then the pressure and temperature are lowered to below the critical pressure and the critical temperature, wherein the pressure reduction is carried out in a plurality of steps.




U.S. Pat. No. 5,578,088 issued to Schrell et al. on Nov. 26, 1996 describes a process for dyeing cellulose fibers or a mixture of cellulose and polyester fibers, wherein the fiber material is first modified by reacting the fibers with one or more compounds containing amino groups, with a fiber-reactive disperse dyestuff in SCF—CO


2


at a temperature of 70-210° C. and a CO


2


pressure of 30-400 bar. Specific examples of the compounds containing amino groups are also disclosed. Thus, this patent attempts to provide level and deep dyeings by chemically altering the fibers prior to dyeing in SCF—CO


2


.




U.S. Pat. No. 5,298,032 issued to Schlenker et al. on Mar. 29, 1994 describes a process for dyeing cellulosic textile substrate, wherein the textile substrate is pretreated with an auxiliary composition that promotes dye uptake subsequent to dyeing, under pressure and at a temperature of at least 90° C. with a disperse dye from SCF—CO


2


. The auxiliary composition is described as being preferably polyethylene glycol. Thus, this patent attempts to provide improved SCF—CO


2


dyeing by pretreating the material to be dyed.




Despite extensive research into SCF—CO


2


textile treatment processes, there remains room for improvement in the development of a process for treating a textile substrate with a textile treatment material. A process for treating a textile substrate would be particularly desirable in a plant-scale application of an SCF—CO


2


textile treatment process. Therefore, the development of such a process meets a long-felt and significant need in the art.




SUMMARY OF THE INVENTION




A process for treating a textile substrate is disclosed. The process comprises providing a textile substrate; providing a treatment bath; entraining a transport material in the treatment bath wherein the transport material further comprises a treatment material dissolved, dispersed or suspended therein and wherein the transport material is substantially immiscible with the treatment bath; and contacting the textile substrate with the transport material in the treatment bath to thereby treat the textile substrate with the treatment material in the transport material. In a preferred embodiment, the process comprises treating a textile substrate in supercritical fluid carbon dioxide (SCF—CO


2


).




Accordingly, it is an object of the present invention to provide a novel process for treating a textile substrate. This object is achieved in whole or in part by the present invention.




An object of the invention having been stated hereinabove, other objects will be evident as the description proceeds, when taken in connection with the accompanying Drawings and Laboratory Examples as best described hereinbelow.











BRIEF DESCRIPTION OF THE DRAWINGS





FIGS. 1A-1B

is a detailed schematic of a system suitable for use in the textile treatment process of the present invention;





FIG. 2

is a detailed perspective view of a system suitable for use in the textile treatment process of the present invention;





FIG. 3

is a schematic of an alternative embodiment of a system suitable for use in the textile treatment process of the present invention;





FIG. 4

is a schematic of another alternative embodiment of a system suitable for use in the textile treatment process of the present invention;





FIG. 5

is a schematic of a system for introducing textile treatment materials into a textile treatment system in accordance with a process of the present invention;





FIG. 6

is a schematic of a system for introducing textile treatment materials into a textile treatment system in accordance with a process of the present invention; and





FIG. 7

is a schematic of a textile treatment system suitable for use in a process of the present invention, wherein the system includes a treatment material preparation subsystem and a dyeing/treatment subsystem.











DETAILED DESCRIPTION OF THE INVENTION




A process for treating a textile substrate is disclosed. The process comprises providing a textile substrate; providing a treatment bath; entraining a transport material in the treatment bath wherein the transport material further comprises a treatment material dissolved, dispersed or suspended therein and wherein the transport material is substantially immiscible with the treatment bath; and contacting the textile substrate with the transport material in the treatment bath to thereby treat the textile substrate with the treatment material in the transport material.




The process of the present invention can further comprise an optional drying step. Optionally, the drying step can be accomplished using a conventional apparatus or system, such as dielectric drying (radio-frequency or microwave), a centrifugal system or other thermal or mechanical/thermal system. Preferably, however, drying is accomplished by a process step, such as by circulating fresh treatment bath (i.e. having substantially no transport material entrained therein) through the textile substrate to remove excess transport material (e.g. water) present in the textile substrate. Optionally, bath temperature can be increased to enhance the drying step.




In a preferred embodiment, the transport material comprises water and the treatment bath comprises near-critical liquid CO


2


or SCF—CO


2


. More preferably, the water is present in the near-critical liquid CO


2


or SCF—CO


2


treatment bath in a trace amount. Thus, a major advantage of a preferred embodiment of the present inventive process is that it eliminates virtually all water usage and attendant waste treatment required in conventional textile dyeing processes. The process also has great advantage in that the present inventive process can easily apply dyes of very low affinity, normally not suitable for batch/exhaust dyeing.




I. Process of the Present Invention




In the process of the present invention, the treatment bath can comprise any fluid that is (1) inert with respect to the dye, transport material and textile substrate and (2) has physical properties (density, viscosity, etc.) sufficient to entrain and transport finely distributed droplets or agglomerations of dye- or chemical-laden transport material. Near-critical liquid CO


2


or SCF—CO


2


represent preferred embodiments of such a fluid that is safe, economical and environmentally acceptable. Nitrogen, hexane and propane are additional examples. High-density fluids are preferred.




By the term “high-density” (for the non-aqueous bath liquid) it is meant sufficient to entrain, propel and inhibit settling of the droplets of transport material. The required magnitude of the density of the bath liquid can depend on the velocity of the bath liquid; the viscosity of the bath liquid; the density of the entrained transport material droplets; the size of the entrained transport material droplets; the design of the treatment machine; and on combinations of any of these characteristics.




In a preferred embodiment, the process uses small amounts (trace amounts) of a transport material that is substantially immiscible in the treatment bath. By the term “substantially immiscible” it is meant that the transport material and the treatment bath do not mix to form a solution, i.e., they are substantially insoluble in each other and usually exist in separate phases when mixed. Representative combinations thus included hydrophobic and hydrophilic materials, polar and non-polar materials and/or aqueous and non-aqueous materials. For example, the transport material can comprise an aqueous material (e.g., water), while the treatment bath comprises a non-aqueous material (e.g., SCF—CO


2


).




Additionally, the term “transport material” is meant to refer to a material that (1) acts as a solvent, as a dispersing agent or as a suspending agent for the dye or other treatment materials; (2) is capable of wetting the textile substrate; and (3) is a liquid under the treatment conditions. Table 1 contrasts the action of conventional carriers that are used in conventional dyeing processes with that of a transport material of the present invention.












TABLE 1











Carrier vs. Transport Material













Feature




Carrier




Transport Material









Entrainment




Emulsion of oil-type material in




Entrained droplets of







water. Carriers are substantially




water-type material in







non-functional in SCF-CO


2


.




SCF-CO


2


. No emulsi-







Neither the carrier-active




fier is involved. The







material (e.g. 1,2,4




treatment bath is not







trichlorobenzene (TCB)), nor the




an emulsion; rather,







emulsifier systems (e.g.




the treatment







ethoxylated nonyl phenol)




bath comprises







are suitable for SCF-CO


2


use.




entrained droplets.






Dye interaction




Carriers do not dissolve non-




Treatment material







ionic dyes within the




(e.g. dye) is dissolved,







emulsified droplets.




dispersed or suspended








in the entrained drop-








lets; however, the








treatment material is








sparingly soluble in








the SCF-CO


2


.






Persistence




Carriers produce persistent




Once removed, the







effects in fibers. For example,




transport material (e.g.







polyester can be treated with




aqueous transport







carrier (1,2,4 TCB) then washed




material) preferably







thoroughly so that




has no permanent







no trace of the carrier




effect.







remains. Then the fiber can







be dyed and will respond







as if carrier were still







present in the bath.






Glass transition




Carriers reduce the glass




Cotton and wool have






of fibers




transition temperature of fibers,




no glass transition







and produce permanent




temperature. They







morphological changes.




decompose upon heat-








ing (or burns)-they








do not melt or undergo








a glass transition.








Therefore, carriers








would have no func-








tion with respect to








cotton, wool, silk








or similar fibers






Action




Carriers act in the fiber. A




The transport material







polyester fiber placed in a dye




acts in the bath to







bath containing fiber will absorb




deliver the treatment







essentially all of the carrier-




material to the







active material. The action of




textile substrate as







the carrier is done by the




entrainment of mater-







absorbed material in the fiber.




ial-laden droplets.






Continuous




The continuous phase is




The continuous phase






phase




aqueous, i.e. a conventional




is preferably non-







aqueous treatment (e.g.




aqueous.







dyeing) bath.














A preferred transport material comprises water or comprises an aqueous solution, an aqueous dispersion, an aqueous emulsification, and/or an aqueous suspension, such as: water/alcohol, water/reducing or oxidizing agent, water/buffer (for pH control), water/salt, or water/surfactant, wherein the surfactant is soluble in water and preferably not soluble in SCF—CO


2


. Though less preferred, other transport materials include, but are not limited to: alcohols, poly-alcohols, fluorocarbons, chlorocarbons, hydrocarbons, amines, esters and amides.




Any dyes, chemicals or other textile treatment materials can be used in the process of the present invention so long as the dyes or chemicals are (1) soluble in the transport material and (2) capable of dyeing or treating the textile substrate. An example is the use of direct dyes to dye cotton in SCF—CO


2


with water as the transport material. Another example is the dyeing of wool in SCF—CO


2


with acid dyes, using water as the transport material. The transport material can be conveniently introduced by using it to prewet the textile substrate, but can also be introduced by injection into the treatment bath, along with or separately from the dye or treatment chemical, at a preferred point in the process, i.e., with respect to location and time.




Dyes that can be used to carry out the present invention include, but are not limited to, acid, basic, azo (mono, di, poly), carbonyl, sulfur, methine, and triarylcarbonium dyes. The dyes can be anionic (acid including non-metallized acid, mordant, direct, reactive), cationic (brilliant color with good color fastness), direct (substantive character without mordants), dispersive (very low solubility in dyebath, substantive toward hydrophobics), and azoid (azo containing small molecule permeation followed by a reaction to form a larger substantive dye) dyes.




Materials that can be dyed by the process of the present invention include, but are not limited to, fiber, yarns and fabrics formed from polyester, nylon, acrylic fibers, acetate (particularly cellulose acetate), triacetate, silk, rayon, cotton and wool, including blends thereof such as cotton/polyester blends, as well as leather. In particular, textile substrates are treated by the process, and encompass a large number of materials. Such substrates are those formed from textile fibers and precursors and include, for example, fabrics, garments, upholstery, carpets, tents, canvas, leather, clean room suits, parachutes, yarns, fibers, threads, footwear, silks, and the other water sensitive fabrics. Articles (e.g., ties, dresses, blouses, shirts, and the like) formed of silk or acetate can also be treated via the process of the present invention.




In one embodiment, the process of the present invention pertains to the treatment of hydrophilic fibers, including natural fibers (e.g., cotton, wool and silk) in a non-aqueous fluid treatment bath (e.g., supercritical fluid carbon dioxide, SCF—CO


2


) with textile dyes and other textile treatment materials. The treatment is accomplished by entraining dye- or chemical-laden transport materials in an inert treatment bath in a manner that delivers the dye- or chemical-laden transport materials to the textile substrate to be dyed or treated.




The amount of transport material employed in the process of the present invention can vary in accordance with the textile substrate and the treatment conditions, among other variables. For example, the amount of transport material includes the amount that is sorbed by the textile substrate as well as the amount of transport material that is free to circulate and to form entrained droplets in the system. Different fibers and different forms of textile substrates (e.g. yarn package, fabric, etc) will sorb different amounts of water. Wool will absorb most, cotton a little less. Nylon and acrylic will absorb less than cotton and wool. And polyester will absorb almost none. Representative amounts of transport material (e.g. water) are disclosed in the Laboratory Examples presented below.




Thus, the term “trace amount” comprises an amount of transport material needed to result in enough entrainment to accomplish the treatment process plus any additional transport material needed directly in the treatment process. For example, some additional amount of transport material (e.g. water), beyond entrainment needs, can be employed to “swell” fibers such as cellulosics (e.g. cotton) so that they can be treated, but there would be no such need in the case of treating polyester. The amount of free transport material is preferably equal to or less than the weight of the textile substrate being dyed, but will also depend on the particular dye or other treatment material being applied.




The terms “supercritical fluid carbon dioxide” or “SCF—CO


2


” are meant to refer to CO


2


under conditions of pressure and temperature which are above the critical pressure (P


c


=about 73 atm) and temperature (T


c


=about 31° C.). In this state the CO


2


has approximately the viscosity of the corresponding gas and a density that is intermediate between the density of the liquid and gas states.




The terms “near-critical liquid carbon dioxide” or “NCL-CO


2


” are meant to refer to liquid CO


2


under conditions of pressure and temperature that are near the critical pressure (P


c


=about 73 atm) and temperature (T


c


=about 31° C.).




The term “textile treatment material” means any material that functions to change, modify, brighten, add color, remove color, or otherwise treat a textile substrate. Examples comprise UV inhibitors, lubricants, whitening agents, brightening agents and dyes. Representative fluorescent whitening agents are described in U.S. Pat. No. 5,269,815, herein incorporated by reference in its entirety. The treatment material is, of course, not restricted to those listed herein; rather, any textile treatment material compatible with the treatment process is provided in accordance with the present invention.




Representative treatment materials also include but are not limited to antimicrobial agents (e.g., algaecides, bacteriocides, biocides, fungicides, germicides, mildewcides, preservatives); antimigrants (fixing agents for dyes); antioxidants; antistatic agents; bleaching agents; bleaching assistants (stabilizers and catalysts); catalysts; lubricants (coning and winding); crease-resisting finishing agents (anticreasing agents, durable press agents); desizing agents (enzymes); detergents; dye fixing agents; flame retardants; gas fading inhibitors (antifume agents, atmospheric protective agents); fumigants (insecticides and insect repellents); leveling agents; oil repellents; oxidizing agents; penetrating agents (rewetting agents, wetting agents); polymers (resins); reducing agents; retarding agents; scouring agents; soaps; softeners; soil release/stain resistant finishes; souring agents; stripping agents; surfactants; ultraviolet absorbers/light stabilizers; water repellents; waxes; whitening finishes; fluorescent finishes; and combinations of any of the foregoing.




Preferably, the process of the present invention is free of a surfactant that is soluble in the treatment bath, e.g., a surfactant that is soluble in SCF—CO


2


. Representative embodiments of such surfactants are disclosed in U.S. Pat. No. 6,010,542 issued to DeYoung et al. on Jan. 4, 2000. However, optionally, the transport material can further comprise a surfactant that is substantially insoluble in the treatment bath, but that is soluble in the transport material, e.g., a surfactant that is soluble in water but sparingly soluble in SCF—CO


2


.




The term “dye” is meant to refer to any material that imparts a color to a textile substrate. Preferred dyes comprise water-soluble and water-dispersible dyes, and many representative dyes are identified in the Colour Index, an art-recognized reference manual.




The term “hydrophilic textile fiber” is meant to refer to any textile fiber comprising a hydrophilic material. More particularly, it is meant to refer to natural and synthetic hydrophilic fibers that are suitable for use in textile substrates such as yarns, fabrics, or other textile substrate as would be appreciated by one having ordinary skill in the art. Preferred examples of hydrophilic materials include cellulosic materials (e.g. cotton, cellulose acetate), wool, silk, nylon and acrylic.




The term “hydrophobic textile fiber” is meant to refer to any textile fiber comprising a hydrophobic material. More particularly, it is meant to refer to hydrophobic polymers that are suitable for use in textile substrates such as yarns, fibers, fabrics, or other textile substrate as would be appreciated by one having ordinary skill in the art. Preferred examples of hydrophobic polymers include linear aromatic polyesters made from terephathalic acid and glycols; from polycarbonates; and/or from fibers based on polyvinyl chloride, polypropylene or polyamide. A most preferred example comprises 150 denier/34 filament type 56 trilobal texturized yarn (polyester fibers) such as that sold under the registered trademark DACRON® Type 54,64 (filaments) and 107W (spun/staple)(E.I. Du Pont De Nemours and Co.). Glass transition temperatures of preferred hydrophobic polymers, such as the listed polyesters, typically fall over a range of about 55° C. to about 65° C. in SCF—CO


2


.




The term “sparingly soluble”, when used in referring to a solute, means that the solute is not readily dissolved in a particular solvent at the temperature and pressure of the solvent. Thus, the solute tends to fail to dissolve in the solvent, or alternatively, to precipitate from the solvent, when the solute is “sparingly soluble” in the solvent at a particular temperature and pressure.




The term “crocking”, when used to describe a dyed article, means that the dye exhibits a transfer from dyed material to other surfaces when rubbed or contacted by the other surfaces.




Following long-standing patent law convention, the terms “a” and “an” mean “one or more” when used in this application, including the claims.




II. Representative Textile Treatment Systems




Any machine that has a suitable mechanical configuration can be used in the practice of the process of the present invention. For instance, in each of the Examples presented below, a package dyeing SCF—CO


2


system was employed. A representative embodiment of such a system is disclosed in U.S. Pat. No. 6,048,369, issued Apr. 11, 2000 to Smith, et al., herein incorporated by reference in its entirety. Other representative systems are disclosed in U.S. Pat. Nos. 5,298,032; 5,518,088; and 6,010,542; and the contents of each of these patents are incorporated herein by reference in their entirety.




Referring now to

FIGS. 1A

,


1


B and


2


, a system suitable for use in the practice of the process of the present invention is referred to generally as


10


. In the following detailed description, the parts of system


10


that are primarily involved in the process of the present invention are described. Additionally, a legend describing other parts of system


10


is provided in Table 2 below. For convenience, system


10


is referred to as an SCF—CO


2


dyeing system; however, system


10


can be adapted for use with any treatment material and any treatment bath.












TABLE 2











LEGEND FOR

FIGS. 1A

, 1B AND 2














Item No.




Name











 10




Supercritical CO


2


Treatment System







 12




CO


2


Supply Cylinder







 14




Line Section







 16




Pressure Regulating Valve







 18




Pressure Indicator







 20




Pressure Alarm







 22




Pressure Relief Valve







 24




Needle Valve







 26




Condenser (Shell-in-Tube Heat Exchanger)







 28




Chiller







 30




Turbine Flow Meter







 32




Temperature Element (Indicator)







 34




System Pressurization Pump (Positive Displacement)







 36




Pressure Control Valve







 38




Static Mixer







 40




Electric Preheater







 42




Temperature Alarm







 44




Over-Temperature Switch







 46




Needle Valve







 50




Co-Solvent Pump (Positive Displacement)







 52




Needle Valve







 54




Needle Valve







 56




Check Valve







 58




Rupture Disk







 60




Temperature Element (Indicator)







 62




Temperature Controller







 64




Needle Valve







 66




Needle Valve







 68




Check Valve







 70




Dye-Add Vessel







 71




Dye-Add Vessel Jacket







 72




Temperature Element (Indicator)







 74




Temperature Alarm







 76




Temperature Controller







 78




Control Valve (Temperature-Controlled)







 80




Control Valve (Temperature-Controlled)







 82




Control Valve (Temperature-Controlled)







 84




Control Valve (Temperature-Controlled)







 86




Rupture Disk







 88




Pressure Indicator







 90




Pressure Alarm







 91




Line Section







 92




Ball Valve (2-Way)







 93




Ball Valve







 94




Ball Valve (2-Way)







 96




Sight Glass







 98




Circulation Pump (Centrifugal)







100




Rupture Disk







102




Ball Valve (2-Way)







104




Ball Valve (2-Way)







106




Dyeing Vessel







107




Dyeing Vessel Jacket







108




Line Section







109




Needle Valve







110




Pressure Indicator







114




Ball Valve (2-Way)







116




Ball Valve (2-Way)







118




Coriolis Flow Meter







120




Ball Valve (3-Way)







122




Temperature Element (Indicator)







124




Temperature Alarm







126




Temperature Controller







128




Pressure Indicator







130




Pressure Alarm







132




Control Valve (Temperature-Controlled)







134




Control Valve (Temperature-Controlled)







136




Control Valve (Temperature-Controlled)







138




Control Valve (Temperature-Controlled)







140




Rupture Disk







142




Needle Valve







144




Needle Valve







146




Line Section







148




Needle Valve







150




Temperature Element (Indicator)







152




Needle Valve







154




Pressure Control Valve







156




Separator Vessel







158




Pressure Indicator







160




Pressure Alarm







162




Temperature Element (Indicator)







164




Rupture Disk







166




Pressure Control Valve







168




Needle Valve







170




Needle Valve







172




Filter







174




Filter







176




Pressure Relief Valve







178




Check Valve







180




Line Section







182




Check Valve







184




Line Section















Referring particularly to

FIGS. 1A

,


1


B and


2


, operation and control of the SCF—CO


2


dyeing system


10


optionally encompasses three distinct equipment subsystems. The subsystems include filling and pressurization subsystem A, dyeing subsystem B, and venting subsystem C. Carbon dioxide is introduced into system


10


via CO


2


supply cylinder


12


. Preferably, supply cylinder


12


contains liquid carbon dioxide. Thus, liquid CO


2


enters the filling and pressurization subsystem A from the supply cylinder


12


through line section


14


and regulating valve


16


and is cooled in condenser


26


by a water/glycol solution supplied by chiller


28


. The CO


2


is cooled to assure that it remains in a liquid state and at a pressure sufficiently low to prevent cavitation of system pressurization pump


34


.




Continuing with

FIGS. 1A

,


1


B and


2


, turbine flow meter


30


measures the amount of liquid CO


2


charged to dyeing system


10


. Pump


34


increases the pressure of the liquid CO


2


to a value above the critical pressure of CO


2


but less than the operating pressure for the dyeing system, typically ranging from about 1000 psig to greater that about 4000 psig, depending of the particular textile substrate being dyed or otherwise treated. A side-stream of water/glycol solution from chiller


28


provides cooling for pump


34


. Control valve


36


allows pump


34


to run continuously by opening to bypass liquid CO


2


back to the suction side of pump


34


once the system pressure set point has been reached. This valve closes if the system pressure falls below the set point that causes additional liquid CO


2


to enter the dyeing subsystem B. Optionally, the transport material can be injected into the liquid CO


2


stream by pump


50


at the discharge of pump


34


and mixed in by static mixer


38


.




Continuing with

FIGS. 1 and 2

, liquid CO


2


leaving mixer


38


enters electrical pre-heater


40


where its temperature is increased. Heated and pressurized CO


2


can enter the dyeing subsystem B through needle valve


66


and into dye-add vessel


70


; through needle valve


64


and into dyeing vessel


106


; or through both of these paths. Typically, dyeing subsystem B is filled and pressurized simultaneously through both the dye-add and dyeing vessels


70


and


106


, respectively.




Once a sufficient quantity of liquid CO


2


has been charged to dyeing subsystem B to achieve the operating density, typically a value in the range of 0 to about 0.75 g/cm


3


, preferably about 0.2 to about 0.7 g/cm


3


, more preferably to about 0.25 to 0.50 g/cm


3


, circulation pump


98


is activated. Optionally, system


10


is configured so that circulation pump


98


first drives the flow of liquid CO


2


through the dyeing vessel


106


, which contains a textile substrate that has been wetted out with transport material. Contacting of the liquid CO


2


flow with the textile substrate that has been wetted out with transport material entrains the transport material into the liquid CO


2


flow.




Once circulation is started, heating of subsystem B is initiated by opening control valves


78


and


84


to supply steam to and remove condensate, respectively, from the heating/cooling jacket


71


on dye-add vessel


70


. Similarly, control valves


132


and


136


are opened to supply steam to and remove condensate from, respectively, the heating/cooling jacket


107


on dyeing vessel


106


. Commercial practice would utilize a heat exchanger in the circulation loop to provide for heating of the CO


2


rather than relying on heating through the vessel jackets


71


and


107


. Heating is continued until the system passes the critical temperature of CO


2


and reaches the operating, or dyeing, temperature, typically ranging from about ambient (e.g., 22° C.-25° C.) to about 130° C., preferably ranging from about 25° C. to about 100° C., more preferably ranging from about 40° C. to about 95° C.




Continuing with FIGS,


1


A,


1


B and


2


, SCF—CO


2


leaving circulation pump


98


passes through sight glass


96


and is diverted, by closing ball valve


94


and opening ball valve


93


, through dye-add vessel


70


where dye is dissolved and/or suspended in the transport material. Transport material-laden SCF—CO


2


passes out of the dye-add vessel


70


through ball valve


92


and flow meter


118


to ball valve


120


. Ball valve


120


is a three-way valve that diverts the SCF—CO


2


flow to the inside or outside of the package loaded in dyeing vessel


106


depending on the direction in which it is set. If ball valve


120


is set to divert flow in the direction of ball valve


104


, and ball valve


104


is open and ball valve


102


is closed, then all of the SCF—CO


2


flow proceeds to the inside of the dye spindle (not shown in

FIGS. 1A

,


1


B and


2


). The flow continues from the inside to the outside of the dye spindle, from the inside to the outside of the dye tube (not shown in

FIGS. 1A

,


1


B and


2


) on which the textile yarn package is wound and out through the textile yarn package to the interior of dyeing vessel


106


. The SCF—CO


2


flow passes out of dyeing vessel


106


, through open ball valves


114


and


116


to the suction of pump


98


, completing a circuit for inside-to-outside dyeing of the yarn package.




If ball valve


120


is set to divert flow in the direction of ball valve


114


, and ball valve


114


is open and ball valve


116


is closed, then all of the SCF—CO


2


flow proceeds to the interior of dyeing vessel


106


and the outside of the textile yarn package. The flow passes through the textile yarn package, continues from the outside to the inside of the dye tube on which the yarn is wound and then passes from the outside to the inside of the dye spindle. The SCF—CO


2


flow exits the interior of the dye spindle and passes through open ball valves


104


and


102


to the suction of pump


98


, which completes a circuit for outside-to-inside dyeing of the textile yarn package.




The SCF—CO


2


flow having treatment material-laden transport material entrained therein is held at values ranging from values of 1 gallon per minute (GPM)/lb of textile or less, to values greater than 15 GPM/lb of textile. The treatment bath flow is periodically switched between the inside-to-outside(I-O) circuit and the outside-to-inside (O-I) circuit to promote uniformity of dyeing of the textile yarn; e.g., 6 min./2 min. I-O/O-I, 6 min./4 min. I-O/O-I, 5 min./5 min. I-O/O-I, etc. This dyeing process is continued with system


10


held at the dyeing temperature, usually about ambient temperature to about 130° C., and preferably about 40° C. to 95° C., until the treatment material in the transport material is exhausted onto the textile substrate to produce an even distribution, typically around 30 minutes.




Continuing with reference to

FIGS. 1A

,


1


B and


2


, venting is initiated by opening needle valve


109


to provide a flow path from the dyeing vessel


106


to control valve


154


. Control valve


154


is opened to set the pressure in dyeing subsystem B and control valve


166


is opened to set the pressure in separator vessel


156


. By adjusting control valves


154


and


166


appropriately, the pressure in the dyeing vessel


106


is reduced at a controlled rate. Dye-add vessel


70


is isolated during venting to prevent any additional dye remaining in dye-add vessel


70


from going into solution in the transport material that is entrained in the SCF—CO


2


. Isolation of dye-add vessel


70


is accomplished by closing ball valves


92


and


93


while opening ball valve


94


to maintain a circulation loop for the dyeing vessel.




During venting SCF—CO


2


flows from dyeing subsystem B through control valve


154


and into separator vessel


156


of venting subsystem C. In separator vessel


156


the pressure is sufficiently low so that the CO


2


is in the gaseous phase and any contaminants, and the treatment material solids collect in separator vessel


156


and gaseous CO


2


exits through control valve


166


. Once the gaseous CO


2


passes through control valve


156


it can be vented to atmosphere by opening needle valve


168


. The gaseous CO


2


can also be recycled to filling and pressurization subsystem A by keeping needle valve


168


closed so that the gaseous CO


2


passes through filters


172


and


174


. Filters


172


and


174


collect any minute amounts of solids that can have escaped separator vessel


156


with the gaseous CO


2


flow. The gaseous CO


2


exiting filters


172


and


174


passes through check valve


178


and enters filling and pressurization subsystem A for re-use in system


10


.




Referring now to

FIG. 3

, an alternative system


10


′ for use in the SCF—CO


2


dyeing process of the present invention is depicted schematically. Generally, however, system


10


′ works in a similar manner as system


10


described above and as depicted in

FIGS. 1 and 2

. System


10


′ includes a CO


2


cylinder


12


′, from which CO


2


flows through check valve


16


′ to a cooling unit


26


′. CO


2


is cooled and pressurized within cooler


26


′ and then is pumped, using positive displacement pump


34


′, into dye injection vessel


70


′. Prior to introduction of CO


2


into vessel


70


′, a dyestuff is placed within vessel


70


′. In dye injection vessel


70


′, the treatment material, i.e., the dyestuff, is dissolved and/or suspended into the transport material, which is preferably water or an aqueous solution. Thus, when CO


2


is introduced into vessel


70


′ the dye-laden transport material is entrained within the SCF—CO


2


flow.




Continuing with

FIG. 3

, the action of pump


34


′ drives the SCF—CO


2


that has dye-laden transport material entrained therein out of dye injection vessel


70


′ through a hand valve


64


′ and a check valve


182


′ into a dyeing vessel


106


′ that contains the textile substrate to be dyed. Dyeing vessel


106


′ is pressurized and heated to SCF dyeing conditions prior to the introduction of the SCF—CO


2


that has dye-laden transport material entrained therein. Steam and/or cooling water are introduced to jacket


107


′ of dyeing vessel


106


′ via valves


132


′ and


134


′, respectively. Thus, appropriate temperatures for dyeing are achieved in vessel


106


′. During and after dyeing, any condensate resulting from the introduction of steam through valve


132


′ is exported through vent


136


′ and any water introduced via valve


134


′ is exported through drain


138


′.




Continuing with

FIG. 3

, during dyeing, the SCF—CO


2


flow that has dye-laden transport material entrained therein is circulated into and out of vessel


106


′ via circulation pump


98


′, valves


104


′ and


114


′, and 3-way valve


120


′ in a manner analogous to that described above for system


10


, valves


104


and


114


, and 3-way valve


120


. Flow meter


118


′ is placed in system


10


′ between circulation pump


98


′ and 3-way valve


120


′ so that the flow rate of SCF—CO


2


can be monitored. Dyeing is thus facilitated by the circulation subsystem. Further, the action of circulation pump


98


′ maintains system flow during the treatment process.




Continuing with particular reference to

FIG. 3

, after a predetermined time, preferably when substantially exhaustion of the treatment material in the transport material onto the textile substrate is observed, SCF—CO


2


is removed from dyeing vessel


106


′ and flows through back pressure regulator


154


′. At this point, the pressure of the process is reduced and CO


2


within the system is introduced into separator vessel


156


′. Any contaminants, likely a small amount, are removed from the CO


2


in separator vessel


156


′. CO


2


then can be vented through vent


170


′. Alternatively, CO


2


can be recycled back into system


10


′ via check valve


178


′.




Referring now to

FIG. 4

, another alternative embodiment of a suitable system for use in the process of the instant invention is described. System


10


″ includes CO


2


cylinder


12


″. CO


2


flows from cylinder


12


″ through check valve


16


″ into subcooler


26


″. The temperature of the CO


2


is reduced within subcooler


26


″ to assure that is remains in a liquid state and at a pressure sufficiently low to prevent cavitation of positive displacement pump


34


″. The positive displacement pump


34


″ then drives the CO


2


through hand valve


64


″, then through a check valve


182


″, into dyeing vessel


106


″. Dyeing vessel


106


″ includes the textile fibers to be dyed. In dye injection vessel


70


′, the treatment material, i.e., the dyestuff, is dissolved and/or suspended into the transport material, which is preferably water or an aqueous solution.




Continuing with particular reference to

FIG. 4

, dyeing vessel


106


″ is pressurized and heated to produce CO


2


at SCF temperature and pressure. SCF—CO


2


is then exported from vessel


106


″ using circulation pump


98


″ and valves


104


″ and


114


″ in a manner analogous to that described above for system


10


and valves


104


and


114


. SCF—CO


2


is introduced via valve


92


″ into a dye injection vessel


70


″ containing a suitable dye. The dye is dissolved and/or suspended in the transport material in dye injection vessel


70


″, and the transport material is entrained in the SCF—CO


2


in dye injection vessel


70


″. Circulation pump


98


″ drives the SCF—CO


2


that has the dye-laden transport material entrained therein from vessel


70


″ through flow meter


118


″ and 3-way valve


120


″ back into dyeing vessel


106


″ wherein dyeing of the textile fibers is accomplished. During dyeing, steam and/or cooling water are introduced to jacket


107


″ of dyeing vessel


106


″ via valves


132


″ and


134


″, respectively. Thus, appropriate temperatures for dye dissolution and dyeing are achieved in vessel


106


″. During and after dyeing, any condensate resulting from the introduction of steam through valve


132


″ is exported through vent


136


″ and any water introduced via valve


134


″ is exported through drain


138


″.




Continuing with

FIG. 4

, after a predetermined time, preferably when substantially complete exhaustion of the treatment material in the transport material onto the textile substrate is observed, the SCF—CO


2


dye bath is removed from vessel


106


″ to back pressure regulator


154


″. The pressure of the process is then reduced using regulator


154


″ and the resulting CO


2


phase is then introduced into separator vessel


156


″. In separator vessel


156


″ the pressure is further reduced so that any contaminants, likely a small amount, are deposited within separator vessel


156


″ and the resulting contaminant-free CO


2


gas is removed from separator vessel


156


″. Particularly, the contaminant-free CO


2


gas can be vented using vent


170


″ or can be recycled back into system


10


″ via check valve


178


″. An aspect of the efficiency of the process of this invention is thus demonstrated.




The present invention also provides a treatment material introduction system to facilitate introduction of a textile treatment material, such as a dye, into a textile treatment process. Preferably, the treatment material is dissolved, dispersed and/or suspended in the transport material when it contacts the treatment bath used in the treatment process.




Referring again to the drawings, a representative embodiment of a textile treatment material introduction system of the present invention is generally designated


200


in FIG.


5


. Referring to

FIG. 5

, system


200


introduces textile treatment materials dissolved and/or suspended in transport material into a textile treatment system


220


, which preferably comprises a SCF—CO


2


textile treatment system such as that described in detail above. System


200


comprises dye-add or preparation vessel


202


, positive-displacement metering pump


204


, line section


206


, control valves


210


and


214


, and return line


218


. Treatment system


220


comprises a treatment vessel


222


, a circulation loop


224


and a circulation pump


226


.




Continuing with reference to

FIG. 5

, a textile treatment material is placed in preparation vessel


202


, which is equipped with a stirring device


228


capable of thoroughly mixing the contents of vessel


202


. Stirring device


228


comprises a motor-driven fan, but can also comprise a motor-driven shaft, a rotatably mounted shaft, or any other suitable stirring device as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention. Other stirring devices include a fan, propeller or paddle that is magnetically coupled to a motor rather than coupled to the motor by a solid shaft. Such devices, and equivalents thereof, thus comprise “stirring means” and “mixing means” as used herein and in the claims.




Continuing with reference to

FIG. 5

, in operation the preparation vessel


202


of system


200


is charged with transport material and treatment material and sealed. The amount of transport material initially charged depends on the transport material concentration desired at the introduction conditions. If a surfactant or dispersing agent, each of which is also soluble in the transport material is to be used, it is charged along with the textile treatment material, or introduced with a metering pump (not shown in

FIG. 5

) into the preparation vessel


202


at some point in the textile treatment material preparation process. The contents of the preparation vessel


202


are then heated with mixing to the introduction conditions, which can optionally, but are not required to, encompass a pressure that is near the textile treatment system pressure.




Introduction system


200


, and particularly preparation vessel


202


, can be isolated from treatment system


220


when the solution or suspension of textile treatment material is prepared in the transport material. Control valves


210


and


214


are used to isolate preparation vessel


202


and thus can be opened and closed for reversibly isolating preparation vessel


202


. Any other suitable structure, such as other valves, piping or couplings, as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention can also be used to isolate, preferably to reversibly isolate, preparation vessel


202


. Such devices and structures, and equivalents thereof, thus comprise “isolation means” as used herein and in the claims.




During introduction of treatment material laden transport material, introduction system


200


can be operated in several different modes. In one mode, introduction is accomplished with closed valve


214


so that only treatment material laden transport material is introduced into the treatment system through open valve


210


. That is, vessel


202


is emptied of treatment material laden transport material without any other type of communication with the treatment system. In a second mode, treatment material laden transport material is mixed with SCF—CO


2


in vessel


202


. In this case, a mixture of SCF—CO


2


and treatment material laden transport material is prepared for introduction into the treatment system. Introduction of this mixture can be with valve


214


closed or open. If valve


214


is closed during the introduction process, vessel


202


is emptied of the mixture of SCF—CO


2


and treatment material laden transport material through open valve


210


, without any other type of communication with the treatment system. If valve


214


is open during the introduction process, vessel


202


is replenished with a mixture of SCF—CO


2


and transport material while a mixture of SCF—CO


2


and treatment material laden transport material is introduced into the treatment system through open valve


210


. This last operating mode might be used in the case that the amount of transport material is insufficient to instantaneously dissolve all of the treatment material resident in vessel


202


. In this case, the stream of SCF—CO


2


entering vessel


202


through open valve


214


would contain transport material exhausted of treatment material and, thereby, ready to dissolve or suspend more treatment material.




Continuing with reference to

FIG. 5

, positive-displacement metering pump


204


introduces the textile treatment material-laden transport material (or mixture of SCF—CO


2


and treatment material-laden transport material) into the circulation loop


224


of treatment system


220


using an introducing rate profile that is consistent with producing uniformly-treated textile substrates in minimum processing time. In a preferred embodiment, pump


204


shown in

FIG. 5

comprises a positive displacement pump with a reciprocating piston. Other representative pumps include a syringe type pump employing a mechanical piston and a syringe type pump employing an inert fluid as a piston. Thus, devices such as pumps, nozzles, injectors, combinations thereof, and other devices as would be apparent to one of ordinary skill in the art after reviewing the disclosure of the present invention, and equivalents thereof, comprise “introducing means” as used herein and in the claims.




Mixing of the preparation vessel


202


is continued throughout the introduction cycle via mechanical stirring with stirring device


228


. Introducing of the textile treatment material-laden transport material (or mixture of SCF—CO


2


and treatment material-laden transport material) occurs at an introduction point


230


in the circulation loop


224


where fluid shear is very high. It is also preferred that introduction point


230


lie relatively near the dyeing/treatment vessel in order to avoid possible recombination of the droplets of the transport material before interaction with the textile substrate; this point could be before or after circulation pump


224


as long as pump


224


is sufficiently close to the dyeing/treatment vessel to avoid droplet recombination. For example, point


230


can lie before or after circulation pump


224


or in a mixing zone that contains static mixing elements (not shown in

FIG. 5

) in order to facilitate mixing with the treatment medium (e.g. SCF—CO


2


) flowing in circulation loop


224


of treatment system


220


. The term “high fluid shear” refers to a turbulent flow or a flow with high rate of momentum transfer. Preferably, the term “high fluid shear” refers to a flow having a Reynolds number greater than 2300, and more preferably, greater than 5000.




Referring now to

FIG. 6

, an alternative embodiment of the textile treatment material introduction system


200


shown in

FIG. 5

is disclosed and generally designated


300


. In alternative embodiment


300


, treatment materials are introduced in transport material into textile treatment system


302


, which preferably comprises a SCF—CO


2


textile treatment system as described hereinabove. System


302


comprises dye-add or preparation vessel


304


, positive-displacement metering pump


306


, line section


308


, control valves


314


and


316


, and return line


320


. Treatment system


302


comprises a treatment vessel


322


, a circulation loop


324


and a circulation pump


326


.




Textile treatment material is placed in the preparation vessel


304


of system


300


. Preparation vessel


304


is equipped with a mixing loop


328


as shown in FIG.


3


. Thus, mixing of the preparation vessel


304


is continued throughout the introducing cycle via fluid circulation (demonstrated by arrows in

FIG. 3

) by circulation pump


330


through mixing loop


328


. Such devices and structures, and equivalents thereof, thus comprise “circulation means” and “mixing means” as used herein and in the claims. Other aspects of alternative embodiment


300


function as described above, including the introduction of treatment material at high fluid shear introduction point


332


.




Referring now to

FIG. 7

, yet another embodiment of a textile treatment system for use in a process of the present invention is generally referenced at


400


. System


400


comprises a treatment material preparation subsystem


402


and a dyeing/treatment subsystem


404


. Preparation subsystem


402


further comprises an injection pump


406


; a preparation vessel


410


with a mixer


414


; line sections


408


and


416


; and an atomizing nozzle


420


. Dyeing/treatment subsystem


404


further comprises a bath preparation vessel


422


; a treatment vessel


426


; line sections


428


,


432


,


438


,


440


and


446


; centrifugal separator


430


; and circulation pump


436


.




Continuing with

FIG. 7

, a transport material is introduced into treatment material preparation subsystem


402


via injection pump


406


. The transport material travels through line section


408


to treatment material preparation vessel


410


, where a treatment material


412


is dissolved, dispersed and/or suspended in the transport material. The dissolving, dispersing and/or suspending of treatment material


412


is facilitated by the action of mixer


414


. Treatment material-laden transport material


418


then travels through line section


416


to atomizing nozzle


420


. The treatment material-laden transport material


418


coming from preparation vessel


410


is added in the form of suitably small droplets to bath preparation vessel


422


via atomizing nozzle


420


and the action of injection pump


406


.




Continuing with

FIG. 7

, a dyeing/treatment bath


424


is prepared by passing bath fluid (flow represented by arrow


448


) through bath preparation vessel


420


. Dyeing/treatment bath


424


then passes on to dyeing/treatment vessel


426


, which holds the textile substrate to be dyed or treated. After exiting dyeing/treatment vessel


426


, dyeing/treatment bath


424


passes into a centrifugal separator


430


via line section


428


. In centrifugal separator


430


, the transport material is separated from the bath fluid by centrifugation, as indicated by arrows


442


. As indicated by flow arrows


434


, bath fluid that is substantially free of transport material leaves centrifugal separator


430


via line section


432


and is circulated by circulation pump


436


through line section


438


back to preparation vessel


422


. Indeed, circulation pump


436


drives the flow of bath fluid and transport material for the dyeing/treatment process as a whole. As indicated by flow arrow


444


, the transport material is returned to injection pump


406


via line section


446


and subsequently is reintroduced into vessel


410


. As described above, the treatment material-laden transport material (represented by flow arrow


418


) coming from preparation vessel


410


is added in the form of suitably small droplets to bath preparation vessel


422


via atomizing nozzle


420


and the action of injection pump


406


. In this way, a continuous flow of properly prepared dyeing/treatment bath


424


is provided to dyeing/treatment vessel


426


and to the dyeing process as a whole.




In the system embodiment presented in

FIG. 7

, bath preparation vessel


422


is integrated within dyeing/treatment subsystem


404


. In order to faciliate uniform dyeing or treatment of the textile substrate, the droplet size for the entrained transport material is preferably very small, on the order a few microns or less. A very small droplet size provides intimate, vigorous contact of the transport material containing the dye or treatment chemical with the textile substrate. This process parameter plays a large role in applications where the dyeing/treatment bath must pass through the micron size pore spaces between individual yarns and fibers; e.g., in the dyeing or treatment of yarn packages.




In the system embodiment presented in

FIG. 7

, atomizing nozzle


420


produces small droplets of dye-laden or treatment material-laden transport material, but other techniques and devices for accomplishing this operation are also provided in accordance with the present invention. For example, a sub-stream of “clean” bath fluid can be removed from the main stream of this fluid before it enters bath preparation vessel


422


. The substream is then reintroduced along with dye-laden or treatment material-laden transport material into bath preparation vessel


422


using a mixing nozzle. That is, bath fluid and dye-laden or treatment material-laden transport material are atomized together into the main bath flow using a mixing nozzle.




In another approach, atomizing nozzle


420


is replaced by a sparging device with numerous, very small sparging holes; e.g., the sparging media can be sintered metal with micron sized pores. In this case, the dye-laden or treatment material-laden transport material is forced through the sparging device, thereby creating small droplets of dye-laden or treatment material-laden transport material that mix with the bath fluid. In yet another approach, the transport material and bath fluid are mixed together in bath preparation vessel


422


using vigorous agitation, such as that generated by a high-speed stirrer or high-speed flow through turbulence-producing devices such as baffles. The examples discussed here are meant to be illustrative only, and not limiting. Indeed, any device that introduces very small droplets into the inert, non-aqueous bath fluid can be utilized.




In the system embodiment presented in

FIG. 7

, it is preferred that dyeing/treatment vessel


426


has a design that is particular to the textile fiber being processed as well as to the form of the textile substrate. For example, equipment that is used in treating natural fibers such as cotton, silk and wool generally varies from that used to treat synthetic fibers such as polyester and nylon. Systems to dye or treat yarn, fabric or garments can also vary, and in some cases, can be substantially different. Examples of such differences include, but are not limited to, multiple ports into dyeing/treatment vessel


426


for dyeing/treatment bath entry, mechanical movement of the textile substrate being treated, and/or a piping and valve system capable of accomplishing flow reversal. In each case, uniform contact of dyeing/treatment bath


424


with the textile substrate is provided.




Continuing with

FIG. 7

, as dyeing/treatment bath


424


passes through and exits dyeing/treatment vessel


426


droplets of transport material suspended in the bath fluid could interact to form larger droplets. Eventually the droplet size could be too large to assure rapid and uniform dying/treatment of the textile substrate. For this reason, it is preferred for some textile substrates that the transport material is separated from the bath fluid and reintroduced into bath preparation vessel


422


in fine droplet form, as discussed above.




In the system embodiment presented in

FIG. 7

, centrifugal separator


430


removes the transport material from the fluid, but other techniques and devices for accomplishing this operation are provided in accordance with the present invention. For example, a settling chamber can be employed. This device is a large tank in which the fluid velocity slows sufficiently to allow entrained transport material to settle by gravity. Since the density of the transport material might be 2-3 times that of the bath fluid, such a device can provide the desired separation. The efficiency of a settling chamber would likely be improved by adding baffles or other solid surfaces to further slow the flow of the transport material and cause agglomeration, so that separation by gravity is enhanced.




Another potential separation method is filtration. Because the viscosity of the transport material is likely much greater than that of the bath fluid, the bath fluid will be expected to pass through the filter while the transport material collects on the upstream side. In this case, the “clean” bath fluid from downstream of the filter is sent to bath preparation vessel


422


, while the transport material from upstream of the filter is siphoned off for reintroduction in bath preparation vessel


422


. The examples discussed here are meant to be illustrative only, and not to be limiting. Any device that can efficiently separate the transport material from the bath fluid can be utilized.




In the system embodiment presented in

FIG. 7

, the transport material can be initially introduced into treatment material preparation subsystem


402


by a variety of techniques and devices. For example, since the textile substrate is preferably initially wetted-out with the transport material, the substrate can be provided with enough excess of transport material to meet the droplet entrainment needs. Alternatively, the amount of transport material needed for proper droplet entrainment can be introduced along with treatment material


412


into treatment material preparation vessel


410


. In yet another alternative, the transport material is injected into dyeing/treatment bath


424


at some convenient point in the process with respect to both time and location. The examples discussed here are meant to be illustrative only, and non-limiting, Thus, any device that efficiently dissolves, disperses or suspends a dye or another treatment material in a suitable amount of transport material can be utilized.




Once dyeing/treatment is complete, partial or complete removal of excess transport material from the textile substrate can optionally be accomplished by continuing the dyeing/treatment bath flow while ceasing reintroduction of the transport material. This process step allows a “clean” bath flow to “strip” excess transport material from the textile substrate to thereby “dry” the textile substrate. Increasing the temperature of the bath can serve to improve the speed and efficiency of the drying step. In the case that this step is not sufficient for complete removal of excess transport material, it can be augmented by conventional mechanical and/or thermal methods either within the dyeing/treatment vessel or in another piece of process equipment. That is, drying of the textile substrate can be performed via centrifuging, vacuum extraction, dielectric heating or convection heating either in situ or in external equipment. The dyeing/treatment process is completed by depressurizing the dyeing/treatment system to a recovery system where a separator removes any trace contaminants from the CO


2


before sending it to storage.




III. Laboratory Examples




The following Laboratory Examples have been included to illustrate preferred modes of the invention. Certain aspects of the following Laboratory Examples are described in terms of techniques and procedures found or contemplated by the present inventors to work well in the practice of the invention. These Laboratory Examples are exemplified through the use of standard laboratory practices of the inventors. In light of the present disclosure and the general level of skill in the art, those of skill will appreciate that the following Laboratory Examples are intended to be exemplary only and that numerous changes, modifications and alterations can be employed without departing from the spirit and scope of the invention.




To summarize, the Laboratory Examples indicate that acid dyes on nylon; basic dyes on acrylic; direct dyes on cotton, Arnel, silk, viscose rayon; disperse dyes on polyester; finishes on any substrate (softener, antistatic, lubricants, etc); preparation (scouring, bleaching chemistry); and disperse/direct dye combinations on polyester/cotton blends and other blends like nylon/cotton (popular in knit underwear fabrics) can be employed in the process of the present invention.




In each of the following Laboratory Examples, a package dyeing SCF—CO


2


system was employed. A representative embodiment of such a system is disclosed in U. S. Pat. No. 6,048,369, issued Apr. 11, 2000 to Smith, et al., herein incorporated by reference in its entirety. Other representative systems are disclosed in U.S. Pat. Nos. 5,298,032; 5,518,088; and 6,010,542; and the contents of each of these patents are incorporated herein by reference in their entirety. In each of the following Laboratory Examples, CO


2


density was about 0.6 g/mL, flow was about 7 gallons bath fluid/lb substrate/minute; and temperature was about 80-100° C. (usually 90° C.). Pressure ranged from about 1,500 to about 5,000 psi, and preferably ranged from about 3,000 to about 4,000 psi. Thus, pressure can vary and can be optionally lowered.




Laboratory Example 1















Laboratory Example 1






Dyeing of Cotton


























Yarn:




Cotton (not prepared, unfinished)







Package Density:




0.5 g/cc (approx.)







Dye:




C.I. Direct Blue 78







Weight of Yarn:




450 g (approx.)







Weight of Dye:




10 g







% o.w.g.:




2.2%







Nominal Dyeing Conditions:







CO


2


Density:




0.6 g/cc







Temperature:




40-83° C.







Volume Flow Rate:




7 gallons per minute (gpm)







Unit Volume Flow Rate:




7 gal/min-lb







Flow Reversal:




5 min Inside-to-outside (I-O) Flow








5 min Outside-to-inside (O-I) Flow















Dyeing Procedure: Wet out yarn package thoroughly; load package and dye into SCF—CO


2


dyeing machine; fill machine to CO


2


density of about 0.6 g/cc at ambient temperature; circulate at about 7 gpm volume flow rate with 5 min./5 min. I-O/O-I flow reversal pattern; heat to 80° C.; circulate at 80° C. for 30 minutes; depressurize.




Results: A dark blue colorfast dyeing was obtained; a stocking was knitted from the dyed yarn and evaluated for shade depth and crocking; the stocking had a color matching Munsell designation 2.5 PB 2/6; a dry crocking of grade 4-5 and a wet crocking of grade 3-4 were obtained for the stocking (AATCC Standard Test Method #8); the tensile strength and elongation of the dyed yarn were measured by the Single Strand Method (ASTM D2256-97) and found to be comparable to values for a sample of undyed yarn, i.e. undyed: T.S.=68 g, % Elongation=3.93; dyed: T.S.=553 g, % Elongation=4.69.




The observed data fell within normal parameters for this dye on unprepared, “unfinished” cotton (unfinished means that the cotton had not yet received any resin treatment for shrinkage control, etc.). The approach of this Example is equally applicable to “prepared” cotton that has been scoured and/or bleached.




Laboratory Example 2















Dyeing of Wool


























Package:




Cotton (served to hold fabric








for dying)







Fabric:




Worsted Wool (woven, natural








state; unscoured, unbleached)







Dye:




C.I. Acid Red 360







Weight of Fabric:




40 g (est.)







Weight of Dye:




2 g







% o.w.g.:




5%







Nominal Dyeing Conditions:







CO2 Density:




0.7 g/cc







Temperature:




75° C.







Volume Flow Rate:




7 gpm







Flow Reverseral:




Outside-to-inside (O-I)








flow over entire cycle















Dyeing Procedure: Wet out yarn package; wet wool fabric swatches; wrap and secure fabric swatches to outside of yarn package; load dye and package with swatches into SCF—CO


2


dyeing machine; fill machine to CO


2


density of about 0.7 g/cc at ambient temperature; circulate O-I at about 7 gpm volume flow rate and heat to 80° C.; circulate at 80° C. for 30 minutes; depressurize.




Results: A dark red colorfast dyeing was obtained; the dyed fabric was evaluated for shade depth and crocking; the fabric had a color matching Munsell designation 2.5 R 2/8; wet and dry crocking were both of grade 4 determined by AATCC Standard Test Method #8; the breaking strength and elongation of the dyed fabric were measured (Fabric Grab/Strip Test, ASTM D5034/5035) and compared to values determined for a sample of undyed fabric; the results are shown in Table 3 below.















TABLE 3









Fabric




Direction




Breaking Strength (g)




Elongation (%)


























Undyed Wool




warp




33.8




18.6






Dyed Wool




warp




34.7




22.3






Undyed Wool




fill




17.0




11.7






Dyed Wool




fill




16.4




19.3














All of the above results are considered normal for the noted dye on wool in its natural state.




In the wool dyeings, two runs were performed, one with and one without surfactant to help the wetting. This is an optional step, and it appeared to contribute to levelness. The approach of this Example is equally applicable to “prepared” wool that has been scoured and/or bleached.




Laboratory Example 3















Dyeing of Nylon


























Package:




Polyester (serves to hold








fabric for dying)







Fabric:




Nylon 6,6 (woven)







Dye:




C.I. Acid Red 360







Weight of Fabric:




40 g (est.)







Weight of Dye:




2 g







% o.w.g.:




5%







Nominal Dyeing Conditions:







CO2 Density:




0.65 g/cc







Temperature:




100° C.







Volume Flow Rate:




7 gpm







Flow Reversal:




Outside-to-inside (O-I) flow








over entire cycle















Dyeing Procedure: Wet out polyester yarn package thoroughly; wet nylon fabric swatches; wrap and secure swatches to outside of yarn package; load dye and package with swatches into SCF—CO


2


dyeing machine; fill machine to CO


2


density of about 0.65 g/cc at ambient temperature; circulate O-I at maximum volume flow rate and heat to 100° C.; circulate 30 minutes; depressurize.




Results: A dark red colorfast dyeing was obtained; the dyed fabric was evaluated for shade depth and crocking; the stocking had a color matching Munsell designation 5 R 2/8; wet and dry crocking were both of grade 4 determined by AATCC Standard Test Method #8; the breaking strength and elongation of the dyed fabric were measured (Fabric Grab/Strip Test, ASTM D5034/5035) and compared to values determined for a sample of undyed fabric; the results are shown in Table 4 below.















TABLE 4









Fabric




Direction




Breaking Strength (g)




Elongation (%)


























Undyed Nylon




warp




122.5




35.4






Dyed Nylon




warp




119.0




52.7






Undyed Nylon




fill




49.5




29.4






Dyed Nylon




fill




58.1




32.8














All of these data fall with normal parameters for this dye on nylon. The approach of this Example is equally applicable to “prepared” nylon that has been scoured and/or bleached.




Laboratory Example 4















Dyeing of Orlon 75 Acrylic


























Package:




Polyester (serves to hold








fabric for dying)







Fabric:




Acrylic (ORLON ® 75)







Dye:




C.I. Basic Blue 38







Weight of Fabric:




40 g (est.)







Weight of Dye:




2 g







% o.w.g.:




5%







Nominal Dyeing Conditions:







CO2 Density:




0.65 g/cc







Temperature:




100° C.







Volume Flow Rate:




7 gpm







Flow Reversal:




Outside-to-inside (O-I)








flow over entire cycle















Dyeing Procedure: Wet out polyester yarn package thoroughly; wet acrylic fabric swatches; wrap and secure swatches to outside of yarn package; load dye and package with swatches into SCF—CO


2


dyeing machine; fill machine to CO


2


density of about 0.65 g/cc at ambient temperature; circulate O-I at maximum volume flow rate and heat to 100° C.; circulate 30 minutes; depressurize.




Results: A dark red colorfast dyeing was obtained; the dyed fabric was evaluated for shade depth and crocking; the stocking had a color matching Munsell designation 2.5 PB 3/8; wet and dry crocking were both of grade 5 determined by AATCC Standard Test Method #8; the breaking strength and elongation of the dyed fabric were measured (Fabric Grab/Strip Test, ASTM D5034/5035) and compared to values determined for a sample of undyed fabric; the results are shown in Table 5 below.















TABLE 5









Fabric




Direction




Breaking Strength [g]




Elongation (%)


























Undyed Acrylic




warp




91.1




34.2






Dyed Acrylic




warp




83.7




43.3






Undyed Acrylic




fill




68.8




33.7






Dyed Acrylic




fill




71.2




40.3














All of the above results are considered normal for this dye on acrylic fabric.




Laboratory Example 5




Dyeing of Polyester




This Example pertains to the dyeing of polyester with a disperse dye. The polyester comprises DACRON®54, DACRON®64 and DACRON®107W fibers (E.I. du Pont de Nemours & Co., Wilmington, Del.).




Package: polyester (filament)




Package Density: 0.5 g/cc (approx.)




Dye: C.I. Disperse Blue 56 (paste)




Weight of Yarn: 450 g (est.)




Weight of Dye: 4 g




% o.w.g.: 0.89%




Nominal Dyeing Conditions:




CO


2


Density: 0.6 g/cc




Temperature: 100° C.




Volume Flow Rate: 15 gpm




Unit Volume Flow Rate: 15 gal/min-lb




Flow Reversal: 5 min inside-to-outside (I-O) flow, 5 min outside-to-inside (O-I) flow




Dyeing Procedure: Wet out yarn package thoroughly; load dye and package into SCF—CO


2


dyeing machine; fill machine to CO


2


density of about 0.6 g/cc at ambient temperature; circulate at about 15 gpm volume flow rate with 5 min./5 min. I-O/O-I flow reversal pattern; heat to 100° C.; circulate at 100° C. for 30 minutes; depressurize.




Results: A dark blue colorfast dyeing was obtained; a stocking was knitted from the dyed yarn; no apparent crocking was noted for the dyeing; quantitative evaluation of shade depth and crocking was not performed; the tensile strength of the dyed yarn was measured by the Single Strand Method (ASTM D2256-97) and found to be comparable to that for a sample of undyed yarn; Undyed yarn T.S.=132 g; Dyed yarn T.S.=127 g; all of these results are considered normal for the trial dye on filament polyester yarn.




Laboratory Example 6















Dyeing of a Blended Textile Substrate


























Package:




Polyester/Cotton (50/50 Blend)







Package Density:




0.4 g/cc (approx.)







Dye:




C.I. Disperse Blue 56 (paste),








C.I. Direct Blue 78







Weight of Yarn:




225 g (est.)







Weight of Dye:




5 g (Total of equal amounts








of the two dyes)







% o.w.g.:




2.22%







Nominal Dyeing Conditions:







CO2 Density:




0.33 g/cc







Temperature:




100° C.







Volume Flow Rate:




7 gpm







Unit Volume Flow Rate:




7 gal/min-lb







Flow Reversal:




5 min inside-to-outside (I-O)








flow, 5 min outside-to-inside








(O-I) flow















Dyeing Procedure: Wet out yarn package thoroughly; load dye and package into SCF—CO


2


dyeing machine; fill machine to CO


2


density of about 0.6 g/cc at ambient temperature; circulate at 7 gpm volume flow rate with 5 min./5 min. I-O/O-I flow reversal pattern; heat to 100° C.; circulate at 100° C. for 30 minutes; depressurize.




Results: A dark blue colorfast dyeing was obtained; a stocking was knitted from the dyed yarn and evaluated for shade depth and crocking; the shade depth of the stocking was found to correspond to approximately a 3% dyeing based on reflectance measurements; a dry crocking of grade 4-5 and wet crocking of grade 4 were obtained for the stocking using AATCC Standard Test Method #8; the tensile strength of the dyed yarn was measured by the Single Strand Method (ASTM D2256-97) and found to be comparable to that for a sample of undyed yarn; Undyed yarn T.S.=67 g; Dyed yarn T.S.=72 g; all of these results are considered normal for this dye combination on polyester/cotton yarn.




Laboratory Example 7




Treatment of a Textile Substrate with Softener




This Example pertains to the treatment of a 100 percent cotton twill textile substrate with a softener. The purpose of the softener is to make the textile substrate feel slicker and softer, and to increase the tearing strength of the textile substrate.


















Package:




Cotton (serves to hold fabric for







application of softener)






Fabric:




Cotton (bleached)







Cotton (unbleached)






Softener:




Cationic (5 parts) and HDPE (5 parts) mixed in







water (10 parts)






Weight of Fabric:




40 g (est.)






Weight of Softener:




5 g






% o.w.g.:




12.5%






Nominal Treatment






Conditions:






CO


2


Density:




0.3 g/cc






Temperature:




50° C.






Volume Flow Rate:




15 gpm






Flow Reversal:




Outside-to-inside (O-I) flow over entire cycle














Treatment Procedure: Wet out cotton yarn package thoroughly; wet cotton fabric swatches; wrap and secure swatches to outside of yarn package; load softener and package with swatches into SCF—CO


2


dyeing machine; fill machine to CO


2


density of about 0.3 g/cc at ambient temperature; circulate outside-to-inside at circulate at about 160 gpm volume flow rate; heat to 50° C.; circulate at 50° C. for 30 minutes; isolate treatment vessel and depressurize.




Results: The treated fabric felt slicker and softer relative to cotton that had not been treated with softener; the tearing strength of the treated fabric was measured and found to be 6.3 pounds; the tearing strength of an untreated fabric sample was measure and found to be 4.4 pounds; therefore, the addition of softener resulted in a tearing strength increase of 43%; these results are considered normal for this softener on cotton fabric.




It will be understood that various details of the invention can be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims.



Claims
  • 1. A process for treating a textile substrate, the process comprising:(a) providing a textile substrate; (b) providing a treatment bath fluid: (c) entraining a transport material in the treatment bath fluid wherein the transport material further comprises a treatment material dissolved or suspended therein and wherein the transport material is substantially immiscible with the treatment bath fluid; and (d) contacting the textile substrate with the transport material entrained the treatment bath fluid to deliver the treatment material to the textile substrate and thereby treat the textile substrate with the treatment material in the transport material.
  • 2. The process of claim 1, wherein the textile substrate comprises a hydrophilic fiber, a hydrophobic fiber, or a blend thereof.
  • 3. The process of claim 2, wherein the hydrophilic fiber comprises a cellulosic fiber, a silk fiber, a wool fiber or a blend thereof.
  • 4. The process of claim 3, wherein the cellulosic fiber is a cotton fiber.
  • 5. The process of claim 1, wherein the treatment bath fluid comprises near critical liquid carbon dioxide, supercritical fluid carbon dioxide or combination thereof.
  • 6. The process of claim 1, wherein the transport material comprises water.
  • 7. The process of claim 1, wherein the transport material is present in a trace amount.
  • 8. The process of claim 1, wherein the treatment material comprises a dye, a bleach, an optical brightener, a softener, an anti-static agent, a lubricant, a scouring agent a sizing agent, an ultraviolet stabilizing agent, an antimicrobial agent, or combinations thereof.
  • 9. The process of claim 1, wherein the treatment bath fluid is free of a surfactant that is soluble in the treatment bath fluid.
  • 10. The process of claim 1, further comprising drying the textile substrate by removing the transport material from the textile substrate.
  • 11. The process of claim 10, wherein the step of drying the textile substrate further comprises circulating the treatment bath fluid through the textile substrate to re-entrain the transport material in the treatment barn fluid, thereby removing transport material from the textile substrate.
  • 12. A process for treating a textile substrate in a near critical liquid or supercritical fluid carbon dioxide treatment bath fluid,, the process comprising:(a) providing a textile substrate; (b) providing a treatment bath fluid comprising near critical liquid carbon dioxide, supercritical fluid carbon dioxide or combinations thereof; (c) entraining a transport material in the treatment bath fluid wherein the transport material further comprises a treatment material dissolved or suspended therein and wherein the transport material is substantially immiscible with the treatment bath fluid; and (d) contacting the textile substrate with the transport material entrained in the treatment bath fluid to deliver the treatment material to the textile substrate and thereby treat the textile substrate with the treatment material dissolved or suspended in the transport material.
  • 13. The process of claim 12, wherein the textile substrate comprises a hydrophilic fiber, a hydrophobic fiber, or a blend thereof.
  • 14. The process of claim 13, wherein the hydrophilic fiber comprises a cellulosic fiber, a silk fiber, a wool fiber or a blend thereof.
  • 15. The process of claim 14, wherein the cellulosic fiber is a cotton fiber.
  • 16. The process of claim 12, wherein the transport material comprises water.
  • 17. The process of claim 12, wherein the transport material is present in a trace amount.
  • 18. The process of claim 12, wherein the treatment material comprises a dye, a bleach, an optical brightener, a softener, an anti-static agent, a lubricant, a scouring agent, a sizing agent, an ultraviolet stabilizing agent, an antimicrobial agent, or blends thereof.
  • 19. The process of claim 12, wherein the treatment bath fluid is free of a surfactant that is soluble in the treatment bath fluid.
  • 20. The process of claim 12, further comprising drying the textile substrate by removing the transport material from the textile substrate.
  • 21. The process of claim 20, wherein the step of drying the textile substrate further comprises circulating the treatment bath fluid through the textile substrate to re-entrain the transport material in the treatment bath fluid, thereby removing transport material from the textile substrate.
  • 22. A process for treating a hydrophilic textile substrate in a near critical liquid or supercritical fluid carbon dioxide treatment bath fluid, the process comprising:(a) providing a hydrophilic textile substrate; (b) providing a treatment bath fluid comprising near critical liquid carbon dioxide, supercritical fluid carbon dioxide or blends thereof; (c) entraining a transport material in the treatment bath fluid wherein the transport material further comprises a treatment material dissolved or suspended therein and wherein the transport material is substantially immiscible with the treatment bath fluid; and (d) contacting the textile substrate with the transport material entrained in the treatment bath fluid to deliver the treatment material to the textile substrate and thereby treat the textile substrate with the treatment material dissolved or suspended in the transport material.
  • 23. The process of claim 22, wherein the hydrophilic fiber comprises a cellulosic fiber, a silk fiber, a wool fiber or blends thereof.
  • 24. The process of claim 23, wherein the cellulosic fiber is a cotton fiber.
  • 25. The process of claim 22, wherein the transport material comprises water.
  • 26. The process of claim 22, wherein the transport material is present in a trace amount.
  • 27. The process of claim 22, wherein the treatment material comprises a dye, a bleach, an optical brightener, a softener, an anti-static agent, a lubricant, a scouring agent, a sizing agent, an ultraviolet stabilizing agent, an antimicrobial agent, or blends thereof.
  • 28. The process of claim 22, wherein the treatment bath fluid is free of a surfactant that is soluble in the treatment bath fluid.
  • 29. The process of claim 22, further comprising drying the textile substrate by removing the transport material from the textile substrate.
  • 30. The process of claim 29, wherein the step of drying the textile substrate further comprises circulating the treatment bath fluid through the textile substrate to re-entrain the transport material in the treatment bath fluid, thereby removing transport material from the textile substrate.
  • 31. A process for treating a hydrophobic textile substrate in a near critical liquid or supercritical fluid carbon dioxide treatment bath fluid, the process comprising:(a) providing a hydrophobic textile substrate; (b) providing a treatment bath fluid comprising near critical liquid carbon dioxide, supercritical fluid carbon dioxide or combinations thereof; (c) entwining a transport material in the treatment bath fluid wherein the transport material further comprises a treatment material dissolved or suspended therein and wherein the transport material is substantially immiscible with the treatment bath fluid; and (d) contacting the hydrophobic textile substrate with the transport material entrained in the treatment bath fluid to deliver the treatment material to the textile substrate and thereby treat the textile substrate with the treatment material dissolved or suspended in the transport material.
  • 32. The process of claim 31, wherein the transport material comprises water.
  • 33. The process of claim 31, wherein the treatment material comprises a dye, a bleach, an optical brightener, a softener, an anti-static agent, a lubricant, a scouring agent, a sizing agent, an ultraviolet stabilizing agent, an antimicrobial agent, or combinations thereof.
  • 34. The process of claim 31, wherein the treatment bath fluid is free of a surfactant that is soluble in the treatment bath fluid.
  • 35. The process of claim 31, further comprising drying the textile substrate by removing the transport material from the textile substrate.
  • 36. The process of claim 35, wherein the step of dying the textile substrate further comprises circulating the treatment bath fluid through the textile substrate to re-entrain the transport material in the treatment bath fluid, thereby removing transport material from the textile substrate.
  • 37. The process of claim 1, wherein the transport material is entrained in the treatment bath fluid in droplets.
  • 38. A process for treating a textile substrate, the process comprising:(a) providing a textile substrate; (b) providing a treatment bath fluid; (c) entraining a transport material in the treatment bath fluid wherein the transport material further comprises a treatment material dissolved or suspended therein and wherein the transport material is substantially immiscible with the treatment bath fluid; and (d) contacting the textile substrate with the transport material in the treatment bath fluid to thereby treat the textile substrate with the treatment material in the transport material, wherein the transport material is entrained in the treatment bath fluid in droplets by one of atomizing and sparging.
  • 39. The process of claim 12, wherein the transport material is entrained in the treatment bath fluid in droplets.
  • 40. A process for treating a textile substrate in a near critical liquid or supercritical fluid carbon dioxide treatment bath fluid, the process comprising:(a) providing a textile substrate; (b) providing a treatment bath fluid comprising near critical liquid carbon dioxide, supercritical fluid carbon dioxide or combinations thereof; (c) entraining a transport material in the treatment barn fluid wherein the transport material further comprises a treatment material dissolved or suspended therein and wherein the transport material is substantially immiscible with the treatment bath fluid; and (d) contacting the textile substrate with the transport material in the treatment bath fluid to thereby treat the textile substrate with the treatment material dissolved or suspended in the transport material, wherein the transport material is entrained in the treatment bath fluid in droplets by one of atomizing and sparging.
  • 41. The process of claim 22, wherein the transport material is entrained in the treatment bath fluid in droplets.
  • 42. A process for treating a hydrophobic textile substrate in a near critical liquid or supercritical fluid carbon dioxide treatment bath fluid, the process comprising:(a) providing a hydrophobic textile substrate; (b) providing a treatment bath fluid comprising near critical liquid carbon dioxide, supercritical fluid carbon dioxide or combinations thereof; (c) entraining a transport material in the treatment bath fluid wherein the transport material further comprises a treatment material dissolved or suspended therein and wherein the transport material is substantially immiscible with the treatment bath fluid; and (d) contacting the textile substrate with the transport material in the treatment bath fluid to thereby treat the textile substrate with the treatment material dissolved or susoended in the transDort material, wherein the transport material is entrained in the treatment bath fluid in droplets by one of atomizing and sparging.
  • 43. The process of claim 31, wherein the transport material is entrained in the treatment bath fluid in droplets.
  • 44. A process for treating a hydrophobic textile substrate in a near critical liquid or supercritical fluid carbon dioxide treatment bath fluid, the process comprising:(a) providing a hydrophobic textile substrate; (b) providing a treatment bath fluid comprising near critical liquid carbon dioxide, supercritical fluid carbon dioxide or combinations thereof; (c) entraining a transport material in the treatment bath fluid wherein the transport material further comprises a treatment material dissolved or suspended therein and wherein the transport material is substantially immiscible with the treatment bath fluid; and (d) contacting the hydrophobic textile substrate with the transport material in the treatment bath fluid to thereby treat the textile substrate with the treatment material dissolved or suspended in the transport material, wherein the transport material is entrained in the treatment bath fluid in droplets by one of atomizing and sparging.
CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority to U.S. provisional patent application serial no. 60/241,262 filed Oct. 18, 2000, herein incorporated by reference in its entirety.

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Provisional Applications (1)
Number Date Country
60/241262 Oct 2000 US