Closed-loop textile dyeing process utilizing real-time metered dosing of dyes and chemicals

Claim 2

A process for dyeing a fibrous article with at least one dye comprising: (a) immersing said article in a suitably heated liquid bath of a solvent medium for said dye, said liquid bath having a predetermined alkaline pH; (b) adding acid to said dyeing bath during dyeing to reduce the pH according to a predetermined profile that is responsive to real-time measurements of dyeing bath pH; (c) adding said dye to said dyeing bath during dyeing as a liquid concentrate in a variable manner that is responsive to real-time calculations of dye uptake by said fibrous article, said adding of said dye occurring independently of said adding of said acid; (d) determining in real-time during dyeing (1) the solution concentration of said dye in said dyeing bath and (2) the amount of said dye added to said dyeing bath, and calculating the dye uptake by said fibrous article from (1) and (2 ); (e) adjusting the rate of addition of said dye to said dyeing bath during dyeing in accordance with said real-time calculated dye uptake by said fibrous article, wherein said adjustment off the rate of addition of said dye is made according to a predetermined exhaustion profile; and (f) controlling said dye uptake by said fibrous article from said dyebath such that said dye uptake follows said predetermined exhaustion profile, whereby said dyeing of said fibrous article is accomplished.

Claim 3

The process of claim 1 wherein said fibrous article is a nylon article.

Claim 4

The process of claim 1 wherein said at least one dye comprises two or more acid dyes.

Claim 5

The method of claim 3, wherein said two or more dyes comprises at least three dyes.

Claim 6

The process of claim 3 further comprising independently adjusting the rate of addition of each of said dyes to the dyeing bath during dyeing in accordance with a predetermined desired ratio of said dyes on said fibrous article during the dyeing process.

Claim 7

The process of claim 1 wherein said liquid bath is heated to about 82° C.

Claim 8

The process of claim 1 wherein said acid is selected from the group consisting of glacial acetic acid and in acetic acid.

Claim 9

The method of claim 1, wherein the predetermined exhaustion profile is further characterized as a profile that profiles for on-tone build-up of shade.

Claim 10

The process of claim 1 wherein said dye is added to said dyeing bath by precision dosing with a metering pump.

Claim 11

The process of claim 1 wherein said calculating of the dye uptake of said fibrous article and said adjusting of the rate of addition of said dyes during dyeing is controlled by a computer.

Claim 12

The process of claim 1 further comprising reusing the exhausted dye bath upon completion of steps (a)-(e).

Claim 13

The process according to claim 1 further comprising utilizing prepackaged liquid concentrate dyes for said dyeing process and thereby eliminating use of a conventional dye drug room.

Claim 14

A process for dyeing a fibrous article with at least two dyes comprising: (a) immersing said article in a suitably heated liquid bath of a solvent medium for said dyes, said liquid bath having a predetermined alkaline pH; (b) adding acid to said dyeing bath during dyeing to reduce the pH according to a predetermined profile that is responsive to real-time measurements of dyeing bath pH; (c) adding said dyes to said dyeing bath during dyeing as liquid concentrates in a variable manner that is responsive to real-time calculations of dye uptake of each of said dyes by said fibrous article, said adding of said dyes occurring independently of said adding of said acid; (d) determining in real-time during dyeing (1) the solution concentration of each of said dyes in said dyeing bath and (2) the amount of each of said dyes added to said dyeing bath, and calculating the uptake of each of said dyes by said fibrous article from (1) and (2); (e) adjusting the rate of addition of said dyes to said dyeing bath during dyeing in accordance with said real-time calculated uptake of said dyes by said fibrous article to maintain a predetermined desired ratio of said dyes on said fibrous article during the dyeing process, wherein said adjustment of the rate of addition of said dye is made according to a predetermined exhaustion profile; and (f) controlling said dye uptake by said fibrous article from said dyebath such that said dye uptake follows said predetermined exhaustion profile, whereby said dyeing of said fibrous article is accomplished.

Claim 15

A process for dyeing a fibrous article with at least two dyes comprising: (a) immersing said article in a suitably heated liquid bath of a solvent medium for said dyes, said liquid bath having a predetermined alkaline pH; (b) adding acid to said dyeing bath during dyeing to reduce the pH according to a predetermined profile that is responsive to real-time measurements of dyeing bath pH; (c) adding said dyes to said dyeing bath during dyeing as liquid concentrates in a variable manner that is responsive to real-time calculations of dye uptake of each of said dyes by said fibrous article, said adding of said dyes occurring independently of said adding of said acid; (d) determining in real-time during dyeing (1) the solution concentration of each of said dyes in said dyeing bath and (2) the amount of each of said dyes added to said dyeing bath, and calculating the uptake of each of said dyes by said fibrous article from (1) and (2); (e) adjusting the rate of addition of said dyes to said dyeing bath during dyeing in accordance with said real-time calculated uptake of said dyes by said fibrous article to maintain a predetermined desired ratio of said dyes on said fibrous article during the dyeing process, wherein said adjustment of the rate of addition of said dye is made according to a predetermined exhaustion profile; and (f) controlling said dye uptake by said fibrous article from said dyebath such that said dye uptake follows said predetermined exhaustion profile, whereby said dyeing of said fibrous article is accomplished.

Claim 16

The process of claim 13 wherein said fibrous article is a nylon article.

Claim 17

The process of claim 13 wherein said at least two dyes is selected from the group consisting of two dyes and three dyes.

Claim 18

The process of claim 15 wherein said dyes consist of acid dyes.

Claim 19

The process of claim 15 further comprising independently adjusting the rate of addition of each of said dyes to the dyeing bath during dyeing in accordance with a predetermined desired ratio of said dyes on said fibrous article during the dyeing process.

Claim 20

The process of claim 13 wherein said liquid bath is heated to about 82° C.

Claim 21

The process of claim 13 wherein said acid is selected from the group consisting of glacial acetic acid and 1N acetic acid.

Claim 22

The process of claim 13 wherein said predetermined pH profile comprises maintaining said liquid bath at a predetermined pH of about 8.0 for about fifteen (15) minutes, reducing the pH to about 7.0 in about ten (10) minutes, and further reducing the pH to about 5.0 in about ninety (90) minutes.

Claim 23

The process of claim 13 wherein said dyes are added to said dyeing bath by precision dosing with a metering pump.

Claim 24

The process of claim 13 wherein said calculating of the dye uptake of said fibrous article and said adjusting of the rate of addition of said dyes during dyeing is controlled by a computer.

Claim 25

The process of claim 13 further comprising reusing the exhausted dye bath upon completion of steps (a)-(e).

Claim 26

The process according to claim 13 further comprising utilizing prepackaged liquid concentrate dyes for said dyeing process and thereby eliminating use of a conventional dye drug room.

Claim 27

A process of dyeing a fibrous nylon article with at least two acid dyes comprising: (a) immersing said article in a suitably heated liquid bath of a solvent medium for said dyes, said liquid bath having a predetermined alkaline pH of about 8.0; (b) adding acid to said dyeing bath during dyeing to reduce the pH to about 5.0 according to a predetermined profile that is responsive to real-time measurements of dyeing bath pH; (c) adding said acid dyes to said dyeing bath during dyeing as liquid concentrates in a variable manner that is responsive to real-time calculations of dye uptake of each of said dyes by said fibrous article, said adding of said dyes occurring independently of said adding of said acid; (d) determining in real-time during dyeing (1) the solution concentration of each of said dyes in said dyeing bath and (2) the amount of each of said dyes added to said dyeing bath, calculating the uptake of each of said dyes by said fibrous article from (1) and (2), and comparing the ratio of the calculated uptake of said dyes to a desired ratio of said dyes on said fibrous article; (e) adjusting the rate of addition of said dyes to said dyeing bath during dyeing in accordance with said real-time calculated uptake of said dyes by said fibrous article to maintain a predetermined desired ratio of said dyes on said fibrous article during the dyeing process, wherein said adjustment of the rate of addition of said dye is made according to a predetermined exhaustion profile; and (f) controlling said dye uptake by said fibrous article from said dyebath such that said dye uptake follows said predetermined exhaustion profile, whereby said dyeing of said fibrous article is accomplished.

Claim 28

A process of dyeing a fibrous nylon article with at least two acid dyes comprising: (a) immersing said article in a suitably heated liquid bath of a solvent medium for said dyes, said liquid bath having a predetermined alkaline pH of about 8.0; (b) adding acid to said dyeing bath during dyeing to reduce the pH to about 5.0 according to a predetermined profile that is responsive to real-time measurements of dyeing bath pH; (c) adding said acid dyes to said dyeing bath during dyeing as liquid concentrates in a variable manner that is responsive to real-time calculations of dye uptake of each of said dyes by said fibrous article, said adding of said dyes occurring independently of said adding of said acid; (d) determining in real-time during dyeing (1) the solution concentration of each of said dyes in said dyeing bath and (2) the amount of each of said dyes added to said dyeing bath, calculating the uptake of each of said dyes by said fibrous article from (1) and (2), and comparing the ratio of the calculated uptake of said dyes to a desired ratio of said dyes on said fibrous article; (e) adjusting the rate of addition of said dyes to said dyeing bath during dyeing in accordance with said real-time calculated uptake of said dyes by said fibrous article to maintain a predetermined desired ratio of said dyes on said fibrous article during the dyeing process, wherein said adjustment of the rate of addition of said dye is made according to a predetermined exhaustion profile; and (f) controlling said dye uptake by said fibrous article from said dyebath such that said dye uptake follows said predetermined exhaustion profile, whereby said dyeing of said fibrous article is accomplished.

Claim 29

The process of claim 25 wherein said liquid bath is heated to about 82° C.

Claim 30

The process of claim 25 further comprising maintaining said liquid bath at a predetermined pH of about 8.0 for about fifteen (15) minutes, reducing the pH to about 7.0 in ten (10) minutes, and further reducing the pH to about 5.0 in an additional ninety (90) minutes.

Claim 31

The process of claim 25 wherein said at least two acid dyes is selected from the group consisting of two dyes and three dyes.

Claim 32

The process of claim 25 wherein said acid is selected from the group consisting of glacial acetic acid and 1N acetic acid.

Claim 33

The process of claim 25 wherein said dyes are added to said dye bath by precision dosing with a metering pump.

Claim 34

The process of claim 25 wherein said calculation of the dye uptake of said fibrous article and said adjusting of the rate of addition of said dyes during dyeing is controlled by a computer.

Claim 35

The process of claim 25 further comprising reusing the exhausted dye bath upon completion of steps (a)-(e).

Claim 36

The process of claim 25 further comprising independently adjusting the rate of addition of each of said at least two dyes to the dyeing bath during dyeing in accordance with a predetermined desired ratio of said at least two dyes on said fibrous article during the dyeing process.

Claim 37

The process according to claim 25 further comprising utilizing prepackaged liquid concentrate dyes for said dyeing process and thereby eliminating use of a conventional dye drug room.

Claim 38

A process for dyeing a fibrous article with at least one dye comprising: (a) immersing said article in a suitably heated liquid bath of a solvent medium for said dye, said liquid bath having a predetermined pH; (b) adding acid to said dyeing bath during dyeing to reduce the pH according to a predetermined profile that is responsive to real-time measurements of dyeing bath pH; (c) adding said dye to said dyeing bath during dyeing as a liquid concentrate in a variable manner that is responsive to real-time calculations of dye uptake by said fibrous article, said adding of said dye occurring independently of said adding of said acid; (d) determining in real-time during dyeing (1) the solution concentration of said dye in said dyeing bath and (2) the amount of said dye added to said dyeing bath, and calculating the dye uptake by said fibrous article from (1) and (2); (e) adjusting the rate of addition of said dye to said dyeing bath during dyeing in accordance with said real-time calculated dye uptake by said fibrous article, wherein said adjustment of the rate of addition of said dye is made according to a predetermined exhaustion profile; and (f) controlling said dye uptake by said fibrous article from said dyebath such that said dye uptake follows said predetermined exhaustion profile, whereby said dyeing of said fibrous article is accomplished.

Claim 39

A process for dyeing a fibrous article with at least one dye comprising: (a) immersing said article in a suitably heated liquid bath of a solvent medium for said dye, said liquid bath having a predetermined pH; (b) adding acid to said dyeing bath during dyeing to reduce the pH according to a predetermined profile that is responsive to real-time measurements of dyeing bath pH; (c) adding said dye to said dyeing bath during dyeing as a liquid concentrate in a variable manner that is responsive to real-time calculations of dye uptake by said fibrous article, said adding of said dye occurring independently of said adding of said acid; (d) determining in real-time during dyeing (1) the solution concentration of said dye in said dyeing bath and (2) the amount of said dye added to said dyeing bath, and calculating the dye uptake by said fibrous article from (1) and (2); (e) adjusting the rate of addition of said dye to said dyeing bath during dyeing in accordance with said real-time calculated dye uptake by said fibrous article, wherein said adjustment of the rate of addition of said dye is made according to a predetermined exhaustion profile; and (f) controlling said dye uptake by said fibrous article from said dyebath such that said dye uptake follows said predetermined exhaustion profile, whereby said dyeing of said fibrous article is accomplished.

Claim 40

The method of claim 35, wherein the predetermined exhaustion profile is further characterized as a profile that provides for on-tone build-up of shade.

Claim 41

The process of claim 35 wherein said liquid bath has a predetermined pH between neutral and slightly acidic.

Claim 42

The process of claim 35 wherein said fibrous article is a nylon article.

Claim 43

The process of claim 35 wherein said at least one dye comprises two or more dyes.

Claim 44

The process of claim 39 wherein said dyes consist of acid dyes.

Claim 45

The process of claim 39 further comprising independently adjusting the rate of addition of each of said dyes to the dyeing bath during dyeing in accordance with a predetermined desired ratio of said dyes on said fibrous article during the dyeing process.

Claim 46

The process of claim 35 wherein said liquid bath is heated to about 82° C.

Claim 47

The process of claim 35 wherein said acid is selected from the group consisting of glacial acetic acid and 1N acetic acid.

Claim 48

The process of claim 35 wherein said predetermined pH profile comprises maintaining said liquid bath at a predetermined pH of about 8.0 for about fifteen (15) minutes, reducing the pH to about 7.0 in about ten (10) minutes, and further reducing the pH to about 5.0 in about ninety (90) minutes.

Claim 49

The process of claim 35 wherein said dye is added to said dyeing bath by precision dosing with a metering pump.

Claim 50

The process of claim 35 wherein said calculating of the dye uptake of said fibrous article and said adjusting of the rate of addition of said dyes during dyeing is controlled by a computer.

Claim 51

The process of claim 35 further comprising reusing the exhausted dye bath upon completion of steps (a)-(e).

Claim 52

The process according to claim 35 further comprising utilizing prepackaged liquid concentrate dyes for said dyeing process and thereby eliminating use of a conventional dye drug room.

Claim 53

The method of claim 39, wherein said two or more dyes comprises at least three dyes.

Claim 54

The method of claim 13, wherein the predetermined exhaustion profile is further characterized as a profile that provides for on-tone build-up of shade.

Claim 55

The method of claim 25, wherein the predetermined exhaustion profile is further characterized as a profile that provides for on-tone build-up of shade.