CN117897526A

CN117897526A - Apparatus and method for improving color fastness

Info

Publication number: CN117897526A
Application number: CN202280059268.5A
Authority: CN
Inventors: 西蒙·丘; 托马斯·布莱思; 斯科特·钱伯斯; 基思·福德姆
Original assignee: Aokemi Technology Co ltd
Current assignee: Aokemi Technology Co ltd
Priority date: 2021-07-01
Filing date: 2022-07-01
Publication date: 2024-04-16
Also published as: CA3226028A1; US20240309569A1; KR20240036015A; EP4363646A1; GB202109535D0; JP2024526289A; WO2023275562A1

Abstract

The present application provides a method for improving the color fastness of dyed textiles. The method comprises the following steps: conveying the dyed textile in a first direction along a processing line; flowing fluid from the reservoir through the dyed textile on the process line in a second direction substantially opposite the first direction; subsequently removing at least 50% of the applied fluid from the dyed textile; removing contaminants from the fluid; and returning the fluid to the reservoir.

Description

Apparatus and method for improving color fastness

Technical Field

The present invention relates to improvements in or relating to textile dyeing and in particular to improving the colour fastness of dyed textiles (dyed text).

Background

Textile coating or dyeing can be an environmentally hazardous process, primarily because the process produces large amounts of wastewater, typically many times the weight of the textile.

Conventional dyeing application processes are dip bath (bath) methods such as dip dyeing (exhaustion) or jet dyeing and pad dyeing (padding) using a roll coating mechanism. Alternatively, the coating or dye may be applied (applied) to the textile via a "tie-dyeing" treatment of the roller. The applied dye is then dried and heated to fix the dye. For both conventional dyeing methods, washing is required to remove excess unbound dye and auxiliary chemicals. Washing typically involves several baths operating at high temperature and may introduce additional chemicals, for example in a "reductive rinse" process using alkaline pH.

Thus, conventional methods typically over-load the dye used by the textile material, and the excess dye must be removed via repeated high temperature washes, thereby producing a large amount of contaminated wastewater. Contaminated wastewater, including water contaminated with dyes, is a considerable worldwide environmental problem and requires extensive wastewater treatment to avoid environmental damage.

The present invention has been made in this context.

Disclosure of Invention

According to the present invention there is provided a method for improving the color fastness of dyed textiles, the method comprising: conveying the dyed textile in a first direction along a processing line; flowing fluid from the reservoir through the dyed textile on the process line in a second direction substantially opposite the first direction; subsequently removing at least 50% of the applied fluid from the dyed textile; removing contaminants from the fluid; and returning the fluid to the reservoir.

The fluid flows through the dyed textile in a direction substantially opposite to the conveying direction of the dyed textile such that the cleanest fluid contacts the cleanest portion of the dyed textile. This prevents the contaminated wastewater from contaminating the clean portion of the dyed textile. In addition, fluid flow in a direction opposite to the direction of movement of the dyed textile may assist in removing excess dye.

According to the present invention there is provided a method for improving the color fastness of dyed textiles, the method comprising: conveying the dyed textile along a processing line; applying a fluid to the dyed textile in a second direction substantially opposite the first direction at a first location on the process line; and subsequently removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line.

The dyed textile may be continuously transported along the processing line. For example, the processing line may be a continuous roll-to-roll (roll-to-roll) processing line. The processing line may be automated. The processing line may include a processor configured to digitally control the processing line. The processor may control the speed at which the textile is transported along the processing line. In some embodiments, the processing line may be a non-immersion processing line. Conventional dyeing, washing and/or fixing treatments generally comprise at least one dipping bath. However, a non-immersion processing line is a processing line that does not include an immersion bath.

In some embodiments, the dyed textile may be in a consolidated form (consolidated form). For example, dyed textiles may be transported as rolls (in-roll transport). Alternatively, the dyed textile may be in an uncured form. For example, dyed textiles may be transported in a linear fashion.

The dyed textile may be subjected to elevated temperatures. For example, the dyed textile may be between 10 ℃ to 220 ℃, 15 ℃ to 200 ℃, 20 ℃ to 180 ℃, 25 ℃ to 140 ℃, or 30 ℃ to 100 ℃. The temperature of the dyed textile and/or the processing line may be controlled. This can improve the hand of the dyed textile.

The first location and the second location on the processing line may be substantially the same location. For example, the first location and the second location on the processing line may overlap. Alternatively or additionally, the first and second locations on the processing line may be adjacent to each other. Conversely, in some embodiments, the first location and the second location may be different from each other.

For example, the first location and the second location may be within 1 meter of each other. Alternatively, the first and second positions may be within 0.75 meters, within 0.5 meters, within 0.25 meters, or within 0.1 meters of each other. For example, the first and second locations on the processing line may be opposite each other, adjacent each other, and/or one above the other.

The fluid may comprise a liquid. More specifically, the fluid may be a liquid. For example, the fluid may be water. However, any suitable liquid may be used. The fluid may include a fragrance. Alternatively or additionally, the fluid may comprise a gas. The gas may be air. However, any suitable gas may be used. The gas may contain solids therein. For example, the fluid may include air and sand/gravel configured to blast the dyed textile.

The removal of fluid from the dyed textile may be in the form of a dewatering step. The physical removal of the fluid from the textile also removes any residual dye and/or chemicals that are not fixed to the textile. Conversely, drying the textile may leave unfixed dye and/or chemicals on the textile.

Removal of the applied fluid enables the fluid to be reused, which reduces the total amount of fluid required. In some embodiments, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or at least 99% of the applied fluid may be removed from the dyed textile. Preferably, at least 75% of the applied fluid is removed from the dyed textile at a second location on the processing line.

The fluid removal rate may be 0.5 times, 1 times, 1.5 times, 2 times, 2.5 times, or 3 times the mass flow rate of the dyed textile. Alternatively or additionally, the mass of fluid remaining in the textile downstream of the second location of the processing line may be less than 0.5, 0.3, 0.2, 0.1, or 0.05 of the textile mass flow rate.

In this case, the mass flow rate may be defined as the mass of dyed textile passing through a given point per unit time. For example, the mass flow rate may be defined as the mass of dyed textile passing through a first location on the process line per unit time.

Fluid may be removed from the textile by vacuum. The vacuum can effectively remove the fluid without damaging the textile. Alternatively or additionally, the fluid may be removed from the textile by applying a high velocity gas to the textile. The gas may be air. High velocity gas may be passed through the textile. The high velocity gas may be configured to remove excess liquid and unsecured solids from the dyed textile.

The fluid applied to the dyed textile at the first location on the process line may be a predetermined volume of fluid. More specifically, the fluid applied to the dyed textile at the first location on the process line may comprise a predetermined volume of liquid.

Accordingly, the method may include the step of applying a predetermined volume of fluid to the dyed textile at a first location on the process line. For example, the fluid may be applied to the dyed textile until the textile reaches a predetermined moisture content. The application of the fluid to the dyed textile may be controlled. Furthermore, the application of the fluid to the dyed textile may be regulated.

Alternatively or additionally, the fluid applied to the dyed textile at the first location on the process line may be applied at a predetermined rate.

The method may further comprise: removing contaminants from the removed fluid; and reapplying the fluid to the dyed textile. More specifically, the method may include: the fluid is reapplied to the dyed textile at a first location on the process line. Alternatively or additionally, the method may comprise: the fluid is reapplied to the dyed textile at a third location on the process line. The third location may be upstream of the second location.

The fluid may be initially applied to a first location of the dyed textile and subsequently removed from that location. The fluid may then be purified and reapplied to the second location of the dyed textile. The reapplied fluid may then be removed from the second location of the dyed textile at the second location on the processing line.

The method may further comprise: applying a fluid to the dyed textile at a third location on the process line; and subsequently removing at least 50% of the fluid applied at the third location from the dyed textile at a fourth location on the processing line.

Thus, the method of claim 1 may be repeated. More specifically, the method may be repeated multiple times. For example, the method may be repeated 1, 2, 3, 4, 5, 8, 10, or more than 10 times.

The reapplied fluid may be reapplied at the first location and/or the third location on the processing line. The fluid may be applied to, removed from, and reapplied to the textile at any number of locations on the dyed textile. For example, the fluid may be applied to, removed from, and reapplied to the textile at 3 locations, 4 locations, 5 locations, 6 locations, 7 locations, 8 locations, 9 locations, 10 locations, or more than 10 locations on the dyed textile.

The process may be continuous. For example, the method may include: continuously conveying the dyed textile along a processing line; applying a fluid continuously to the dyed textile at a first location on the process line; and subsequently continuously removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line.

The method may further comprise continuously removing contaminants from the removed fluid. Furthermore, the method may comprise: the removed fluid is again continuously applied to the dyed textile. More specifically, the method may include: the removed fluid is again continuously applied to the dyed textile at a first location on the process line. Alternatively or additionally, the method may comprise: the removed fluid is again continuously applied to the dyed textile at a third location on the process line. This recycling method further reduces the water consumption.

The total mass of fluid applied to the dyed textile may reach up to 500% of the mass of the (up to) dyed textile. More specifically, in some embodiments, the total mass of fluid applied to the dyed textile may be up to 75%, 100%, 150%, 200%, 250% or 300% of the mass of the dyed textile. Alternatively or additionally, the total mass of fluid applied to the dyed textile may be 50% -350%, 100% -300% or 150% -250% of the mass of the dyed textile. The fluid application rate may be 0.5 times, 1 times, 1.5 times, 2 times, 2.5 times or 3 times the mass flow rate of the dyed textile. However, in some embodiments, the total mass of fluid applied to the dyed textile may be 50%, 30%, 20%, 10% or 5% of the mass of the dyed textile.

The fluid may be applied to the dyed textile at the first location at a rate of 1-50 liters per minute. Alternatively, the fluid may be applied at 1-20 liters per minute (liters per minute). The textile may be transported at 1-100 meters per minute (m/min). More specifically, the textile may be transported at 5-50 meters/minute or 10-20 meters/minute.

In some embodiments, the fluid removed from the dyed textile at the second location is less than the fluid applied to the dyed textile at the first location. For example, to leave a predetermined chemical in the fluid of the textile, it may be desirable to remove less fluid than the applied fluid.

The method may further comprise heating the fluid to above 40 ℃. More specifically, the fluid may be heated to above 50 ℃, above 60 ℃ or above 70 ℃. Alternatively or additionally, the fluid may be heated to 40-80 ℃, 50-70 ℃, or about 60 ℃. For example, the temperature of the fluid may be adjusted to optimize the cost of the process and the total energy used during the process.

The method may further comprise: the first location on the processing line is heated to 40-95 ℃. More specifically, the method may include: the first location on the processing line is heated to 50-70 c or about 60 c. Increasing the ambient temperature at the first location reduces the cooling effect exerted by the fluid and thus reduces the total energy required for the method. In some embodiments, excess heat from the fixation chamber may be used to heat the first location.

The method may further comprise: determining an acceptable flow rate range for the applied fluid; monitoring the flow rate of the applied fluid; and adjusting the flow rate of the applied fluid if the flow rate of the applied fluid is outside of the acceptable flow rate range. Thus, in use, the applied fluid can be accurately monitored and regulated. This can be used to optimise the process and thereby increase the efficiency of the process.

The fluid may be sprayed onto the dyed textile. The fluid may be sprayed onto the dyed textile through a plurality of nozzles. This ensures that the entire textile is sprayed. In addition, the jet fluid may agitate (agite) the textile, thereby removing some excess and/or unsecured dye from the textile. This can improve the color fastness of the dyed textiles. Furthermore, spraying fluid onto dyed textiles can use significantly less water than more traditional methods. This is particularly advantageous in terms of cost and environmental impact. The fluid may be sprayed onto the textile at a speed of at least 10 meters per second, at least 15 meters per second, or most preferably at least 20 meters per second.

However, in some embodiments, the fluid may be applied to the textile via slot die liquid application (lot die liquid application) or soak application. Alternatively or additionally, the fluid may be applied to the textile via a rotary printing application (such as a rotary spiral or gravure sprayer). Further, in some embodiments, the fluid may be applied to the textile via waterfall devices (waterfall), weir devices (weir), sprinklers, or ejectors.

The method may further comprise mechanically agitating the dyed textile. Mechanically agitating the dyed textile may remove some excess dye, thereby improving the color fastness of the dyed textile. More specifically, the mechanical agitation may be configured to move the textile fibers, thereby exposing excess, unfixed dye.

Mechanical agitation can apply pressure to the dyed textile. Mechanical agitation can be effective to squeeze fluid out of the textile. The mechanical agitation may be configured to reduce the mass of water within the textile to less than the mass flow rate of the textile.

For example, the mechanical agitation may include a pair of rollers configured to contact the textile conveyed along the processing line. More specifically, the mechanical agitation may include a pair of rollers (nip rollers). The pair of nip rolls may reduce the mass of water within the dyed textile to less than 60% of the mass flow rate of the dyed textile.

Mechanical agitation may occur between a first location and a second location on the processing line. Alternatively or additionally, the mechanical agitation occurs at a first location and/or a second location on the processing line. For example, the applied fluid may also be combined by mechanical agitation of the roller in contact with the textile.

Further, in some embodiments, mechanical agitation may occur between a third location and a fourth location on the processing line.

Alternatively or additionally, the applied fluid may be configured to agitate the textile. For example, the fluid may be forced through the textile at a first location on the process line. In such embodiments, fluid removal may occur at opposite sides of the fluid applicator. The second location on the process line may be directly opposite the first location on the fluid process line.

The fluid may include an additive configured to increase the color fastness of the textile. In some embodiments, the fluid includes a plurality of additives configured to enhance the color fastness of the textile. For example, the additive may be a finishing chemical. The additive may be configured to allow movement of the textile fibers without causing removal of dye from the textile.

Alternatively or additionally, the additive may comprise an anionic surfactant or a cationic surfactant. Alternatively, the additive may comprise any detergent species. In some embodiments, the additive may include a polymer species. The polymer species may comprise an aliphatic or silicon-based backbone.

Alternatively or additionally, the fluid may include a lubricating and/or softening additive. The fluid may include an additive configured to increase the softness of the textile. The additive may be a chemical softener. The chemical softener may be a silicone resin. The softening agent may be a biological extract. Alternatively, or in addition, the fluid may include a colorless dispersant. Furthermore, in use, the fluid may be water-based and/or may be mixed with fresh water.

Alternatively or additionally, there is also provided a method for improving the color fastness of dyed textiles, the method comprising: conveying the dyed textile along a processing line into a first chamber having a first controlled environment; temporarily storing the dyed textile in the first chamber for a first period of time; delivering the dyed textile into a second chamber having a second controlled environment; and temporarily storing the dyed textile in the second chamber for a second period of time. The processing line may be automated. The processing line may be the same processing line as previously disclosed.

The first controllable environment may be different from the second controllable environment. Alternatively, the first controllable environment and the second controllable environment may be the same. More specifically, the first controllable environment may include a plurality of parameters. For example, the first controllable environment may include a first temperature, a first humidity, a first pressure, a first gas flow rate, and/or a first inert gas. Alternatively or additionally, the second controllable environment may comprise a plurality of parameters. For example, the second controllable environment may include a second temperature, a second humidity, a second pressure, a second gas flow rate, and/or a second inert gas.

In some embodiments, at least one of the first temperature, the first humidity, the first pressure, the first gas flow rate, and the first inert gas may be the same as the second temperature, the second humidity, the second pressure, the second gas flow rate, and the second inert gas. Alternatively or additionally, at least one of the first temperature, the first humidity, the first pressure, the first gas flow rate, and the first inert gas may be different from the second temperature, the second humidity, the second pressure, the second gas flow rate, and the second inert gas. Any of the foregoing parameters may be used to define a controllable environment for each chamber. More specifically, any combination of these parameters may be used to define a controllable environment for each chamber.

In some embodiments, the temperature may include a temperature gradient. Alternatively or additionally, the air flow may be used to maintain a uniform temperature within the chamber. For example, heat may be applied in the form of hot air in the first chamber and/or the second chamber. The velocity of the air introduced into the chamber ensures that the air circulates throughout the chamber. The circulated air can ensure thermal uniformity. The humidity may be the relative humidity within the chamber. The relative humidity may be between 0% and 100%, more preferably between 30% and 70%, and most preferably about 50%. The pressure may be about atmospheric pressure. Alternatively, the pressure may be raised above atmospheric pressure. For example, the pressure may be up to 1.5, 2, 2.5 or 3 atmospheres. Further, in some embodiments, the first chamber and/or the second chamber may be filled with an inert gas. For example, the chamber may be filled with Nobel gas (Nobel gas). Alternatively or additionally, the chamber may be filled with nitrogen or argon.

The dyed textile may be continuously transported along the processing line. For example, dyed textiles may be continuously fed into the first chamber. At least a portion of the processing line may be automated. Alternatively, the entire processing line may be automated. Thus, dyed textiles may be automatically transported into the first chamber.

Furthermore, the dyed textile may be continuously transported into the second chamber. The dyed textile may be automatically transported into the second chamber. Alternatively or additionally, the dyed textile may be manually transported into the second chamber. The dyed textile may be a textile comprising a dye.

The method may further comprise: the first controllable environment and/or the second controllable environment is adjusted based on characteristics of the textile to be dyed, characteristics of a dye used to dye the textile, and/or characteristics of the dyed textile. The first environment and/or the second environment may be conditioned in use. In other words, the first environment and/or the second environment may be adjusted while the processing line is transporting the textile.

The characteristics of the dye may include dye concentration, color, hue, pantone number, reflectance, water content, color index, and/or molecular weight. For example, dyes with higher molecular weights may require more energy to fix to textiles. Dyes having higher molecular weights may result in dyed textiles being stored in the first chamber and/or the second chamber for longer periods of time and/or at higher temperatures. Further, the characteristics of the dyed textile and/or the textile to be dyed may include the basis weight, absorption capacity (water absorption capacity), reflectivity, moisture content, thickness, diameter, and/or lot number of the textile.

The textile to be dyed and/or the dyed textile may comprise polyester, cotton, wool, nylon, elastane and/or silk. However, any other textile or textile product may also be used. Further, the dye may include a disperse dye, a pigment, an acid dye, and/or a reactive dye. For example, in some embodiments, the textile may be polyester and the colorant may be a disperse dye. Alternatively, the textile may be cotton and the colorant may be a reactive dye. In some embodiments, the textile may be cotton and the colorant may be a pigment dye. Alternatively, the textile may be nylon and the colorant may be an acid dye.

Alternatively or additionally, the characteristics of the textile to be dyed and/or the dye used to dye the textile may be determined before, during and/or after the textile is dyed. This enables multiple characteristics to be measured throughout the dyeing and fixing process.

Accordingly, the method may include: determining textile and/or dye characteristics before, during and after the textile is dyed, and adjusting the first controllable environment and/or the second controllable environment based on the determined characteristics. The comparison between the characteristics measured at different points in the method can also be used to optimize the controllable environment within each chamber. This can improve the quality and, more particularly, the color fastness of the dyed textile.

The first chamber may include a first internal temperature. The second chamber includes a second internal temperature that is lower than the first internal temperature. Having a second temperature that is lower than the first temperature allows energy applied to the textile within the first chamber to be at least partially utilized within the second chamber. This reduces the energy required to heat the textile in the second chamber.

For example, the method may include: temporarily storing the dyed textile in a first chamber having a first internal temperature for a first period of time; and temporarily storing the dyed textile in a second chamber having a second internal temperature for a second period of time, wherein the first internal temperature is higher than the second internal temperature. However, in some embodiments, the second chamber may include a second internal temperature that is substantially equal to or higher than the first internal temperature.

Placing the dyed textile in a first chamber having a first temperature for a first period of time and in a second chamber having a second temperature for a second period of time may improve the color fastness and/or softness of the dyed textile. For example, the use of two chambers allows the dye to be almost completely immobilized on the textile. This may be due to loosely bound dye molecules on the surface of the textile fibre now being more firmly bound to the fibre. Thus, only very small concentrations of dye molecules can be separated from the textile during the color fastness test.

The first internal temperature may be between 140 ℃ and 230 ℃. The dyed textile is temporarily stored between 140 ℃ and 230 ℃ so that the dye can be locally immobilized around the individual fibers. This increases the final color fastness of the dyed textiles. More specifically, the first internal temperature may be between 150 ℃ and 215 ℃. Most particularly, the first internal temperature may be between 160 ℃ and 200 ℃.

The second internal temperature may be between 120 ℃ and 200 ℃. The lower temperature in the second chamber enables the textile to cool slightly. This cooling effect can be used to increase the softness of the textile. Furthermore, the lower temperature in the second chamber eliminates the need for further heat to be applied to the textile, which reduces the total energy used in the process. In some embodiments, the second internal temperature is between 130 ℃ and 190 ℃ and/or between 140 ℃ and 180 ℃.

The second period of time may be longer than the first period of time. The first period of time may be at least 10 minutes. More preferably, the first period of time may be between 30 minutes and 4 hours. Most preferably, the first period of time may be between 45 minutes and 2 hours. However, in some embodiments, the first period of time may be up to 5 hours, 8 hours, 10 hours, or 12 hours. For example, the dyed textile may be temporarily stored in the first chamber overnight.

The second period of time may be at least 2 hours. For example, the second period of time may be between 5-60 minutes or 10-30 minutes. Alternatively, the second period of time may be up to 4 hours, 6 hours, 8 hours, 12 hours, 24 hours, or 48 hours. However, in some embodiments, the second period of time may exceed 48 hours.

The method may further comprise: the cooling rate of the dyed textile is determined and the controlled environment of the first chamber and/or the second chamber is adjusted based on the cooling rate. In this case, the cooling rate may be defined as the time it takes for the textile to drop 1 ℃. Furthermore, the cooling rate may be determined based on the properties of the textile to be dyed, the dyed textile and/or the dye. The cooling rate may be calculated prior to the textile dyeing process. The cooling rate may be adjusted to increase the softness and/or color fastness of the dyed textile.

The method may further comprise: the dyed textile is temporarily stored in the second chamber at a plurality of different temperatures. For example, the second chamber may be configured to subject the dyed textile to a plurality of different temperatures within the temperature gradient. The temperature gradient in the second chamber may define a cooling rate of the dyed textile. In some embodiments, the second chamber may include a plurality of heaters. Each heater may be configured to produce a different temperature. The plurality of heaters may generate a temperature gradient within the second chamber.

In some embodiments, the dyed textile is temporarily stored at each temperature within the temperature gradient for up to 1 hour. Alternatively, the dyed textile may be temporarily stored at each temperature within the temperature gradient for up to 10 minutes, 20 minutes, 30 minutes, 45 minutes, 1 hour, 2 hours, 3 hours, or 4 hours.

The method may further comprise: the dyed textile is conveyed through a plurality of different temperatures within the second chamber. Transporting the textile through the second chamber may include temporarily storing the dyed textile in the second chamber. A plurality of different temperatures within the second chamber may create a temperature gradient. The thermal energy used to provide the temperature gradient in the second chamber may be at least partially received by the dyed textile. The dyed textile cools as it is transported through the second chamber.

The second chamber may include a proximal end having a first opening, wherein the first opening is configured to receive a dyed textile. In some embodiments, the first opening is configured to receive a roll of dyed textile. The second chamber may include a distal end having a second opening, wherein the second opening is configured to output dyed textiles. In some embodiments, the second opening is configured to output a roll of dyed textile. The first opening and the second opening may each comprise a door and/or a seal. The temperature of the proximal end may be higher than the distal end. For example, the proximal end may be about 180 ℃ and the distal end may be about 140 ℃. There may be a substantially linear temperature gradient between the proximal and distal ends. In use, the dyed textile, or more specifically, the roll of dyed textile, may be moved between the proximal and distal ends. The movement of the dyed textile between the proximal and distal ends may take at least 2 hours.

The method may further comprise: the dyed textile is secured in a roll (consolidate into a roll) within the first chamber. Alternatively, the textile may be consolidated into any spatially compressed structure. For example, the method may include: the textile is secured into a folded pile (tile), accordion-like pile or unstructured pile. Consolidating the textile in the first chamber increases the amount of dyed textile that can be stored in the second chamber. In addition, consolidating the dyed textile removes air currents and/or eddies within the textile. This improves the dye fixing treatment and thus the color fastness.

The speed at which the dyed textile is delivered to the first chamber may vary. For example, dyed textiles may be delivered to the first chamber at a faster rate than to the second chamber. This can create an excess of dyed textile in the first chamber. A roll (consolidated textile roll) of consolidated textile may be separated from the processing line and transferred to a second chamber. At the same time, the excess dyed textile may begin to consolidate to produce a second roll within the first chamber. In addition, the speed at which the dyed textile is delivered to the first chamber may be reduced until the excess dyed textile has been consolidated. This may reduce downtime in the process. Alternatively, in some embodiments, the processing line is paused in order to remove the roll from the first chamber.

The length of the roll may be 50-3000 meters. More specifically, the length of the roll may be between 500 meters and 1500 meters, or about 1000 meters.

The method may further comprise: a plurality of rolls of dyed textile are temporarily stored in a second chamber. Temporarily storing a plurality of dyed textiles (or more specifically, rolls of textiles) in the second chamber increases thermal mass and reduces free space within the chamber. This reduces the energy required to maintain a controlled environment within the chamber.

Furthermore, in some embodiments, the method comprises: a plurality of rolls of dyed textile are conveyed through a plurality of different temperatures within the second chamber. Once the roll of dyed textile has been conveyed a predetermined distance through the second chamber, a subsequent roll of dyed textile may be added to the second chamber.

As previously described, the second chamber may include a plurality of temperatures and/or temperature gradients. Each roll of dyed textile may be cooled as it is conveyed through the second chamber. Thus, the thermal energy used to provide the temperature gradient within the second chamber may be at least partially accommodated by the subsequently added roll of dyed textile. For example, the subsequent roll of dyed textile may be at a temperature of about 180 ℃ upon entering the second chamber. When a subsequent roll of dyed textile is entered into the second chamber, the initial roll of dyed textile may be at a temperature of less than 180 ℃. For example, the temperature of the initially dyed fabric roll may have been reduced to about 175 ℃, 170 ℃, 165 ℃, or 160 ℃.

Each roller in the second chamber may be rotatable. For example, each roller may rotate about a roller axis. The roller may be a shaft that winds the textile in order to produce the roll. More specifically, each roller within the second chamber may rotate at a constant speed. Further, each roll may be transported along a conveyor within the second chamber. More specifically, as new rolls are added, each roll may be transported along a conveyor within the second chamber. In some embodiments, new volumes are added every 10-30 minutes.

In some embodiments, the method further comprises: the cooling rate of the dyed textile is monitored and/or controlled after the dyed textile exits the second chamber. This may further improve the color fastness. For example, the dyed textile may exit the second chamber at about 140 ℃. Rolls of dyed textiles may be left to cool slowly in storage. The slow cooling described above can further increase the color fastness of the dyed textiles compared to samples taken in uncured form and immediately cooled.

The method may further comprise: the dyed textile is conveyed through a fixation chamber having a third controlled environment. For example, the dyed textile may be transported through the fixation chamber before being temporarily stored in the first chamber and/or the second chamber. The fixation chamber may be configured to reduce the moisture content of the textile containing the dye and simultaneously initiate the fixation process between the dye and the textile. The third controllable environment may have a third internal temperature.

The temperature in the fixation chamber may be between 180 ℃ and 220 ℃. The third controllable environment may have a third internal temperature. Heating the textile to between 180 ℃ and 220 ℃ in the fixation chamber results in fixation of the dye to/into the textile. For example, heating the dyed textile to between 180 ℃ and 220 ℃ may allow at least 90% of the dye to diffuse into the textile fibers. However, in some embodiments, heating the dyed textile to between 180 ℃ and 220 ℃ may allow at least 80%, at least 85%, at least 90%, at least 93%, at least 95%, at least 96%, at least 97%, at least 98%, or at least 99% of the dye to diffuse into the textile fibers.

Subsequent storage of the dyed textile between 160 ℃ and 200 ℃ in the first chamber may allow the residual dye to diffuse locally into the textile fibers. For example, at least 85%, at least 90%, at least 93%, at least 95%, at least 96%, at least 97%, at least 98%, at least 99% or 100% of the dye may diffuse into the textile fibers within the first chamber.

The fixation chamber may be configured to heat the dyed textile to the third temperature for between 1 minute and 15 minutes. In some embodiments, the fixation chamber may be configured to heat the dyed textile to a third temperature for between 0 and 20 minutes; between 1 and 15 minutes; between 2 and 10 minutes; between 3 and 8 minutes; or about 5 minutes.

The method may further comprise: the second chamber is transported to a new location while the dyed textile is temporarily stored in the second chamber. Transporting the second chamber to a new location while the dyed textile is temporarily stored in the second chamber reduces the total time it takes for the end user to receive the dyed textile after requesting access to the dyed textile. This increases the overall efficiency of the process.

In some embodiments, the method comprises: the dye is applied to the undyed textile. More specifically, the method may include: the undyed textile is transported along the processing line and the dye is applied to the undyed textile. A single process line can be used to apply the dye to the undyed textile and to increase the color fastness of the dyed textile. Alternatively, in some embodiments, at least two separate processing lines may be used. For example, the first processing line may be configured to apply dye to an undyed textile, and the second processing line may be configured to increase the color fastness of the dyed textile.

The method may further comprise: a dye comprising a colorless dispersant is applied to an undyed textile. The colorless dispersant can further improve the color fastness obtained. For example, colorless dispersants may be used instead of the washing treatment. This significantly reduces the total amount of water required to produce a dyed textile.

The method may further comprise: dye is dispensed onto the textile via an array of flow channel dispensers. The array of flow channel distributors may be digitally controlled. Digital control of the array of flow channel dispensers may provide versatility, such as real-time or near real-time color inconsistency correction and/or near-instant color switching may be achieved on the same process line. Contrary to conventional methods, such as immersing the textile in a bath of disperse dye, applying the dye to the textile via an array of flow channel dispensers allows accurate deposition of the correct dose of dye according to the measured parameters of the textile.

The present invention thus relates to a method for improving the color fastness and/or hand feel of dyed textiles. The present invention enables a continuous roll-to-roll dyeing process to achieve improved color fastness and hand feel, eliminating the need for additional downstream processing and washing.

The present invention includes two methods that can be used alone or in combination. Thus, according to the present invention there is also provided a method for improving the color fastness of dyed textiles, the method comprising: conveying the dyed textile along a processing line; applying a fluid to the dyed textile at a first location on the process line, and subsequently removing at least 50% of the applied fluid from the dyed textile at a second location on the process line; delivering the dyed textile into a first chamber having a first controlled environment and temporarily storing the dyed textile in the first chamber for a first period of time; and delivering the dyed textile into a second chamber having a second controlled environment and temporarily storing the dyed textile in the second chamber for a second period of time.

The method may further include removing contaminants from the removed fluid; and reapplying the fluid to the dyed textile. The fluid may be sprayed onto the dyed textile.

The method may further comprise: the dyed textile is mechanically agitated. The method may further comprise: the first controllable environment and/or the second controllable environment is adjusted based on characteristics of the textile to be dyed, characteristics of a dye used to dye the textile, and/or characteristics of the dyed textile. The first chamber may include a first internal temperature. The second chamber may include a second internal temperature that is lower than the first internal temperature.

The method may further comprise: the dyed textile is temporarily stored in the second chamber at a plurality of different temperatures. Alternatively or additionally, the method may further comprise: the dyed textile is consolidated into a roll within the first chamber. The method may further comprise: the dyed textile is conveyed through a fixation chamber having a third controlled environment. The method may further comprise: dye is dispensed onto the textile via an array of flow channel dispensers.

Accordingly, there is also provided a method for improving the color fastness of dyed textiles, the method comprising: conveying the textile along a processing line; dispensing dye onto the textile via an array of flow channel dispensers; transporting the dyed textile through a fixation chamber having a first controlled environment; applying a fluid to the dyed textile at a first location on the process line, and subsequently removing at least 50% of the applied fluid from the dyed textile at a second location on the process line; delivering the dyed textile into a first chamber having a first controlled environment and temporarily storing the dyed textile in the first chamber for a first period of time; and delivering the dyed textile into a second chamber having a second controlled environment and temporarily storing the dyed textile in the second chamber for a second period of time.

In some embodiments, the dye applied to the textile may comprise a standard formulation. The standard formulation may comprise: about 5g/L of Levafix blue (reactive dye); 5g/L sodium carbonate (alkaline buffer); 1g/L caustic soda (catalyst); 1g/L Meropan DA (chelator); 2g/L of wetting agent; humectant at 5 g/L: glycerol or PEG 400; and 0.5g/L sodium alginate (leveling agent). Such formulations are useful, for example, for dyeing cotton textiles.

According to the present invention there is also provided an apparatus for improving the color fastness of dyed textiles, the apparatus comprising: a processing line for transporting the textile in a first direction; a reverse osmosis unit comprising a fluid reservoir for holding a fluid and a filtration unit for removing contaminants from the fluid; a fluid applicator configured to apply a fluid to the textile in a second direction substantially opposite the first direction; a fluid removal device configured to remove fluid from the textile and return the removed fluid to the reverse osmosis unit.

The application of the fluid enables the textile fibers to move and act to increase the overall color fastness. Applying the fluid to the textile via the fluid applicator, followed by removing the fluid from the textile via the fluid removal device, may improve the color fastness of the textile. In addition, excess dye within or on the dyed textile may be removed with the fluid by a fluid removal device.

The fluid removal device may be downstream of the fluid applicator. Alternatively or additionally, the fluid removal device may be located opposite the fluid applicator. The fluid may pass through the textile.

Contaminants are removed via reverse osmosis in a reverse osmosis unit configured to force contaminated fluid through a semipermeable membrane to remove the contaminants. The reverse osmosis unit may be configured to remove salts, ions, and/or polymers such as lignin from the fluid.

The reverse osmosis unit may comprise a fluid reservoir in communication with the fluid applicator.

The reverse osmosis unit may further comprise a filtration unit configured to receive fluid from the fluid removal device, remove contaminants from the removed fluid, and supply purified fluid to the return fluid reservoir. The filtration unit may be in fluid communication with a fluid reservoir. The fluid applied to the textile and the fluid removed from the textile may be recycled via the fluid reservoir.

The reverse osmosis unit may recover more than 60% of the water used in the plant, or more specifically more than 70% of the water used in the plant, or most specifically more than 80% of the water used in the plant. Alternatively or additionally, the filtration unit may have an efficiency of higher than 90%, or more preferably higher than 95%, or most preferably higher than 98%.

The water and energy used by the recycled and/or regenerated fluid is significantly less than alternative solutions requiring a large volume of wash bath. The filter unit may include a plurality of filters having gradually decreasing pore sizes. The filter unit may be located between the fluid reservoir and the fluid applicator. Alternatively or additionally, the filter unit may be located between the fluid removal device and the fluid reservoir. The filter unit may be in line with the fluid applicator, the fluid reservoir and the fluid removal device.

Alternatively or additionally, the filter unit may be arranged parallel to the fluid reservoir. Fluid may flow out of the fluid reservoir, through the filter unit and back to the reservoir. The reverse osmosis unit may comprise a plurality of filtration units. The filter unit may be configured to remove dye particles from the fluid.

The fluid reservoir may be at least partially filled with a liquid. Alternatively or additionally, the fluid reservoir may be at least partially filled with a gas. The liquid may be water. The gas may be air.

The fluid applicator and the reverse osmosis device may form a fluid flow circuit. The fluid flow circuit may be a continuous fluid flow circuit.

Alternatively or additionally, the contaminants may be removed via Ozonation (Ozonation). Ozonation may be used to remove oxidizing chemicals from fluids. The fluid purification treatment may be a combination of filtration, reverse osmosis and/or ozonation.

The fluid applicator may include a nozzle. The nozzles may uniformly distribute the fluid over the textile. Further, the fluid applicator may include a plurality of nozzles. The plurality of nozzles may be an array of nozzles. The array of nozzles can ensure that the textile is fully subjected to the fluid being sprayed. In some embodiments, the fluid applicator is a liquid applicator.

More specifically, in some embodiments, each nozzle may be configured to force fluid through the textile in use. Alternatively or additionally, in use, the fluid may be sprayed onto, into and/or through the textile.

The fluid removal device may be configured to create a partial vacuum in use. In use, the partial vacuum may draw fluid onto, into, and/or through the textile. This may remove fluid from the textile in use without contacting and/or damaging the textile.

Alternatively or additionally, the fluid removal device may be configured to generate a high velocity air stream through the dyed textile. For example, dyed textiles may be transported between high velocity air streams and vacuum.

The apparatus may also include a mechanical agitator. The mechanical agitator may comprise a roller. A single roller may be advantageous because a single roller provides less mechanical agitation than a pair of rollers, which may allow a more elaborate textile to remove excess dye without damaging the textile.

The mechanical agitator may comprise a pair of rollers. At least one of the pair of rollers may be a roller for transporting the dyed textile along a processing line. The rollers may be reciprocating rollers. The at least one roller may be configured to reciprocate in a first direction parallel to the movement of the dyed textile to stretch the dyed textile. Alternatively or additionally, the at least one roller may be configured to reciprocate in a second direction transverse to the motion of the dyed textile in order to shear the dyed textile. The rollers can reciprocate up to 100mm. More specifically, the rollers may reciprocate up to 75mm, 50mm, 30mm, 20mm or 10mm. For example, the rollers may reciprocate 10mm away from the starting position. However, in some embodiments, the rollers may reciprocate 25mm away from the starting position. Alternatively or additionally, the mechanical agitator may be configured to vibrate. More specifically, the roller(s) may be configured to vibrate. This may improve the mechanical agitation applied to the textile.

There may be a plurality of mechanical agitators. Each agitator may be configured to contact the conveyed textile in use. The mechanical agitator may move the textile fibre in use.

The mechanical agitator may comprise a textured surface configured to contact the textile in use. The textured surface can be configured to transmit mechanical force to the textile. This is advantageous because the mechanical forces acting on the textile can remove excess dye remaining in the textile, thereby further improving the color fastness of the textile.

The textured surface of the roller may be knurled.

The textured surface of the roller may be helical.

Alternatively or additionally, the mechanical agitator may comprise a brush. The brush may be configured to contact the textile in use.

The mechanical agitator may comprise at least one shaft, with respect to which the mechanical agitator is movable. For example, the mechanical agitator may include a longitudinal axis along its maximum extension. The agitator may be configured to rotate about its longitudinal axis. Alternatively or additionally, the agitator may be configured to move along its longitudinal axis.

For example, the rollers in contact with the textile product may be configured to rotate about a longitudinal axis that is generally perpendicular to the conveyed textile product. Instead, the brush in contact with the textile may be configured to move along a longitudinal axis, which may be substantially perpendicular or parallel to the transported textile.

The mechanical agitator may be configured to move at a speed different from the speed of the conveyed textile. This may increase the efficiency of the mechanical agitation.

The apparatus may also include a heat exchanger. The heat exchange element is configured to remove thermal energy from the purified/contaminated fluid and apply the thermal energy to the fluid to be applied to the textile. This will enable the heat energy that would otherwise be lost to be re-used to help heat the fluid to the desired temperature. This means that less energy from an external source is required to heat the fluid to its required temperature.

The water discharge of the process is reduced to less than 10L/Kg at ambient temperature, or more specifically to less than 1L/Kg at ambient temperature, using a reverse osmosis unit and heat exchanger in series that recirculates heat from the first stage to the last stage of the process. Furthermore, the heat loss is reduced to less than 30% (i.e., less than 0.20 MJ/kg), or, more specifically, less than 20% (i.e., less than 0.15 MJ/kg), or, most specifically, less than 10% (i.e., less than 0.10 MJ/kg).

Alternatively or additionally, there is also provided an apparatus for improving the color fastness of dyed textiles, the apparatus comprising: a processing line configured to deliver the dyed textile into a first chamber having a first controlled environment, wherein the first chamber is configured to temporarily store the dyed textile for a first period of time; and a second chamber having a second controlled environment, wherein the second chamber is configured to temporarily store the dyed textile for a second period of time.

As previously described, each of the first and second predetermined controllable environments may include first and second temperatures, humidity, pressure, gas flow rate, and/or inert gas, respectively.

The second chamber may be immediately adjacent (immediately adjacent) to the first chamber. Positioning the second chamber directly adjacent to the first chamber reduces thermal energy loss as the textile travels between the second chamber and the first chamber.

The second chamber may be mobile. The second chamber may be used to transport the dyed textile, thereby also taking advantage of the time the textile is in the second chamber to move and/or deliver the textile to potential users. This increases the overall efficiency of the dyeing process. For example, the second chamber may be an insulated hopper or trolley. Alternatively or additionally, the second chamber may be an actively heated hopper or trolley. The second chamber may include at least one wheel, roller, and/or caster. More specifically, the second chamber may include a plurality of wheels, rollers, and/or casters.

The first chamber may be downstream of the second chamber. As previously described, the first chamber may include a first internal temperature and the second chamber may include a second internal temperature that is lower than the first internal temperature. Positioning the first chamber downstream of the second chamber allows the textile to be heated most effectively to the higher of the two temperatures and then to cool slightly as the textile travels to and through the second chamber.

The second chamber may comprise a temperature gradient. For example, dyed textiles may enter the second chamber at an elevated temperature. The thermal energy within the textile may already be applied in the first chamber and/or the third chamber. Thus, a temperature gradient may be created by natural cooling of the textile as it is conveyed through the second chamber.

The first chamber may comprise a cylindrical core configured to receive the dyed textile and form a roll of dyed textile in use. The cylindrical core may be a tube. The core is configured to receive the dyed textile and form a roll effective to package the dyed textile. This consolidated form is easier to move, store and transport. Furthermore, the cylindrical core may be configured to maintain an equal pressure across the roller. The core may be cardboard, plastic or metal.

The apparatus may comprise a plurality of cores. For example, the device may comprise two cores. Each core may be configured to sequentially receive dyed textiles.

The first chamber may include a cutting module configured to cut the textile and produce a roll of discrete (discrete) dyed textile. The cutting module may comprise a blade. Cutting the textile to produce discrete rolls of dyed textile such that each roll comprises a predetermined length of dyed textile. This improves the packaging of the roll.

The second chamber may be configured to receive a plurality of discrete rolls of dyed textile. Enabling the second chamber to receive a plurality of discrete rolls of dyed textile increases the efficiency of the apparatus. Multiple textile rolls provide greater thermal mass, which reduces the amount of heat required to generate and maintain a predetermined temperature.

Alternatively or additionally, in use, each discrete roll of dyed textile may pass through the second chamber. Further, as previously described, the second chamber may include a temperature gradient. The dyed textile cools as it passes through the second chamber. Thus, the thermal energy used to provide the temperature gradient within the second chamber may be at least partially accepted by the addition of subsequently dyed rolls of textile. The roll of subsequently dyed textile may be at about 180 ℃ upon entering the second chamber. When a subsequently dyed roll of textile is entered into the second chamber, the initially dyed roll of textile may be less than 180 ℃. For example, the rolls of initially dyed textile may be at about 175 ℃, 170 ℃, 165 ℃, or 160 ℃.

More specifically, the second chamber may include a proximal end having a first opening, wherein the first opening is configured to receive a roll of discrete dyed textile. The second chamber may include a distal end having a second opening, wherein the second opening is configured to output a roll of discrete dyed textile. The first opening and the second opening may each comprise a door and/or a seal. The temperature of the proximal end may be higher than the distal end. For example, the proximal end may be about 180 ℃ and the distal end may be about 140 ℃. There may be a substantially linear temperature gradient between the proximal and distal ends. In use, a roll of dyed textile may be moved between the proximal and distal ends. The movement of the dyed textile between the proximal and distal ends may take at least 2 hours. Once the roll of dyed textile has been moved a predetermined distance towards the distal end of the second chamber, a subsequent roll of dyed textile may be added to the second chamber via the first opening.

The apparatus may also include a fixation chamber configured to receive the dyed textile. The fixation chamber may include a third controllable environment configured to heat the dyed textile to a third temperature. The fixation chamber may be configured to heat the textile to between 150 ℃ and 240 ℃. Furthermore, the residence time of the textile in the fixing chamber can be as long as 10 seconds. Alternatively, the textile may stay in the fixation chamber for up to 20, 30, 40 or 60 seconds. However, in some embodiments, the residence time of the textile in the fixation chamber may be in excess of 60 seconds. The fixation chamber may be configured to reduce the moisture content of the textile containing the dye and simultaneously initiate the fixation process between the dye and the textile.

The fixation chamber may be located downstream of the first chamber and the second chamber. Alternatively or additionally, the fixation chamber may be located upstream of the digital dyeing process. Alternatively or additionally, the first chamber and the second chamber may be located upstream of the digital dyeing process. The digital dyeing process may be as described in WO 2020/208362, the disclosure of which WO 2020/208362 is incorporated herein by reference. However, in some embodiments, the fixation chamber may be located upstream of the simulated dyeing process. For example, the fixation chamber may be located upstream of a dip dyeing process, a pad dyeing process, a spray deposition process, a thermal or cold transfer process, and/or a dye bath.

The fixation chamber may include an Infrared (IR) or Near Infrared (NIR) drying module configured to heat the dyed textile. IR or NIR is an effective method of increasing the temperature of a textile and fixing dyes to a textile without damaging the textile. The energy supplied to the textile via IR or NIR can also be easily handled and optimized. Furthermore, the use of digital dyeing and/or infrared drying may further limit the presence of agglomerates on the surface of the textile fibers which may negatively affect the color fastness properties.

The invention therefore also relates to a device for improving the color fastness and/or the hand feel of dyed textiles. The invention includes two devices that can be used alone or in combination. Thus, according to the present invention there is also provided an apparatus for improving the color fastness of dyed textiles, the apparatus comprising: a processing line for conveying textiles; a fluid applicator configured to apply a fluid to the conveyed textile; a fluid removal device configured to remove fluid from the transported textile; a first chamber configured to receive the transported textile, wherein the first chamber comprises a first controlled environment, and wherein the first chamber is configured to temporarily store the dyed textile for a first period of time; and a second chamber having a second controlled environment, wherein the second chamber is configured to temporarily store the dyed textile for a second period of time.

Each of the above chamber environments may be digitally controlled. Alternatively or additionally, the fluid applicator and/or the fluid removal device may be digitally controlled. More specifically, the entire processing line may be digitally controlled. For example, the processing line may comprise a control unit. The control unit may comprise a processor. The control unit may be configured to control the environment within each chamber, including but not limited to temperature and/or cooling rate (where applicable). Alternatively or additionally, the control unit may be configured to control parameters of the processing line. This includes, but is not limited to, the speed at which the textile is transported along the processing line and/or the temperature of the processing line.

In use, the process line, chamber environment, fluid applicator and/or fluid removal device may be digitally controlled. Thus, the processing line, chamber environment, fluid applicator, and/or fluid removal device may be digitally controlled as the processing line transports the textile.

Drawings

The invention will now be described further in more detail, by way of example only, with reference to the accompanying drawings.

FIG. 1 illustrates a method for improving the color fastness of dyed textiles according to some embodiments of the invention;

FIG. 2 illustrates a method for improving the color fastness of dyed textiles according to some embodiments of the invention;

FIG. 3 illustrates a method for improving the color fastness of dyed textiles according to some embodiments of the invention;

FIG. 4 illustrates an apparatus for improving the color fastness of dyed textiles according to some embodiments of the invention;

FIG. 5 illustrates an apparatus for improving the color fastness of dyed textiles according to some embodiments of the invention;

FIG. 6 illustrates an apparatus for improving the color fastness of dyed textiles according to some embodiments of the invention;

FIG. 7 illustrates an apparatus for improving the color fastness of dyed textiles according to some embodiments of the invention;

FIG. 8A shows a mechanical agitator in the form of a helical roller;

FIG. 8B shows a mechanical agitator in the form of a threaded roller;

FIG. 8C shows a mechanical agitator in the form of a profiled roller;

FIG. 8D shows a mechanical agitator in the form of a knurled roller;

FIG. 9A shows a cross-sectional view of a mechanical agitator in the form of a brushroll; and

fig. 9B shows a cross-sectional view of a mechanical agitator in the form of a gear roller.

Detailed Description

Fig. 1 illustrates a method of improving the color fastness of dyed textiles. The method comprises the following steps: conveying the dyed textile along a processing line (step 110); applying a fluid to the dyed textile at a first location on the process line (step 120); and subsequently removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line (step 130).

More specifically, the method comprises: a predetermined volume of fluid is applied to the dyed textile at a first location on the process line (step 120). The predetermined volume is based on the desired moisture content of the textile. The predetermined volume of fluid to be applied to the textile is calculated based on the mass flow rate of the textile along the processing line.

The total mass of fluid applied to the dyed textile is 100% -300% of the mass of the dyed textile. The fluid applied to the dyed textile at the first location is typically applied at a rate of 1-20 liters per minute. However, the volumetric rate of the applied fluid varies depending on the textile and dye used. In addition, the textile is typically transported along the processing line at a speed of 1-100 meters per minute (m/min). However, the speed at which the textile is transported along the processing line also varies depending on the textile and dye used.

Fluid applied to the dyed textile at a first location on the process line is sprayed. That is, the method includes: fluid is injected at a first location on the process line to the dyed textile (step 120). The fluid is sprayed onto the dyed textile via a plurality of nozzles. The plurality of nozzles are configured to spray fluid across the width of the conveyed textile.

Fluid is removed from the textile by vacuum. More specifically, the method comprises: at least 50% of the applied fluid is removed from the dyed textile at a second location on the process line using a vacuum (step 130).

The method further comprises the steps of: a fluid purification step (step 140). Accordingly, the method comprises: conveying the dyed textile along a processing line (step 110); applying a fluid to the dyed textile at a first location on the process line (step 120); subsequently removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line (step 130); removing contaminants from the removed fluid (step 140); and reapplying the fluid to the dyed textile (step 150).

The reapplied fluid is reapplied at the first location on the process line (step 120). However, in other embodiments not shown in the figures, the reapplied fluid may be reapplied at a third location on the processing line.

The process is continuous. Accordingly, the method comprises: continuously conveying the dyed textile along a processing line (step 110); applying fluid continuously to the dyed textile at a first location on the process line (step 120); and subsequently continuously removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line (step 130). Further, contaminants are continuously removed from the removed fluid (step 140), and the decontaminated fluid is continuously reapplied to the dyed textile (step 150). The continuously reapplied fluid is applied to the dyed textile at a first location on the process line (step 150). The decontaminated fluid is at least partially a fluid applied (step 120) to the dyed textile at a first location on the process line.

The method further comprises heating the fluid to above 40 ℃. Thus, the fluid applied (step 120) to the dyed textile at the first location on the process line is above 40 ℃. More specifically, the method includes heating the fluid to above 55 ℃.

The method further comprises the steps of: the first location on the processing line is heated to 40-95 ℃. More specifically, the ambient temperature at the first location 120 on the processing line is 40-95 ℃. Most particularly, the method comprises: the first location on the processing line is heated to 50-70 c or about 60 c.

The method further comprises the steps of: determining a range of acceptable flow rates of the applied fluid; monitoring the flow rate of the applied fluid; and adjusting the flow rate of the applied fluid if the flow rate of the applied fluid is outside of the acceptable flow rate range. In use, the applied fluid is accurately monitored and may be regulated.

The method further comprises the steps of: the dyed textile is mechanically agitated. Accordingly, the method comprises: conveying the dyed textile along a processing line (step 110); applying a fluid to the dyed textile at a first location on the process line (step 120); agitating the textile (step 125); subsequently removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line (step 130); removing contaminants from the removed fluid (step 140); and reapplying the fluid to the dyed textile (step 150).

Mechanical agitation occurs between the fluid application step (step 120) and the fluid removal step (step 130). More specifically, the dyed textile is mechanically agitated via a pair of rollers configured to contact the textile conveyed along the processing line. These rolls are nip rolls. Mechanical agitation occurs between a first location and a second location on the processing line.

Fig. 2 shows a method of improving the color fastness of dyed textiles. The method comprises the following steps: conveying the dyed textile along a processing line (step 110) and conveying the dyed textile into a first chamber having a first controlled environment (step 210); temporarily storing the dyed textile in the first chamber for a first period of time (step 220); delivering the dyed textile into a second chamber having a second controlled environment (step 230); and temporarily storing the dyed textile in the second chamber for a second period of time (step 240). The first controllable environment is different from the second controllable environment. More specifically, the second controllable environment comprises a temperature gradient.

The dyed textile is automatically transported into the first chamber. Instead, the dyed textile is manually transported into the second chamber.

The method further comprises the steps of: the first controllable environment and/or the second controllable environment is adjusted based on characteristics of the textile to be dyed, characteristics of a dye used to dye the textile, and/or characteristics of the dyed textile (step 215). The characteristics of the dye include dye concentration, color, hue, pantone number, reflectance, water content, color index, and/or molecular weight. In addition, the characteristics of the dyed textile and/or the textile to be dyed include the basis weight, absorption capacity, reflectivity, moisture content, thickness, diameter and/or lot number of the textile.

The first chamber is maintained at a first internal temperature and the second chamber is maintained at a second internal temperature. The second internal temperature is lower than the first internal temperature.

More specifically, the first internal temperature is between 140 ℃ and 240 ℃ and the second internal temperature is between 120 ℃ and 220 ℃. Most particularly, the first internal temperature is between 160 ℃ and 220 ℃, and the second internal temperature is between 140 ℃ and 200 ℃.

The second period of time is longer than the first period of time. More specifically, the first period of time is at least 10 minutes and the second period of time is at least 30 minutes. Most particularly, the first period of time is at least 40 minutes and the second period of time is at least 2 hours.

The method further comprises the steps of: a cooling rate of the dyed textile is determined (step 250), and a controlled environment of the first chamber and/or the second chamber is adjusted based on the cooling rate (step 260). The cooling rate is defined as the time it takes for the textile to drop 1 ℃. Furthermore, the cooling rate is determined on the basis of the properties of the textile to be dyed, the dyed textile and/or the dye. The cooling rate is calculated prior to the textile dyeing process.

More specifically, the method comprises: the dyed textile is temporarily stored in the second chamber at a plurality of different temperatures for a second period of time (step 240). Most particularly, the method comprises: the dyed textile is transported through a plurality of different temperatures in the second chamber for a second period of time (step 240). Thus, the second chamber comprises a temperature gradient.

The method further comprises the steps of: the dyed textile is consolidated into a roll within the first chamber (step 270). Furthermore, in use, the speed at which the dyed textile is delivered to the first chamber is varied. More specifically, the rate of delivery of the dyed textile to the first chamber is greater than the rate of delivery to the second chamber. This creates an excess of dyed textile in the first chamber. The roll of consolidated textile is then separated from the processing line and transported into a second chamber. At the same time, the excess dyed textile begins to consolidate to create a second roll within the first chamber. In addition, the rate of delivering the dyed textile to the first chamber is reduced until the excess dyed textile is consolidated.

The roll of consolidated textile comprises 50-3000 meters of dyed textile. More specifically, the roll comprises a dyed textile of 500 m-1500 m or about 1000 m. In addition, each roller in the second chamber rotates about its axis, wherein the axis is the axis about which the textile is wound to create the roll.

More specifically, the method comprises: a plurality of rolls of dyed textile are temporarily stored in a second chamber (step 240). Once the roll of first dyed textile has been conveyed a predetermined distance through the second chamber, a subsequent roll of dyed textile is added to the second chamber. As previously mentioned, the second chamber includes a temperature gradient. Thus, each roll of dyed textile cools as it is conveyed through the second chamber.

The method further comprises the steps of: the dyed textile is transported through a fixation chamber with a third controlled environment (step 280). More specifically, the dyed textile is transported through the fixation chamber before being temporarily stored in the first chamber and/or the second chamber. The fixation chamber is configured to reduce the moisture content of the textile containing the dye and simultaneously initiate a fixation process between the dye and the textile.

The third controllable environment is maintained at a third internal temperature. More particularly, the temperature in the fixation chamber is between 180 ℃ and 220 ℃. Furthermore, the fixation chamber is configured to heat the dyed textile to the third temperature for 1 to 15 minutes. More specifically, the fixation chamber is configured to heat the dyed textile to the third temperature for 3 to 8 minutes.

Fig. 3 illustrates a method of improving the color fastness of dyed textiles. The method comprises the following steps: conveying the dyed textile along a processing line (step 110); applying a fluid to the dyed textile at a first location on the process line (step 120); subsequently removing at least 50% of the applied fluid from the dyed textile at a second location on the processing line (step 130); delivering the dyed textile into a first chamber having a first controlled environment (step 210) and temporarily storing the dyed textile in the first chamber for a first period of time (step 220); and delivering the dyed textile into a second chamber having a second controlled environment (step 230) and temporarily storing the dyed textile in the second chamber for a second period of time (step 240).

The method further comprises the steps of: removing contaminants (140) from the removed fluid; and reapplying the fluid to the dyed textile (step 150). Furthermore, the method comprises: the dyed textile is mechanically agitated (step 125), wherein the mechanical agitation occurs between fluid application (steps 120, 150) and fluid removal (step 130).

In some embodiments not shown in the drawings, the method may further comprise: dye is dispensed onto the textile via an array of flow channel dispensers. The dye may be dispensed onto the textile prior to application of the fluid. In addition, the dye may contain a colorless dispersant.

Fig. 4 shows an apparatus for improving the color fastness of dyed textiles. The apparatus 400 includes: a processing line 410 for conveying textiles 420; a fluid applicator 430, the fluid applicator 430 being configured to apply, in use, a fluid 435 to the transported textile 420; and a fluid removal device 440, the fluid removal device 440 being configured to remove fluid from the transported textile 420 in use. The fluid removal device 440 is located downstream of the fluid applicator 430. In addition, fluid removal device 440 is in fluid communication with fluid applicator 430 via reverse osmosis unit 445.

The fluid applicator 430 and the fluid removal device 440 are located within the chamber 480. The interior environment of the chamber 480 is heated. More specifically, the internal environment of chamber 480 is between 40 ℃ and 95 ℃. More specifically, the internal environment of chamber 480 is between 50 ℃ and 70 ℃. In addition, fluid 435 is heated. Fluid 435 is heated to above 40 ℃. More specifically, the fluid is heated to 50 ℃ to 70 ℃.

The apparatus 400 further comprises a reverse osmosis unit 445. Reverse osmosis unit 445 includes a filtration unit 455 and a fluid reservoir 450. The filtration unit 455 is configured to receive fluid from the fluid removal device 440, remove contaminants from the removed fluid 435, and supply purified fluid to the fluid applicator 430. More specifically, filter unit 455 is in fluid communication with fluid reservoir 450, and filter unit 455 is located between fluid removal device 440 and fluid reservoir 455. The filter unit 455 includes a plurality of filters each having a different pore size.

The fluid applicator 430 includes a nozzle. In use, the fluid is sprayed onto the textile. More specifically, fluid applicator 430 includes a first spray head 432 and a second spray head 434. Each spray head includes a plurality of spray nozzles. In addition, the fluid removal device 440 includes a vacuum device. The fluid removal device 440 is configured to create a partial vacuum in use.

The apparatus 400 also includes a mechanical agitator 460. The mechanical agitator 460 includes a roller 462. More specifically, the mechanical agitator 460 includes a pair of rollers 462, 464. The rollers 462, 464 are reciprocating rollers. The rollers reciprocate by 10 mm at the start position. Each roller 462, 464 is configured to contact the conveyed textile 420 in use. The mechanical agitator 460 is configured to move the textile fibers in use. More specifically, the mechanical agitator 460 comprises a textured surface. Most particularly, each roller 462, 464 includes a textured surface. Fig. 8A-8D and 9A-9B illustrate some examples of rollers having textured surfaces.

Fig. 5 shows an apparatus for improving the color fastness of dyed textiles. The apparatus 500 includes: processing line 410, processing line 410 is configured to convey dyed textile 420 into a first chamber 530 having a first controlled environment. The first chamber 530 is configured to temporarily store dyed textiles for a first period of time. The apparatus 500 further includes a second chamber 540 having a second controlled environment. The second chamber 540 is configured to temporarily store the dyed textile for a second period of time.

The first chamber 530 includes a cylindrical core 532, the cylindrical core 532 configured to receive the dyed textile 420 and form a roll 534 of dyed textile in use. The first chamber 530 further includes a cutting module 536, the cutting module 536 configured to cut the textile 420 and produce a discrete roll 380 of dyed textile. Cutting module 536 includes a blade 538.

The second chamber 540 is located upstream of the first chamber 530. In addition, the second chamber 540 includes wheels 542. The second chamber 549 is movable. Further, the second chamber 540 is configured to receive a plurality of discrete rolls 380 of dyed textile.

The second chamber 540 includes a temperature gradient. More specifically, the second chamber 540 includes a proximal end 544 having a first opening. The first opening 545 is configured to receive a dyed textile 380. The second chamber 540 includes a distal end 546 having a second opening 547. The second opening 547 is configured to output a roll 380 of dyed textile. The first opening 545 and the second opening 547 each include a door and/or a seal. The temperature of the proximal end 544 is higher than the temperature of the distal end 546. More specifically, the proximal end 544 is at about 180 ℃ and the distal end 547 is at about 140 ℃. There is a substantially linear temperature gradient between the proximal and distal ends. The roll 380 of dyed textile is transported from the proximal end 544 of the second chamber 540 to the distal end 546 of the second chamber 530. More specifically, the rolls 380 of dyed textile are transported from the proximal end 544 of the second chamber 540 to the distal end 546 of the second chamber 530 via a conveyor belt 548.

Fig. 6 shows an apparatus for improving the color fastness of dyed textiles. The apparatus 600 includes: a processing line 410 for conveying textiles 420; a fluid applicator 430, the fluid applicator 430 configured to apply a fluid 435 to the conveyed textile 420; a fluid removal device 440, the fluid removal device 440 configured to remove fluid from the transported textile 420; a first chamber 530, the first chamber 530 configured to receive the conveyed textile 420, wherein the first chamber 530 comprises a first controlled environment; and a second chamber 540 having a second controlled environment. The first chamber 530 is configured to temporarily store dyed textiles for a first period of time and the second chamber 540 is configured to temporarily store dyed textiles for a second period of time.

The apparatus 600 further includes a reverse osmosis unit 445, the reverse osmosis unit 445 being configured to receive fluid from the fluid removal device 440. The reverse osmosis unit includes a filtration unit 455 and a fluid reservoir 450. The filtering device 455 is configured to remove contaminants from the removed fluid 435 and supply purified fluid to the fluid applicator 430. More specifically, filter unit 455 is in fluid communication with fluid reservoir 450, and filter unit 455 is located between fluid removal device 440 and fluid reservoir 450.

In addition, the apparatus 600 includes a processing line 410 for conveying the textile 420. The processing line 410 is defined by a plurality of rollers 410, the rollers 410 being configured to define a path for transporting the dyed textile. Any number of rollers 410 may be used. Each of the plurality of rollers 410 is configured to move relative to each other in order to lengthen or shorten the length of the processing line. This can be used to control the mass flow rate of the textile product at a given location on the process line.

The apparatus 600 further includes a fixation chamber 610 configured to receive the dyed textile 420. The fixation chamber 610 includes a third controllable environment configured to heat the dyed textile 420 to a third temperature. More specifically, the fixation chamber is configured to heat the textile to between 150 ℃ and 240 ℃. Furthermore, the textile is held in the fixation chamber for 10-60 seconds.

The fixation chamber 610 is located downstream of the fluid applicator 430, the fluid removal device 440, the first chamber 530, and the second chamber 540. In addition, the fixing chamber 610 is located upstream of the digital dyeing process (not shown in the drawings). The digital dyeing process is as described in WO 2020/208362.

The fixation chamber 610 includes a drying unit 620 located above the dyed textile 420. The drying unit 620 is configured to release energy in the form of electromagnetic waves. The drying unit emits between 20kW and 200kW of energy. For example, the drying unit is configured to transfer approximately 50kW of energy to the dyed textile. A drying unit of 90-150kW is used. The emitted energy is in the form of Infrared (IR), near Infrared (NIR), mid-infrared (MIR), microwave and/or Ultraviolet (UV). However, in some embodiments not shown in the drawings, a plasma heater may be used.

Drying unit 620 also includes an air stream configured to remove any steam and/or moisture from the vicinity of dyed textile 420. The air flow is configured to remove up to 5 liters of water vapor from the vicinity of the textile product per minute. More specifically, the textile 420 enters the fixation chamber 610 at a moisture content of about 25%. The textile leaves the fixing chamber at a moisture content of 0% -10%.

The fixation chamber 610 also includes a reflector 630 positioned below the dyed textile 420. The reflector 630 is configured to optimize the amount of energy released for transfer to the dyed textile.

The fixation chamber 610 also includes a temperature sensor 640 configured to measure the temperature of the dyed textile. The dyed textile enters the fixation chamber at about room temperature, which may be between 5 ℃ and 45 ℃, but more preferably may be between 10 ℃ and 35 ℃, and most preferably may be between 15 ℃ and 30 ℃. The temperature of the dyed textile 420 in the fixing chamber 610 is increased by 5 ℃ to 240 ℃. For example, the textile may enter the fixing chamber 610 at about 25 ℃ and exit the fixing chamber 610 at about 240 ℃.

The fixation chamber 610 is configured to enable the dispensed dye to diffuse into the textile substrate, chemically reacting with the substrate; and/or thermally fused to the substrate.

The internal environment of the fixation chamber 610 is between 100 ℃ and 300 ℃. More specifically, the internal environment of the fixation chamber 610 is between 140 ℃ and 240 ℃. However, in use, the temperature may be controlled and/or regulated.

Fig. 7 shows an apparatus for improving the color fastness of dyed textiles. The apparatus 700 includes processing lines 410, 462, 464, 766 for conveying the textile 420; a fluid applicator 430, the fluid applicator 430 configured to apply a fluid 435 to the conveyed textile 420; and a fluid removal device 440, the fluid removal device 440 configured to remove fluid from the transported textile 420. The processing lines 410, 462, 464, 766 are driven via a belt drive 730 connected between the two rollers 462, 464. Belt drive 730 is driven by a motor. Dyed textile 420 moves from left to right in fig. 7.

The fluid applicator 430 is located within the chamber 480. The internal temperature of chamber 480 is between 40-80 c, for example about 60 c. Fluid applicator 430 includes twenty-four (24) nozzles configured to spray fluid onto dyed textiles. The fluid is a liquid. The fluid is ejected generally vertically downward (i.e., in the direction of gravity). The ejected fluid spreads between the nozzle and the dyed textile such that the ejected fluid creates a cone-shaped ejection pattern. The dyed textile is transported at an angle of between 30 ° and 60 ° relative to a substantially vertical axis. The sprayed fluid thus contacts the dyed textile at an angle between 20 ° and 70 °.

The ejected fluid is heated to above 60 ℃, or more specifically, to about 80-90 ℃ via heating element 705. The heating element 705 is a trace heater. The fluid is ejected at a rate of about 45 liters/minute. In addition, the fluid is injected at a pressure of about 0.7 bar. The apparatus 700 includes a pump 710 configured to generate a desired fluid flow rate and pressure.

In some embodiments, the fluid applicator 430 is configured to rotate. More specifically, the fluid applicator 430 is configured to rotate up to 360 degrees so that the nozzle can be used to clear excess dye from within the chamber 480.

The chamber 480 is partially filled with a fluid. The fluid is a liquid. The fluid includes any excess fluid ejected by the fluid applicator 430. More specifically, the fluid is primarily water. However, any suitable fluid may be used. As shown in fig. 7, the fluid collects at the bottom of the chamber 480. The chamber is configured to receive up to 28 liters of liquid. The chamber also includes a discharge 720 having an adjustable weir 722. The adjustable weir is configured to control the amount of liquid within the chamber 480, thereby controlling the liquid level X. More specifically, weir 722 is configured to control whether dyed textiles conveyed along the processing line pass below the level of chamber 480. In fig. 7, the liquid level within chamber 480 is configured such that the dyed textile is immersed in the liquid at location Y. However, in some embodiments, the level Y is lowered by adjusting the adjustable weir 722 such that the dyed textile remains above the level at position Y.

Excess liquid within the chamber 480 overflows the weir 722 and exits the chamber 480 via the drain 720. The discharge 720 includes a pump 724, the pump 724 configured to pump fluid from the discharge back to the fluid reservoir 450. The pump 724 is configured to pump fluid at a rate of 12 liters/minute. The drain also includes a filter unit 455 positioned between the weir 722 and the fluid reservoir 450. The filter unit 455 is configured to remove contaminants and particulates from the fluid.

Further, the fluid reservoir 450 is in fluid communication with the chamber 480 via a conduit 736 having a pump 738. The pump 738 is configured to pump liquid from the fluid reservoir 450 into the chamber 480 so as to maintain a predetermined liquid level X. Pump 738 is configured to pump a liquid at a rate of approximately 10 liters/minute.

In some embodiments not shown in fig. 7, the fluid reservoir 450 is operably connected to a reverse osmosis unit configured to draw fluid from within the fluid reservoir 450 via a pump; forcing the fluid through a semipermeable membrane to remove contaminants; and then returns the fluid to the fluid reservoir 450.

The fluid reservoir 450 is configured to hold up to 10 liters of liquid. The fluid reservoir 450 also includes a gas, such as air. The fluid reservoir 450 is in fluid communication with a bulk fluid source (bulk fluid source) 726 via a pump 728. Pump 728 is a bi-directional pump configured to ensure that the fluid reservoir continuously holds 10 liters of liquid. The pump 728 is configured to pump fluid at a rate of 10 liters/minute.

The chamber 480 includes a mechanical agitator in the form of two rollers 462, 464. The first roller 462 is located upstream of the fluid applicator 430 and the second roller 464 is located downstream of the fluid applicator 430. The two rollers 462, 464 are configured to reciprocate along a first axis that is substantially parallel to the movement of the dyed textile between the first roller 462 and the second roller 464 to cause the dyed textile to be stretched. Further, the two rollers 462, 464 are configured to reciprocate along a second axis that is transverse to the movement of the dyed textile between the first roller 462 and the second roller 464 such that the dyed textile is sheared. These two reciprocating motions agitate the fibers of the dyed textile. In addition, the movement of the dyed textile is configured to push an applied chemical, such as a softener or fragrance, into the dyed textile fibers. The reciprocation of the rollers 462, 464 is controlled via a rotating cam 732.

The chamber 480 also includes nip roll 766, the nip roll 766 configured to apply pressure to the dyed textile as the dyed textile passes between nip roll 766 and a second roll (in this case, roll 464). However, in other embodiments not shown in fig. 7, another type of second roller may be used. For example, in some embodiments, multiple rolls 766 may be used. The pressure applied by nip roll 766 to the dyed textile is 1500-3500Kg/cm ² Between 2000 Kg/cm and 3000Kg/cm ² Between or about 2500Kg/cm ² . The applied pressure extrudes the liquid from the dyed textile. This reduces the liquid content in the dyed textile to less than 50%. More specifically, the pressure applied by nip roll 766 reduces the liquid content in the dyed textile to less than 45%.

The fluid removal device 440 includes a tube 770 configured to spray a gas onto the textile. The gas is air. However, any suitable gas may be used. In some embodiments, the gas may include a fragrance. The gas is also heated to between 40-100 ℃. More specifically, the gas is heated to between 60-95 ℃, or more specifically, the gas is heated to between 80-90 ℃. The gas is heated via a plurality of finned heaters 772. The gas exits the tube 770 at a rate of between 50 and 160 meters per second. More specifically, the gas exits the tube 770 at a rate of between 80 and 140 meters per second, or most specifically, the gas exits the tube 770 at a rate of between 100 and 120 meters per second.

The fluid removal device 440 also includes a collection chamber 773, the collection chamber 773 configured to collect fluids including liquids and gases, as well as any solids including, but not limited to, contaminants and excess dye particulates, that pass through the surface of the dyed textile 420 near the tube 770 or are discharged from the surface of the dyed textile 420 near the tube 770. The collection chamber 773 includes a knife-edge roller 778, the knife-edge roller 778 configured to contact the dyed textile 420 in the vicinity of the fluid removal apparatus 440. More specifically, the collection chamber includes a plurality of knife edge rollers 778. The knife edge roller 778 supports the dyed textile 420 to minimize deflection of the dyed textile due to the fluid removal apparatus 440.

The collection chamber 773 is in fluid communication with a separation unit 774, the separation unit 774 configured to separate gas from liquid and solids. The separation unit 774 includes a vortex or cyclone separator configured to collect liquid and solid particles at a first end 775 (such as the bottom) and to collect the exiting gas from a second end 776 (such as the top). The first end 775 of the separation unit 774 is in fluid communication with the fluid reservoir 450 via the pump 715. The pump 715 is configured to pump fluid collected at the first end 775 of the separation unit 774 back to the fluid reservoir 450 at a rate of 3 liters/minute. The second end 776 of the separation unit 774 is in fluid communication with the tube 770 via a plurality of finned heaters 772. The apparatus 700 further comprises a fan 781, the fan 781 being configured to generate an air flow within a conduit 782 connecting the tube separation unit 774 to the tube 770.

The dyed textile downstream of the fluid removal device 440 comprises a liquid content of less than 15%, or more specifically, between 5-10%.

The chamber 480 also includes an ionizer 771, the ionizer 771 configured to ionize air adjacent to the dyed textile of the fluid removal device 440. This reduces the charge and thus the surface tension of the dyed textile.

Fig. 8A shows a mechanical agitator in the form of a helical roller. The mechanical agitator 460 includes a roller 462. The roller 462 includes a textured surface. More specifically, roller 462 includes at least one protrusion 466 on an outer surface thereof. Most particularly, roller 462 includes two protrusions 466, 467 on its outer surface. Each projection is helical and therefore spirals around the outer surface of the roll. Each spiral protrusion includes four turns (loops) around the roller, one of which is defined by one complete "loop" (i.e., 360 degrees) around the circumference of the roller. Each turn of the spiral is spaced apart from one another. The gap between each turn is a groove 481. As an example, the first turn 471 and the second turn 472 have been marked. Each helical projection extends over substantially half of the roller 462. The two spirals meet at about the middle of the roll.

Fig. 8B shows a mechanical agitator in the form of a threaded roller. The threaded roller is similar to a helical roller, but each protrusion 466, 467 has a greater number of turns per unit length of roller. The more turns, the greater the spiral density around the roller. In fact, the spiral density is so great that each turn of the spiral remains in contact with the adjacent turns. Thus, the protrusions completely surround the roller. Again, as an example, the first turn 471 and the second turn 472 have been marked.

Fig. 8C shows a mechanical agitator in the form of a form roll. The roller 462 includes a plurality of protrusions 468 on an outer surface thereof. 16 protrusions are shown in fig. 8C, but only 3 are labeled. However, any number of protrusions may be present. Each protrusion surrounds the roller such that each protrusion extends around the entire circumference of the roller. In addition, each projection includes a ridge or point that extends around the entire circumference of the roller 462.

Fig. 8D shows a mechanical agitator in the form of a knurled roller. The roller 462 includes a plurality of overlapping protrusions 473, 474. Accordingly, the roller further includes a plurality of overlapping grooves 481 located between the plurality of overlapping protrusions 473, 474.

Fig. 9A shows a cross-sectional view of a mechanical agitator in the form of a brushroll. The roller 462 includes a plurality of protrusions 476 in the form of bristles protruding from the outer surface of the roller. Each protrusion 476 is flexible. For example, each bristle may be made of nylon.

Fig. 9B shows a cross-sectional view of a mechanical agitator in the form of a gear roller. More specifically, the mechanical agitator 460 includes a pair of gear rollers 462, 464. Each roller 462, 464 is configured to contact the conveyed textile 420 in use. More specifically, the textile is transported between rollers 462, 464. Each roller 462, 464 includes a textured surface. More specifically, each roller includes a plurality of protrusions 478. Each protrusion may be solid and/or rigid. Each roller also includes a plurality of grooves, with each groove 479 being located between two adjacent protrusions 478. The pair of rollers 462, 464 are configured to rotate such that the protrusion 478A of one roller 462 is located within the groove 179B of the other roller. In this way, the conveyed textile 420 deforms as it passes between the rollers 462, 464.

The invention is further illustrated by the following examples, which, as mentioned above, are for illustrative purposes only and are not intended to limit the invention. Various modifications may be made to the examples provided without departing from the scope of the invention.

Example 1

In this example, the continuous digital dyeing process described in WO 2020/208362 is used for the roll-to-roll deposition step. Commercially available disperse dyes were applied to 100% polyester textiles with high precision and control over uniformity and wet add-on. The digital method ensures that all deposited dye is required for the target shade, ensuring that no washing step is required to remove excess dye to achieve good color fastness. The resulting wet loaded textile is passed through an Infrared (IR) fixation chamber to remove the carrier water used in the deposition process. The use of IR further improves the uniformity of the dye across the width of the textile and ensures limited agglomerate formation during the wetting of the textile.

The resulting roll of dried dyed textile is then transferred to a first chamber set at a temperature of 200 ℃. The speed of the processing line was then set to allow the textile to dwell in the first chamber for 5 minutes. The heat treated rolls were held in the first chamber to ensure that heat was not lost from the rolls and the heat treated rolls were cut to a set size of 100 meters in length.

The 100 meter discrete roll was then moved into the second chamber for two hours for additional treatment. To ensure that the productivity of the fixation unit is maintained, several rolls are cut in sequence and stored in the second chamber, ensuring that each roll is exposed to the same thermal conditions. The rolls are then removed and stored for cooling.

Additional diffusion occurs during the cooling step. Due to the low thermal conductivity of the textile, the substrate closest to the core will remain at a sufficient temperature to allow further diffusion enhancement.

The resulting product has improved color fastness while the hand of the textile is unaffected.

Example 2

The dye deposition method was the same as that applied to example 1.

The resulting roll of dried dyed textile was then transported in a roll-to-roll fashion into a first chamber set at a temperature of 170 ℃. In addition, steam is added to the first chamber to create a high humidity environment. The speed of the processing line was then set to allow the textile to stay in the heated steam zone for 8 minutes. The treated substrate was then loosely folded into an insulated drum (insulated drum) and cut to a specific length of 500 meters. The insulated drum was then heated to 180 ℃ by an external heat source for 1 hour for additional heat treatment. The resulting product has improved color fastness while the hand of the textile is unaffected.

The resulting textile roll may be maintained in an insulated environment, such as a second chamber, to limit cooling of the textile. This extends the time at a temperature deemed sufficient for thermally enhanced diffusion. The thermally insulating carrier is also removable to ensure that the dyed textile can be removed.

Example 3

In the method using the digital dyeing method, commercially available dyes having high color fastness properties and minimal or no formulation aids are applied. An accurate amount of dye is applied to achieve the target shade and IR heating is used to dry the loaded textile. The wash-free fastness properties of the process can be further improved using minimal or colourless adjuvants, such as surfactants or levelling agents.

The dried dyed substrate was then treated in a fixation chamber at 220 ℃ for 3 minutes. The resulting hot substrate is rewound into a consolidated roll in the first chamber to ensure that the textile retains heat, minimizing any additional heating required to maintain the target temperature. The resulting rolls are then moved into a second chamber where one or more rolls are incubated (incubated) for a series of temperature steps and for different times. The specific temperature profile is dye and/or textile specific. However, the temperature profile usually takes the form of a 20 ℃ step from 180 ℃ to 140 ℃ with a typical time per step of 20 minutes. This will be controlled by the second chamber.

Example 4

The dye deposition method was the same as that applied to example 1.

Commercially available disperse dyes are applied with high precision and control of uniformity and wet pick up. The digital method ensures that almost all of the deposited dye is required for the target shade, ensuring that after drying by IR heating and an initial heat treatment in the fixation chamber at 200 ℃ for 5 minutes, the residual excess unfixed dye on the surface is minimal.

The resulting feedstock is then treated by exposure to a combination of a recycle fluid stream, water, and a silicone softener. The fluid was applied to the textile through the nozzle at a flow rate of 15 liters/min, providing a wet pick-up of 150% of the original source textile weight. The textile is then agitated by the use of a textured roller to provide movement between the fibers and to expose any excess dye to the fluid. This mechanical agitation treatment also increases the penetration of the surface treatment chemical (finishing chemistries). Vacuum removal was then used to reduce the wet pick-up to 20%. The process of applying, agitating and removing is repeated to obtain the best results. The resulting high color fastness textile is then dried to a wet increment of <10% and the fluid removed from the textile by vacuum is continuously recovered by filtration and reverse osmosis to produce pure water throughout the treatment.

Example 5

The dye deposition method was the same as that applied to examples 1, 2 and 4.

The resulting dyeing raw material is then treated by exposure to a recirculating fluid bath. The textile is immersed in the fluid bath and a wet pick-up of 300% of the weight of the textile is obtained. Agitation is then generated in the textile by reducing the wet pick-up to 100% after the bath using a nip roller and mechanically agitating by applying a rotating brush at a speed of 5X relative to the wire speed. The fluid is then removed by vacuum, yielding a wet increment of 40%, and recovered by filtration and circulated within the fluid system. The resulting textile is dried to full dryness by heating.

Various further aspects and embodiments of the present invention will be apparent to those skilled in the art in view of this disclosure. As used herein, "and/or" is considered a specific disclosure of each of two particular features or components, with or without the other. For example, "a and/or B" is considered a specific disclosure of each of (i) a, (ii) B, and (iii) a and B, as if each were individually set forth herein.

Unless the context indicates otherwise, the description and definition of the features above is not limited to any particular aspect or embodiment of the invention, but applies equally to all aspects and embodiments described. It will be further understood by those skilled in the art that while the present invention has been described by way of example with reference to several embodiments, the invention is not limited to the embodiments disclosed and that alternative embodiments may be constructed without departing from the scope of the invention as defined in the appended claims.

Claims

1. A method for improving the color fastness of dyed textiles, the method comprising:

conveying the dyed textile in a first direction along a processing line;

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

subsequently removing at least 50% of the applied fluid from the dyed textile;

removing contaminants from the fluid; and

the fluid is returned to the reservoir.

2. The method of claim 1, further comprising: mechanically agitating the dyed textile.

3. The method according to any of the preceding claims, wherein the total mass of fluid applied to the dyed textile is up to 500% of the mass of the dyed textile.

4. The method of any of the preceding claims, wherein the fluid is applied to the dyed textile at a rate of 1-50 liters per minute.

5. The method of any of the preceding claims, further comprising: the fluid is heated to above 40 ℃.

6. The method of any of the preceding claims, further comprising: the fluid is heated to above 50 ℃.

7. The method of any of the preceding claims, further comprising: the fluid is heated to above 60 ℃.

8. The method of any of the preceding claims, further comprising: the fluid is heated to above 70 ℃.

9. The method of any one of claims 1 to 5, further comprising: the fluid is heated to 40 ℃ to 80 ℃.

10. The method of any one of claims 1 to 6, further comprising: the fluid is heated to 50 ℃ to 70 ℃.

11. The method of any of the preceding claims, further comprising:

determining an acceptable flow rate range for the applied fluid;

monitoring the flow rate of the applied fluid;

if the flow rate of the applied fluid is outside the acceptable flow rate range, the flow rate of the applied fluid is adjusted.

12. The method of any of the preceding claims, wherein the fluid is sprayed onto the dyed textile.

13. The method of any of the preceding claims, wherein the fluid comprises an additive configured to increase the color fastness of the textile.

14. An apparatus for improving the color fastness of dyed textiles, the apparatus comprising:

A processing line for transporting the textile in a first direction;

a reverse osmosis unit comprising a fluid reservoir for holding a fluid and a filtration unit for removing contaminants from the fluid;

a fluid applicator configured to apply the fluid to the textile in a second direction substantially opposite the first direction;

a fluid removal device configured to remove the fluid from the textile and return the removed fluid to the reverse osmosis unit.

15. The apparatus of claim 14, wherein the fluid applicator comprises a nozzle.

16. Apparatus according to claim 14 or 15, wherein the fluid removal device is configured to create a partial vacuum in use.

17. The apparatus of any one of claims 14 to 16, further comprising a mechanical agitator.

18. The apparatus of claim 17, wherein the mechanical agitator comprises at least one shaft, the mechanical agitator moving relative to the shaft.

19. The apparatus of claim 16 or 17, wherein the mechanical agitator is configured to agitate the textile between application of the fluid and removal of the fluid.

20. The apparatus of any one of claims 17 to 19, wherein the mechanical agitator is a roller.

21. The apparatus of any one of claims 17 to 20, wherein the mechanical agitator is a pair of rollers.

22. The apparatus of any one of claims 17 to 21, wherein the roller has a textured surface.

23. The apparatus of claim 22, wherein the textured surface is knurled.

24. The apparatus of any of claims 14-19, wherein the textured surface has a spiral pattern.