Methods and apparatuses for processing textile fibers, kettle automatic operation devices, and textile fiber products

A method for processing textile fibers is provided. The method comprises: adding a plurality of raw materials for processing textile fibers into a plurality of kettles; preparing supercritical carbon dioxide; obtaining one or more natural plant dyes and one or more natural plant extracts from the plurality of raw materials, and dissolving the one or more natural plant dyes and the one or more natural plant extracts in the supercritical carbon dioxide; dyeing and functionally modifying the textile fibers simultaneously by using the supercritical carbon dioxide carrying a mixture of the one or more natural plant dyes and the one or more natural plant extracts; performing a post-process to recycle the supercritical carbon dioxide; and performing a cleaning process to clean the one or more natural plant dyes and one or more natural plant extracts.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to Chinese Patent Application No. 201710213544.X, filed on Apr. 1, 2017, Chinese Patent Application No. 201710668883.7, filed on Aug. 8, 2017, Chinese Patent Application No. 201720980428.6, filed on Aug. 8, 2017, the entire contents of all of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to the field of textile fiber manufacturing technology and, more particularly, to methods and apparatuses for processing textile fibers, related kettle automatic operation devices, and related textile fiber products.

BACKGROUND

Natural fibers, as the important material sources of the textile industry, are textile fibers directly obtained from natural or artificial cultivation of plants and artificial breeding animals. At present, natural fibers are the most important raw materials of the textile industry.

The naturally existing natural fibers include cotton, linen, silk, and animal hair, etc. The molecular components of cotton and hemp are mainly cellulose. The molecular components of silk and hair are mainly proteins in the form of polyamide polymer.

Chemical fibers are manufactured fibers that have textile properties. The raw materials of the chemical fibers are natural polymer compounds or synthetic polymer compounds. A typical manufactural process of a chemical fiber includes preparation of spinning dope, spinning, and post-processing, etc.

Chemical fibers include man-made fibers and synthetic fibers. The man-made fibers include viscose fiber, nitrate fiber, acetate fiber, copper ammonium fiber, and artificial protein fiber. The viscose fiber includes ordinary viscose fiber and outstanding performance viscose fiber. The synthetic fibers are made of synthetic polymer compounds. The synthetic fibers include polyester fiber, polyamide fiber, polyacrylonitrile fiber, etc.

The extraction of natural plant dyes, the conventional dyeing and functional modification of natural fibers include a process of wet chemical reaction, which consumes a lot of water resources and chemicals, and produces a lot of waste water that is highly concentrated, highly COD colored, smell, and even toxic. Such waste water causes serious pollutions to surrounding waters and ecological environments. Further, the extraction step and dyeing step in the existing fiber processes require dedicated devices, and various kettles are manually operated. As such, a one-time input cost and the energy consuming are high, and the process efficiency is low.

Accordingly, methods and apparatuses for processing textile fibers, related kettle automatic operation devices, and related textile fiber products are desired to be provided.

SUMMARY

One aspect of present disclosure provides a method for processing textile fibers, comprising: adding a plurality of raw materials for processing textile fibers into a plurality of kettles; preparing supercritical carbon dioxide; obtaining one or more natural plant dyes and one or more natural plant extracts from the plurality of raw materials, and dissolving the one or more natural plant dyes and the one or more natural plant extracts in the supercritical carbon dioxide; dyeing and functionally modifying the textile fibers simultaneously by using the supercritical carbon dioxide carrying a mixture of the one or more natural plant dyes and the one or more natural plant extracts; performing a post-process to recycle the supercritical carbon dioxide; and performing a cleaning process to clean the one or more natural plant dyes and one or more natural plant extracts.

In some embodiments, adding the plurality of raw materials for processing textile fibers into the plurality of kettles includes: automatically opening, using a kettle automatic operation device, kettle covers of a natural plant dye extraction kettle, a natural plant dyes and extracts kettle, and a dyeing and functional modification kettle; adding textile fibers to be dyed and functionally modified into the dyeing and functional modification kettle; adding one or more natural plant extracts into the natural plant dyes and extracts kettle; adding one or more natural plants into the natural plant dye extraction kettle; and automatically closing, using the kettle automatic operation device, the kettle covers of the plant dye extraction kettle, the natural plant dyes and extracts kettle, and the dyeing and functional modification kettle.

In some embodiments, adding the plurality of raw materials for processing textile fibers into the plurality of kettles includes: automatically opening, using a kettle automatic operation device, kettle covers of a natural plant dye extraction kettle, a natural plant dyes and extracts kettle, and a dyeing and functional modification kettle; adding textile fibers to be dyed and functionally modified into the dyeing and functional modification kettle; adding one or more natural plant extracts and one or more natural plant dyes into the natural plant dyes and extracts kettle; and automatically closing, using the kettle automatic operation device, the kettle covers of the plant dye extraction kettle, the natural plant dyes and extracts kettle, and the dyeing and functional modification kettle.

In some embodiments, preparing supercritical carbon dioxide includes: injecting the liquid carbon dioxide stored in a carbon dioxide storage tank into a carbon dioxide high pressure pump; increasing the pressure of the liquid carbon dioxide in the carbon dioxide high pressure pump to about 30 Mpa-32 MPa; and heating the liquid carbon dioxide in the carbon dioxide high pressure pump to about 90° C.-120° C.

In some embodiments, obtaining one or more natural plant dyes and one or more natural plant extracts from the plurality of raw materials and dissolving the one or more natural plant dyes and the one or more natural plant extracts in the supercritical carbon dioxide includes: extracting one or more natural plant dyes of the one or more natural plants in the natural plant dye extraction kettle; dissolving the one or more natural plant extract in the supercritical carbon dioxide respectively in the natural plant dye extraction kettle; dissolving the one or more natural plant dyes in the supercritical carbon dioxide respectively in the natural plant dyes and extracts kettle; and mixing the supercritical carbon dioxide carrying the one or more natural plant dyes and the supercritical carbon dioxide carrying the one or more natural plant extracts in a mixing kettle.

In some embodiments, a time period for dyeing and functionally modifying the textile fibers simultaneously by using the supercritical carbon dioxide carrying a mixture of the one or more natural plant dyes and the one or more natural plant extracts is in a range from 90 minutes to 150 minutes.

In some embodiments, the post-process includes: separating the supercritical carbon dioxide from the one or more natural plant dyes and the one or more natural plant extracts by converting the supercritical carbon dioxide into gaseous carbon dioxide; and converting the gaseous carbon dioxide into liquid carbon dioxide.

In some embodiments, the cleaning process includes: injecting the liquid carbon dioxide from a carbon dioxide storage tank into a carbon dioxide high pressure pump; increasing a pressure and a temperature of the liquid carbon dioxide in the high-pressure pump; adding a solubilizing agent into a dyeing and functional modification kettle to dissolve the one or more natural plant dyes and the one or more natural plant extracts; and separating the liquid carbon dioxide from the one or more natural plant dyes and the one or more natural plant extracts.

In some embodiments, the textile fibers include at least one of natural cotton fiber, natural linen fiber, natural silk fiber, natural wool fiber, and polyester fiber; the one or more natural plant extracts include at least one of mint extract, wormwood extract, and grass coral extract; and the one or more natural plant dyes include at least one of rose dye, violet dye, safflower dye, and perilla dye.

In some embodiments, a mass ratio of the textile fibers and the one or more natural plants is in a range from about 20:1 to about 10:1; and a mass ratio of the textile fibers and the one or more natural plant extracts is in a range from about 20:1 to about 10:1.

In some embodiments, a mass ratio of the textile fibers and the one or more natural plant dyes is in a range from about 50:1 to about 20:1; and a mass ratio of the textile fibers and the one or more natural plant extracts is in a range from about 20:1 to about 10:1.

Another aspect of the present disclosure provides an apparatus for processing textile fibers, comprising: a natural plant dye extraction kettle for extracting one or more natural plant dyes from one or more natural plants; a natural plant dyes or extracts kettle for storing one or more natural plant dyes and one or more natural plant extracts; a supercritical carbon dioxide preparation device for preparing supercritical carbon dioxide; a mixing kettle for dissolving one or more natural plant dyes and one or more natural plant extracts in the supercritical carbon dioxide; a dyeing and functional modification kettle for dyeing and functionally modifying the textile fibers simultaneously by using the supercritical carbon dioxide carrying a mixture of the one or more natural plant dyes and the one or more natural plant extracts; and a post-processing device for recycling the supercritical carbon dioxide.

In some embodiments, the supercritical carbon dioxide preparation device includes: a carbon dioxide storage tank for storing liquid carbon dioxide; and a carbon dioxide high pressure pump for increasing the pressure of the liquid carbon dioxide.

In some embodiments, the apparatus further comprises: one or more preheaters for heating the carbon dioxide high pressure pump, the natural plant dye extraction kettle, the natural plant dyes and extracts kettle, and the dyeing and functional modification kettle.

In some embodiments, the post-processing device includes: a separating kettle for separating the supercritical carbon dioxide from the one or more natural plant dyes and the one or more natural plant extracts by converting the supercritical carbon dioxide into gaseous carbon dioxide; and a condensing kettle for converting the gaseous carbon dioxide into liquid carbon dioxide.

In some embodiments, the apparatus further comprises: a kettle automatic operation device for automatically opening and closing kettle covers of the natural plant dye extraction kettle, the natural plant dyes and extracts kettle, and the dyeing and functional modification kettle.

In some embodiments, the kettle automatic operation device includes: a frame including an upper bracket, a support beam, a fixed base plate, and expansion bolts; a stretching mechanism for moving the kettle covers in a vertical direction; a rotation mechanism connecting with the stretching mechanism for rotating the kettle covers; and a slide mechanism on the upper bracket for moving the stretching mechanism and the rotation mechanism in a horizontal direction.

In some embodiments, the slide mechanism includes: a slide rail on the upper bracket; one or more sliders that are capable sliding on the slide rail; a mounting plate on the one or more sliders, wherein the mounting plate is connected with one of the stretching mechanism and the rotation mechanism; and two stoppers located on both ends of the slide rail respectively.

In some embodiments, the rotation mechanism includes: a motor connected to the mounting plate; a universal coupling connected to an output end of the motor; a rotation shaft connected to the universal coupling; a cylinder release plate connected to the rotation shaft; and a control apparatus for controlling the operation of the motor.

In some embodiments, the stretching mechanism includes: an air pump; a cylinder located on the magnet placing plate, and connected to the air pump through an air pipe; a magnet placing plate connected to a piston of the cylinder; a magnet located below the magnet placing plate; and a solenoid valve having a first end connecting to the cylinder and a second end connected to the control apparatus; wherein the control apparatus is further configured for controlling the operation of the cylinder through the solenoid valve.

DETAILED DESCRIPTION

Embodiments of the disclosure will be described in detail with reference to the accompanying drawings. The following description is made only by way of example, but does not limit the present disclosure. Various embodiments of the present disclosure and various features in the embodiments that do not conflict with each other can be combined and rearranged in various ways. Without departing from the spirit and scope of the present disclosure, modifications, equivalents, or improvements to the present disclosure are conceivable to those skilled in the art and are intended to be encompassed within the scope of the present disclosure.

In some embodiments, methods and apparatuses for processing textile fibers, related kettle automatic operation devices, and related textile fiber products are provided to at least solve the following technical problems.

In the disclosed methods for processing textile fibers, the textile fibers can be dyed and functional modified by using supercritical carbon dioxide, without using water or other reagents as a solvent. As such, there is no generation and emissions of waste water and waste byproducts during the entire processing. Therefore, the disclosed methods for processing textile fibers are environmental-friendly functional modification processes.

The disclosed methods used for natural fiber dyeing and modification can have a fast and short process. The operations of the kettles during the process can be automatic without any manual operations. Thus, the labor intensity can be reduced and the efficiency of the disclosed methods is high. The cost of post-processing can be saved, and the production costs can be reduced.

The raw materials used in the disclosed methods for natural fiber dyeing and modification using supercritical carbon dioxide, including carbon dioxide, natural plant dyes, and natural plant extracts, can be fully recycled for a repeated use. Therefore, the production costs can be decreased, and potential pollution can be reduced. The disclosed methods for processing textile fibers can have good social benefits and can be widely used in the textile industry.

The fabrics, garments, home textiles and other textile products manufactured by the disclosed methods do not go through a bleaching process, therefore have no chemical reagent residue, are highly secure to human skin. Further, the fabrics, garments, home textiles and other textile products manufactured by the disclosed methods can have excellent antibacterial and bacteriostatic properties.

The natural fibers processed by the disclosed methods can have uniform colors and excellent color reproducibility. The disclosed methods used for natural fiber dyeing and modification using supercritical carbon dioxide do not damage the natural fibers. The fabric products manufactured by the disclosed methods can have good physical properties, and a color washing fastness up to five degree.

In some embodiments, any suitable textile fibers, including natural fibers and chemical fibers, can be processed by the disclosed methods and apparatuses. For example, the textile fibers can include but not limited to cotton, hemp, silk, polyester, etc.

Referring toFIG. 1, a schematic structure diagram of an exemplary apparatus for processing textile fibers in accordance with the present disclosure. In one embodiment, the apparatus for processing textile fibers may be a machine having one or more integrated machine components. In another embodiment, the apparatus for processing textile fibers may be a flower-dyeing machine, for example, using flowers as dyes for processing the disclosed textile fibers.

The apparatus100for processing textile fibers can include a natural plant dye extraction kettle111, a natural plant dyes and extracts kettle113, a mixing kettle115, a dyeing and functional modification kettle117, a kettle automatic operation device200, one or more filters120, one or more preheaters122, a supercritical carbon dioxide preparation device130, and a post-processing device140.

In some embodiments, the supercritical carbon dioxide preparation device130can include a carbon dioxide high pressure pump134and a carbon dioxide storage tank136. The carbon dioxide storage tank136can be used to store liquid carbon dioxide.

The carbon dioxide storage tank136can be connected to the carbon dioxide high pressure pump134through a pipeline. The liquid carbon dioxide stored in the carbon dioxide storage tank136can be injected into the carbon dioxide high pressure pump134to increase the pressure. In some embodiments, the carbon dioxide can be pressurized to about 30 Mpa to about 32 MPa in the carbon dioxide high pressure pump134.

The carbon dioxide high pressure pump134can be heated by one preheater122. In some embodiments, the preheater122can heat the carbon dioxide to about 90° C. to about 120° C. to obtain the supercritical carbon dioxide.

The natural plant dye extraction kettle111can be used to extract dye from natural plants. The natural plant dye extraction kettle111can be connected to the carbon dioxide high pressure pump134. The supercritical carbon dioxide can be injected into the natural plant dye extraction kettle111to dissolve the pigments in the natural plants. According to different temperatures and different pressures of the supercritical carbon dioxide, the effective components in the pigments of different plants may have different degrees of solubility in the supercritical carbon dioxide. As such, the dyes can be extracted from the natural plants.

The natural plant dyes and extracts kettle113can be used to dissolve the natural plant dyes or plant extracts in the supercritical carbon dioxide. The natural plant dyes and extracts kettle113can be connected to the carbon dioxide high pressure pump134. The supercritical carbon dioxide can be injected into the natural plant dyes and extracts kettle113, and can keep a pressure of about 30 Mpa to about 32 MPa and a temperature of about 90° C. to about 120° C. The natural plant dyes and/or natural plant extracts can be fully contacted with the supercritical carbon dioxide in the natural plant dyes and extracts kettle113. As such, the natural plant dyes and/or natural plant extracts can be evenly dispersed and dissolved in the supercritical carbon dioxide.

The mixing kettle115can be connected to both of the natural plant dye extraction kettle111and the natural plant dyes and extracts kettle113through pipelines. The supercritical carbon dioxide carrying the extracted plant dyes, and the supercritical carbon dioxide carrying the natural plant extracts can pass through the one or more filters120, and go into the mixing kettle117to be evenly mixed.

The dyeing and functional modification kettle117can be connected to the mixing kettle115through a pipeline. In some embodiments, the textile fibers to be dyed or modified can be put into the dyeing and functional modification kettle117, can be heated by one preheater122to about 90° C. to about 120° C., and be increased the pressure to 30 Mpa. Then, the supercritical carbon dioxide in the mixing kettle117can be injected into the dyeing and functional modification kettle117. The supercritical carbon dioxide can be circulated in the dyeing and functional modification kettle117to fully mix with the textile fibers for about 120 minutes to about 180 minutes. As such, the textile fibers can be dyed or modified in the dyeing and functional modification kettle117.

FIG. 2illustrates a schematic structure diagram of an exemplary kettle automatic operation device in accordance with the present disclosure. The kettle automatic operation device200can automatically open and close one or more kettles1without manual operation, thereby reducing the labor intensity, reducing the operating time, improving the work efficiency and facilitating the fiber processing.

As shown, the kettle automatic operation device200can include a frame2, at least one slide mechanism3, at least one rotation mechanism4, and at least one stretching mechanism5. The one or more kettles1can include a natural plant dye extraction kettle111, a natural plant dyes and extracts kettle113, a dyeing and functional modification kettle117shown inFIG. 1.

The frame2can include an upper bracket21, a support beam22, a fixed base plate23, and expansion bolts24. The support beam22is located on the fixed base plate23. The upper frame21is located on the support beam22. The expansion bolts24are located on the four sides of the fixed base plate23.

In some embodiments, the frame2can include multiple support beams22and multiple fixed base plates23. One support beam22can be located in correspondence with one fixed base plate23. The upper frame21can include an upper horizontal beam211and an upper vertical beam212. The upper horizontal beam211and the upper vertical beam212can be arranged vertically crossed with each other. The expansion bolts24can fix the support beams22to a base or the ground. The frame2can be placed above the one or more kettles1. In some embodiments, the frame2can extend in a direction of the arrangement of multiple kettles1.

The slide mechanism3can includes a slide rail31, a mounting plate32, and one or more sliders33. The slide rail31can be located on the upper frame21along a longitudinal direction of the upper frame21. The one or more sliders33can be located on the slide rail31. The mounting plate32is located on the one or more sliders33.

Two stoppers34can be located on the upper frame21on both sides of the slide rail31for preventing the derailment accident. When the one or more sliders3are moving along the slide rail31, the one or more sliders3can drive the mounting plate32to move from a first position above one kettle1to a second position above another kettle1.

FIG. 3illustrates a schematic structure diagram of an exemplary rotation mechanism and an exemplary stretching mechanism of a kettle automatic operation device in accordance with the present disclosure.FIG. 4illustrates a schematic structure diagram of an exemplary kettle cover and an exemplary magnet of a kettle automatic operation device in accordance with the present disclosure.

The rotation mechanism4can be located on the mounting plate32. The rotation mechanism4can include a motor41, a universal coupling42, a rotation shaft43, a control apparatus44, and a cylinder release plate45. The motor41can be connected to the mounting plate32. An output end of the motor41can be connected to one end of the universal coupling42. Another end of the universal coupling42can be connected to one end of the rotation shaft43. The cylinder release plate45can be located on another end of the rotation shaft43.

The stretching mechanism5can include an air pump51, a cylinder52, a magnet placing plate53, a magnet54, an air pipe55, and a solenoid valve56. The cylinder52can be located on the magnet placing plate53. The cylinder52can be connected to the air pump51through the air pipe55.

A piston of the cylinder52can be connected to the magnet placing plate53. The magnet54can be located below the magnet placing plate53. One end of the solenoid valve56can be connected to the cylinder52, and another end of the solenoid valve56can be connected to the control apparatus44. The control apparatus44can control the operation of the cylinder52through the solenoid valve56.

Each of the one or more kettles1can include a kettle body11and a kettle cover12. A recessed groove121can be located on an upper portion of the kettle cover12, and be symmetric respect to a central axis of the kettle cover12, and can penetrate the kettle cover12in a horizontal direction. The magnet54can have a square shape, and can be arranged to match the recessed groove121.

In some embodiments, the kettle cover12of the kettle1can be opened and closed by rotating the rotation mechanism4. The magnet54can fix the kettle cover12to the stretching mechanism5. The kettle cover12can be fastened by the magnet54to prevent from slipping.

When the motor41of the rotation mechanism4is rotating in a positive direction, the kettle cover12can be rotated in the positive direction alone with the rotation mechanism4due to the magnet54. Driven by the cylinder51, the length of the stretching mechanism5can be shorten. The control apparatus44can coordinate the rotation mechanism4and the stretching mechanism5to continuously raise the kettle cover12. As such, the kettle cover12can be separated from the kettle body11.

Similarly, when the motor41of the rotation mechanism4is rotating in a negative direction, the kettle cover12can be rotated in the negative direction alone with the rotation mechanism4due to the magnet54. Driven by the cylinder51, the length of the stretching mechanism5can be lengthen. The control apparatus44can coordinate the rotation mechanism4and the stretching mechanism5to continuously lower the kettle cover12. As such, the kettle cover12can be tightened with the kettle body11.

Therefore, the kettle cover12of the kettle1can be opened and closed by rotating the rotation mechanism4, thereby reducing the labor intensity, reducing the operating time, improving the work efficiency and facilitating the fiber processing.

In some embodiments, one or more sensors6can be located on the upper frame21. The one or more sensors can be electrically connected to the control apparatus44. In some embodiments, each sensor6can be located in correspondence with one kettle1. When the rotation mechanism4moves to a position above one kettle1, the sensor6corresponding to the one kettle can receive a signal. The sensor6can cause the rotation mechanism4to stop moving, and to perform a subsequence operation. As such, the multiple kettles1can be operated by the rotation mechanism4in turn. The position correspondence between the rotation mechanism4and each kettle1can be determined accurately.

Referring back toFIG. 1, the post-processing device140can include a separating kettle142and a condensing kettle144. The separating kettle142can be used to separate the supercritical carbon dioxide from the natural plant dyes and natural plant extracts. The temperature of the separating kettle142can be set to about 80° C. to about 100° C., and the pressure of the separating kettle142can be set to about 2 MPa to about 3 MPa.

After the separation, the gaseous carbon dioxide can enter the condensing kettle144, and the natural plant dyes and the natural plant extracts can be left in the separating kettle142. The temperature of the condensing kettle144can be set as the room temperature, such as about 20° C. to about 25° C. The pressure of the condensing kettle144can be set as about 4 MPa to about 6 MPa. The gaseous carbon dioxide can be converted into the liquid carbon dioxide for recycling in the condensing kettle144. As such, the liquid carbon dioxide can then reflux into the carbon dioxide storage tank136to participate in a next round of dyeing process or functional modification process.

It is noted that, inFIG. 1, the solid lines with arrows indicate that the components connected by the solid lines are interconnected through one or more pipelines, and the arrows indicates the moving directions of the gas flow or liquid flow. The dotted lines with arrows indicate that the components are heated by the one or more preheaters122, and the arrows indicate the directions of the heat transfer. The hollow dashed lines with arrows indicate that the kettles pointed by the arrows are automatically operated by the kettle automatic operation device200.

FIG. 5illustrates a schematic flow diagram of an exemplary method for processing textile fibers in accordance with the present disclosure. The disclosed method can be implemented by the apparatus100for processing textile fibers described above in connection withFIG. 1.

As shown, at step510, materials for processing textile fibers can be added into multiple kettles.FIG. 6illustrates a schematic flow diagram of an exemplary process for adding materials for processing textile fibers into multiple kettles in accordance with the present disclosure.

At611, a kettle automatic operation device can automatically open kettle covers of a natural plant dye extraction kettle, a natural plant dyes and extracts kettle, and a dyeing and functional modification kettle. The automatic opening operations of the kettle covers by the kettle automatic operation device can be referred to the described above in connection withFIGS. 2-4.

At613, textile fibers to be dyed or modified can be added into the dyeing and functional modification kettle. The textile fibers can include natural fibers, such as cotton, hemp, silk, etc., or chemical fibers, such as polyester, etc., or any fabrics made by the textile fibers. In some embodiments, a weight of the textile fibers added into the dyeing and functional modification kettle can be in a range from about 50 Kg to about 100 Kg.

At615, one or more natural plant extracts can be added into the natural plant dyes and extracts kettle. The natural plant extract can include one or more of the mint extract, the wormwood extract, the grass coral extract, etc. A weight of the one or more natural plant extracts can be in a range from about 0.5 Kg to about 2 Kg. In some other embodiments, one or more natural plant dyes can also be added into the natural plant dyes and extracts kettle. The one or more natural plant dyes can include one or more of the rose dyes, violet dyes, safflower dyes, perilla dyes, etc. A weight of the one or more natural plant dyes can be in a range from about 1 Kg to about 3 Kg.

At617, one or more natural plants can be added into the natural plant dye extraction kettle. The one or more natural plants can include any suitable natural plant flowers or natural plant dried flowers. A weight of the one or more natural plants added into the natural plant dye extraction kettle can be in a range from 5 Kg to 20 Kg.

It is note that, the weights of the one or more natural plants, the one or more natural plant dyes, the one or more natural plant extracts, and the textile fibers described above are merely examples, which do not limit the present disclosure. In some embodiments, a mass ratio of the textile fibers and the one or more natural plant dyes can be in a range from about 50:1 to about 20:1. A mass ratio of the textile fibers and the one or more natural plants can be in a range from about 20:1 to about 10:1. A mass ratio of the textile fibers and the one or more natural plant extracts can be in a range from about 20:1 to about 10:1.

In some embodiments, the selection of the one or more natural plant extracts and/or the one or more natural plat dyes can be determined based on the type of the textile fibers to be dyed or modified. For example, the rose dyes and mint extracts can be selected for dyeing and/or functional modification for natural cotton fibers.

At619, the kettle automatic operation device can automatically close the kettle covers of the plant dye extraction kettle, the natural plant dyes and extracts kettle, and the dyeing and functional modification kettle. The automatic closing operations of the kettle covers by the kettle automatic operation device can be referred to the described above in connection withFIGS. 2-4.

Referring back toFIG. 5, at520, the supercritical carbon dioxide can be prepared.FIG. 7illustrates a schematic flow diagram of an exemplary process for preparing the supercritical carbon dioxide in accordance with the present disclosure.

At722, the liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. At724, the pressure of the liquid carbon dioxide in the carbon dioxide high pressure pump can be increased to about 30 Mpa-32 MPa. At726, the liquid carbon dioxide can be heated to about 90° C.-120° C. As such, the supercritical carbon dioxide can be obtained.

Referring back toFIG. 5, at530, a mixture of the one or more natural plant dyes and the one or more natural plant extracts can be dissolved in the supercritical carbon dioxide.FIG. 8illustrates a schematic flow diagram of an exemplary process for dissolving one or more natural plant dyes and one or more natural plant extracts in the supercritical carbon dioxide in accordance with the present disclosure.

At832, the dyes of the one or more natural plants in the natural plant dye extraction kettle can be extracted. In some embodiments, a pressure of the natural plant dye extraction kettle can be increased to about 30 Mpa to about 32 MPa, and a temperature of the natural plant dye extraction kettle can be increased to about 90° C.-120° C. According to different temperatures and different pressures of the supercritical carbon dioxide, the effective components in the pigments of different plants may have different degrees of solubility in the supercritical carbon dioxide. As such, the pigments in the natural plants can be dissolved in the supercritical carbon dioxide, and the dyes can be extracted from the natural plants. It is noted that, in some other embodiments, when the one or more natural plant dyes are directly added into the natural plant dyes and extracts kettle at515, step832can be omitted.

At834, the one or more natural plant extracts in the natural plant dyes and extracts kettle can be dissolved in the supercritical carbon dioxide. In some embodiments, the supercritical carbon dioxide prepared at520can be injected into the natural plant dyes and extracts kettle. A pressure of the natural plant dyes and extracts kettle can be increased to about 30 Mpa to about 32 MPa, and a temperature of the natural plant dyes and extracts kettle can be increased to about 90° C.-120° C. The supercritical carbon dioxide can be fully contacted with the one or more natural plant extracts. As such, the one or more natural plant extracts can be evenly dispersed and then dissolved in the supercritical carbon dioxide.

In some other embodiments, when the one or more natural plant dyes are also directly added into the natural plant dyes and extracts kettle, the supercritical carbon dioxide can be fully contacted with the one or more natural plant dyes and the one or more natural plant extracts. As such, the one or more natural plant dyes and the one or more natural plant extracts can be evenly dispersed and then dissolved in the supercritical carbon dioxide.

At836, the one or more natural plant dyes and the one or more natural plant extracts can be mixed in a mixing kettle. The supercritical carbon dioxide carrying the one or more natural plant dyes extracted at832can pass through a filter, and enter the mixing kettle through a pipeline. The supercritical carbon dioxide carrying the one or more natural plant prepared at834can pass through a filter, and enter the mixing kettle through another pipeline. The supercritical carbon dioxide carrying the one or more natural plant dyes and the supercritical carbon dioxide carrying the one or more natural plant can be mixed together in the mixing kettle. As such, the one or more natural plant dyes and the one or more natural plant extracts can be evenly dispersed and then dissolved in the supercritical carbon dioxide.

In some embodiments, when the one or more natural plant dyes are also directly added into the natural plant dyes and extracts kettle, step832can be omitted. Thus, the supercritical carbon dioxide carrying a mixture of the one or more natural plant dyes and the one or more natural plant extracts at834can pass through a filter, and enter the mixing kettle through a pipeline.

At540, the textile fibers can be dyed and/or modified by using the supercritical carbon dioxide carrying a mixture of the one or more natural plant dyes and the one or more natural plant extracts. In some embodiments, the dyeing and functional modification kettle can be heated and pressurized. A temperature of the dyeing and functional modification kettle can be set in a range from about 90° C. to about 120° C. A pressure of the dyeing and functional modification kettle can be set as about 30 MPa.

The supercritical carbon dioxide carrying the mixture of the one or more natural plant dyes and the one or more natural plant extracts in the mixing kettle can be injected into the dyeing and functional modification kettle. The supercritical carbon dioxide can be circulated in the dyeing and functional modification kettle to fully mix with the textile fibers for a time period. As such, the textile fibers can be dyed and/or modified in the dyeing and functional modification kettle.

In some embodiments, the time period can be determined based on the type of the textile fibers to be dyed or modified, and the expected properties of the textile fibers after the dyeing and/or functional modification process. For example, the time period can be related to the antibacterial rate, the fineness, the dry breaking strength, the wet breaking strength, and the dry breaking elongation, the color washing fastness of the stained dyes, the instantly touching cool sensation, etc. In some embodiments, the time period can be in a range from about 90 minutes to 180 minutes.

At550, after the process for dyeing and functional modification to the textile fibers, a post-process can be performed.FIG. 9illustrates a schematic flow diagram of an exemplary post-process in accordance with the present disclosure.

At952, the supercritical carbon dioxide can be separated from the one or more natural plant dyes and one or more natural plant extracts. In some embodiments, the supercritical carbon dioxide carrying the mixture of the one or more natural plant dyes and the one or more natural plant extracts can be transferred from the dyeing and functional modification kettle to a separating kettle. A temperature of the separating kettle142can be set to about 80° C. to about 100° C., and a pressure of the separating kettle142can be set to about 2 MPa to about 3 MPa. As such, the gaseous carbon dioxide can enter a condensing kettle, and the natural plant dyes and the natural plant extracts can be left in the separating kettle.

At954, the gaseous carbon dioxide can be converted into the liquid carbon dioxide. In some embodiments, a temperature of the condensing kettle can be set as the room temperature, such as about 20° C. to about 25° C. The pressure of the condensing kettle can be set as about 4 MPa to about 6 MPa. As such, the gaseous carbon dioxide can be converted into the liquid carbon dioxide for recycling in the condensing kettle. As such, the liquid carbon dioxide can then reflux into the carbon dioxide storage tank to participate in a next round of dyeing process or functional modification process.

At956, the dyed and modified textile fibers can be taken out from the dyeing and functional modification kettle. In some embodiments, the kettle automatic operation device can open the kettle cover of the dyeing and functional modification kettle. The dyed and modified textile fibers can be taken out from the dyeing and functional modification kettle.

Referring back toFIG. 5, at560, it can be determined whether a next round of dyeing process or functional modification process is to be performed. In response to determining that a next round of dyeing process or functional modification process is to be performed (“Yes” at560), the process can go back to510to add materials for the next round of dyeing process or functional modification process into the multiple kettles.

In response to determining that a next round of dyeing process or functional modification process is not to be performed (“No” at560), the process can perform a cleaning process to the apparatus at570.FIG. 10illustrates a schematic flow diagram of an exemplary cleaning process in accordance with the present disclosure.

At1071, the liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. At1073, the carbon dioxide in the high-pressure pump can be pressurized to about 7.382 MPa. At1075, a temperature of the carbon dioxide in the high-pressure pump can be heated to about 65° C. to about 70° C. by one preheater.

At1077, a solubilizing agent can be added into the dyeing and functional modification kettle to dissolve the one or more natural plant dyes and the one or more natural plant extracts. In some embodiments, the solubilizing agent can be a mixture of anhydrous ethanol and ethyl acetate. A mass ratio of anhydrous ethanol and the ethyl acetate in the dissolving agent can be in a range from 1:9 to 5:13. A temperature of the dyeing and functional modification kettle can be heated to about 65° C. to about 70° C. by one preheater. A stirrer in the dyeing and functional modification kettle can be started to stir for about 5 minutes to about 10 minutes.

At1079, the stirred fluid can pass through the separator to separate the carbon dioxide from the one or more natural plant dyes and the one or more natural plant extracts. A temperature of the separator can be heated to about 80° C. to about 100° C. by one preheater, and a pressure of the separator can be set to about 2 MPa to about 3 MPa. As such, the liquid carbon dioxide can be converted to gaseous carbon dioxide that is separated from the one or more natural plant dyes and the one or more natural plant extracts.

In some embodiments, the gaseous carbon dioxide can enter the condenser. The one or more natural plant dyes and the one or more natural plant extracts can be remained in the separator. Therefore, the one or more natural plant dyes and the one or more natural plant extracts in the pipelines can be cleaned up.

It should be noted that the above steps of the flow diagrams ofFIGS. 5-10can be executed or performed in any order or sequence not limited to the order and sequence shown and described in the figure. Also, some of the above steps of the flow diagrams ofFIGS. 5-10can be executed or performed substantially simultaneously where appropriate or in parallel to reduce latency and processing times. Furthermore, it should be noted thatFIGS. 5-10are provided as examples only. At least some of the steps shown in the figures may be performed in a different order than represented, performed concurrently, or altogether omitted.

In the disclosed methods for processing textile fibers, the textile fibers can be dyed and modified by using supercritical carbon dioxide, without using water or other reagents as a solvent. As such, there is no generation and emissions of waste water and waste byproducts during the entire processing. Therefore, the significant cost for processing solid waste and/or liquid waste can be saved. The disclosed methods for processing textile fibers are eco-friendly and environmental-friendly functional modification processes.

The disclosed methods used for natural fiber dyeing and modification can have a fast and short process. The operations of the kettles during the process can be automatic without any manual operations. And after the dyeing and modification process, the supercritical carbon dioxide can be rapidly gasified, thus there is no need to dry the dyed or functional modified fibers. Thus, the labor intensity can be reduced and the efficiency of the disclosed methods is high. The cost of post-processing can be saved, and the production costs can be reduced.

The raw materials used in the disclosed methods for natural fiber dyeing and modification using supercritical carbon dioxide, including carbon dioxide, natural plant dyes, and natural plant extracts, can be fully recycled for a repeated use. Carbon dioxide is non-toxic, tasteless, and nonflammable. The dyeing and modification process requires no dispersants, stabilizers or buffers. Therefore, the production costs can be decreased, and potential pollution can be reduced. The disclosed methods for processing textile fibers can have good social benefits and can be widely used in the textile industry.

The fabrics, garments, home textiles and other textile products manufactured by the disclosed methods do not go through a bleaching process, therefore have no chemical reagent residue, are highly secure to human skin. Further, the fabrics, garments, home textiles and other textile products manufactured by the disclosed methods can have excellent antibacterial and bacteriostatic properties.

The natural fibers processed by the disclosed methods can have uniform colors and excellent color reproducibility. The disclosed methods used for natural fiber dyeing and modification using supercritical carbon dioxide do not damage the natural fibers. The fabric products manufactured by the disclosed methods can have good physical properties, and a color fastness up to five degree.

The natural fibers processed by the disclosed methods can have excellent physical properties. For example, a wet breaking strength of the modified natural cotton fiber can be in a range from about 2.8 cN/dtex to about 3.5 cN/dtex, a wet breaking strength of the modified natural silk fiber can be in a range from about 30 cN/dtex to about 33 cN/dtex, a wet breaking strength of the modified natural wool fiber can be in a range from about 1.9 cN/dtex to about 2.7 cN/dtex, and a wet breaking strength of the modified polyester fiber can be in a range from about 4.1 cN/dtex to about 5.0 cN/dtex.

The natural fibers processed by the disclosed methods can have excellent antibacterial and bacteriostatic properties. For example, a modified natural cotton fiber having: an inhibitory rate toEscherichia coliin a range from about 93% to about 95%, an inhibition rate toStaphylococcus aureusin a range from about 91% to about 95%, an inhibitory rate toCandida albicansin a range from about 87% to about 89%. As another example, a modified polyester fiber having: an inhibitory rate toEscherichia coliin a range from about 90% to about 98%, an inhibition rate toStaphylococcus aureusin a range from about 92% to about 96%, an inhibitory rate toCandida albicansin a range from about 87% to about 88%. As yet another example, a knitted fabric made by modified cotton-blended fiber having: an inhibitory rate toEscherichia coliin a range from about 93% to about 97%, an inhibition rate toStaphylococcus aureusin a range from about 93% to about 95%, an inhibitory rate toCandida albicansin a range from about 87% to about 96%. As yet another example, a modified natural silk fiber having: an inhibitory rate toEscherichia coliin a range from about 91% to about 94%, an inhibition rate toStaphylococcus aureusin a range from about 89% to about 92%, an inhibitory rate toCandida albicansin a range from about 84% to about 91%.

In the following, multiple examples are described to show the implementations of the disclosed method for processing the textile fibers.

The Rose Dye and/or the Mint Extract are Used to Dye and Modify the Natural Cotton Fiber.

About 50 Kg natural cotton fibers to be dyed or modified can be added into the dyeing and functional modification kettle. About 2 Kg rose dye and/or about 1 Kg mint extract can be added into the mixing kettle. The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The pressure of the liquid carbon dioxide in the carbon dioxide high pressure pump can be increased to about 30 Mpa, and the temperature of the liquid carbon dioxide can be heated to about 120° C. to obtain the supercritical carbon dioxide.

The supercritical carbon dioxide can be injected into the mixing kettle. A pressure of the mixing kettle can be increased to about 30 Mpa, and a temperature of the mixing kettle can be increased to about 120° C. The supercritical carbon dioxide can be fully contacted with the rose dye and/or the mint extract and to fully dissolve the rose dye and/or mint extract.

The dyeing and functional modification kettle can be heated and pressurized. A temperature of the dyeing and functional modification kettle can be set to about 120° C. A pressure of the dyeing and functional modification kettle can be set to about 30 MPa. The supercritical carbon dioxide carrying the rose dye and/or the mint extract in the mixing kettle can be injected into the dyeing and functional modification kettle. The supercritical carbon dioxide can be circulated in the dyeing and functional modification kettle to fully mix with the natural cotton fiber for about a time period.

After the process for dyeing and functional modification to the textile fibers, a post-process can be performed. The supercritical carbon dioxide carrying the rose dye and/or the mint extract can be transferred from the dyeing and functional modification kettle to the separating kettle. A temperature of the separating kettle can be set to about 100° C., and a pressure of the separating kettle can be set to about 4 MPa. The gaseous carbon dioxide can enter a condensing kettle, and the rose dye and/or the mint extract can be left in the separating kettle.

A temperature of the condensing kettle can be set as the room temperature, such as about 20° C. The pressure of the condensing kettle can be set as about 4 MPa. The gaseous carbon dioxide can be converted into the liquid carbon dioxide for recycling. The liquid carbon dioxide can then reflux from the condensing kettle into the carbon dioxide storage tank to participate in a next round of dyeing process or functional modification process.

A cleaning process can be performed after the dyed and modified cotton fiber can be taken out from the dyeing and functional modification kettle. The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The carbon dioxide in the high-pressure pump can be pressurized to about 7.382 MPa. A temperature of the carbon dioxide in the high-pressure pump can be heated to about 65° C. to about 70° C. by one preheater. A solubilizing agent can be added into the dyeing and functional modification kettle to dissolve the rose dye and/or mint extract.

In some embodiments, the solubilizing agent can be a mixture of anhydrous ethanol and ethyl acetate. A mass ratio of anhydrous ethanol and the ethyl acetate in the dissolving agent can be in a range from 1:9 to 5:13. A temperature of the dyeing and functional modification kettle can be heated to about 65° C. to about 70° C. by one preheater. A stirrer in the dyeing and functional modification kettle can be started to stir for about 5 minutes to about 10 minutes.

The stirred fluid can pass through the separator to separate the carbon dioxide from the rose dye and/or mint extract. A temperature of the separator can be heated to about 80° C. to about 100° C. by one preheater, and a pressure of the separator can be set to about 2 MPa to about 3 MPa. As such, the liquid carbon dioxide can be converted to gaseous carbon dioxide that is separated from the rose dye and/or mint extract. The gaseous carbon dioxide can enter the condenser. The rose dye and/or mint extract can be remained in the separator. Therefore, the rose dye and/or mint extract in the pipelines can be cleaned up.

The specific antibacterial rate of the functional modified natural cotton fiber can be related to the time period. The effects of the time period for functional modification process on the specific antibacterial rate can be shown in Table 1 below.

As shown in Table 1, with the increasing of the time period for functional modification process, the functional modified natural cotton fiber can have better antibacterial rates toEscherichia coli, Staphylococcus aureus, andCandida albicans. However, when the time period for functional modification process is more than 120 minutes, the increases of the antibacterial rates are not significant. Therefore, the time period for functional modification process for natural cotton fiber can be about 120 minutes.

As shown in Table 1, when the rose dye and the mint extract are used to dye and modify the natural cotton fiber for about 120 minutes, the modified natural cotton fiber can have an inhibitory rate toEscherichia coliin a range from about 93% to about 95%, an inhibition rate toStaphylococcus aureusin a range from about 91% to about 95%, an inhibitory rate toCandida albicansin a range from about 87% to about 89%.

The rose dye and/or the mint extract are used to dye and modify the natural fibers including natural cotton fiber, natural silk fiber, and natural wool fiber that have same fineness, breaking strength and other physical indicators. The dyeing and functional modification process can be referred to Example 1 described above.

The specific properties of the functional modified natural fibers can be shown in Table 2 below. It is noted that, in the testing groups the supercritical carbon dioxide is used in the dyeing and modification process, while in the reference groups (‘Ref group’ in Table 2) the water is used as a solvent in the dyeing and modification process.

As shown in the testing groups of Table 2, the natural cotton fiber, natural silk fiber, and the natural wool fiber containing the mint extract that has a weight of 1% of the weight of the natural fiber can be processed respectively by using the supercritical carbon dioxide. In the reference groups of Table 2, the natural cotton fiber, natural silk fiber, and the natural wool fiber containing the mint extract that has a weight of 1% of the weight of the natural fiber can be processed respectively by using the water as the solvent.

Comparing the properties of the modified natural fibers shown in the testing groups and the reference groups of Table 2, it is noted that, the physical properties of the modified natural fibers including the dry breaking strength, the wet breaking strength, and the dry breaking elongation, are proximately same. Further, the antibacterial rates toEscherichia coli, Staphylococcus aureus, andCandida albicansare also close to each other.

As shown in Table 2, when using the rose dye and/or the mint extract to functional modify the natural silk fiber for about 120 minutes, the modified natural silk fiber can have a dry breaking strength as about 28.7 cN/dtex, a wet breaking strength as about 32.2 cN/dtex, a dry breaking elongation as about 35%, an antibacterial rate toEscherichia colias about 98%, an antibacterial rate toStaphylococcus aureusas about 96%, and an antibacterial rate toCandida albicansas about 97%.

When using the rose dye and/or the mint extract to functional modify the natural woll fiber for about 120 minutes, the modified natural wool fiber can have a dry breaking strength as about 2.83 cN/dtex, a wet breaking strength as about 2.61 cN/dtex, a dry breaking elongation as about 24.1%, an antibacterial rate toEscherichia colias about 97%, an antibacterial rate toStaphylococcus aureusas about 95%, and an antibacterial rate toCandida albicansas about 96%.

The mint extract includes menthone, menthol and other chemical ingredients that can provide cool senses. The textile fibers modified by using the mint extract can be weaved into fabric that can be tested on the instantly touching cool sensation (Q-max). The value of Q-max can indicate a maximum amount of heat loss on human skin surface when touches the fabric, which is also the maximum heat flow through the fabric. A unit of Q-max is heat flow per square centimeter (W/cm2).

The standard indicator of Q-max is equal to or larger than 0.140 W/cm2. A test sample of the fabric weaved by the textile fibers modified by using the mint extract can be 20×20 square centimeters, a measuring area can be about 5×5 square centimeters. The sample to be tested can be placed in an environment having a temperature of about 20±2° C. and a humidity of about 65±2% for about 24 hours before testing. The instrument for measuring Q-max can be a thermal effect tester, such as KES-F7 THERMO II. A testing result of Q-max is 0.390 W/cm2. The testing result of Q-max can be an average of five testing data, and have a valid data for three decimal places. Clearly, the testing result of Q-max is much higher than the standard indicator of Q-max.

Further, the color washing fastness of the rose dye of the textile fibers processed by using the supercritical carbon dioxide can be up to level five, while the color washing fastness of the rose dye of the textile fibers processed by using the water as the solvent is only level three.

It is noted that, when the fabric including at least 30% of the textile fibers modified by using the mint extract, and less than 70% of the ordinary viscose fiber, the performance indicators of the fabric can achieve the properties described above.

The violet dye and/or the wormwood extract are used to dye and modify the natural fibers.

About 50 Kg natural fiber to be dyed or modified can be added into the dyeing and functional modification kettle. The natural fiber can be natural cotton fiber, natural linen fiber, natural silk fiber, and/or natural wool fiber. About 1 Kg of wormwood extract can be added into the natural plant dyes and extracts kettle.

The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The pressure of the liquid carbon dioxide in the carbon dioxide high pressure pump can be increased to about 30 Mpa to about 32 Mpa, and the temperature of the liquid carbon dioxide can be heated to about 90° C. to about 120° C. to obtain the supercritical carbon dioxide.

About 5 Kg of violet plant fresh petals and/or dry petals can be added into the natural plant dye extraction kettle. The natural plant dye extraction kettle can be pressured to about 30 Mpa, and be heated to about 90° C. The supercritical carbon dioxide can be injected into the natural plant dye extraction kettle. According to different temperatures and different pressures of the supercritical carbon dioxide, the effective components in the pigments of violet plant may have different degrees of solubility in the supercritical carbon dioxide. As such, the pigments in the violet plant petals can be dissolved in the supercritical carbon dioxide, and the violet dye can be extracted.

The supercritical carbon dioxide can also be injected into the natural plant dyes and extracts kettle. A pressure of the natural plant dyes and extracts kettle can be increased to about 30 Mpa to about 32 MPa, and a temperature of the natural plant dyes and extracts kettle can be increased to about 90° C.-120° C. The supercritical carbon dioxide can be fully contacted with the wormwood extract. As such, the wormwood extract can be evenly dispersed and then dissolved in the supercritical carbon dioxide.

The supercritical carbon dioxide carrying the wormwood extract and the supercritical carbon dioxide carrying the violet dye can pass through one or more filters, and enter the mixing kettle through one or more pipelines, and be mixed together in the mixing kettle. As such, the wormwood extract and the violet dye can be evenly dispersed and dissolved in the supercritical carbon dioxide.

The dyeing and functional modification kettle can be heated and pressurized. A temperature of the dyeing and functional modification kettle can be set to about 90° C. A pressure of the dyeing and functional modification kettle can be set to about 30 MPa. The supercritical carbon dioxide carrying the wormwood extract and the violet dye in the mixing kettle can be injected into the dyeing and functional modification kettle. The supercritical carbon dioxide can be circulated in the dyeing and functional modification kettle to fully mix with the natural fiber for about 120 minutes.

After the process for dyeing and functional modification to the textile fibers, a post-process can be performed. The supercritical carbon dioxide carrying the wormwood extract and the violet dye can be transferred from the dyeing and functional modification kettle to the separating kettle. A temperature of the separating kettle can be set to about 80° C., and a pressure of the separating kettle can be set to about 2 MPa. The gaseous carbon dioxide can enter a condensing kettle, and the wormwood extract and the violet dye can be left in the separating kettle.

A temperature of the condensing kettle can be set as the room temperature, such as about 20° C. to 25° C. The pressure of the condensing kettle can be set as about 4 MPa. The gaseous carbon dioxide can be converted into the liquid carbon dioxide for recycling. The liquid carbon dioxide can then reflux from the condensing kettle into the carbon dioxide storage tank to participate in a next round of dyeing process or functional modification process.

A cleaning process can be performed after the dyed and modified natural fiber can be taken out from the dyeing and functional modification kettle. The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The carbon dioxide in the high-pressure pump can be pressurized to about 7.382 MPa. A temperature of the carbon dioxide in the high-pressure pump can be heated to about 65° C. to about 70° C. by one preheater. A solubilizing agent can be added into the dyeing and functional modification kettle to dissolve the rose dye and/or mint extract.

In some embodiments, the solubilizing agent can be a mixture of anhydrous ethanol and ethyl acetate. A mass ratio of anhydrous ethanol and the ethyl acetate in the dissolving agent can be in a range from 1:9 to 5:13. A temperature of the dyeing and functional modification kettle can be heated to about 65° C. to about 70° C. by one preheater. A stirrer in the dyeing and functional modification kettle can be started to stir for about 5 minutes to about 10 minutes.

The stirred fluid can pass through the separator to separate the carbon dioxide from the wormwood extract and the violet dye. A temperature of the separator can be heated to about 80° C. to about 100° C. by one preheater, and a pressure of the separator can be set to about 2 MPa to about 3 MPa. As such, the liquid carbon dioxide can be converted to gaseous carbon dioxide that is separated from the wormwood extract and the violet dye. The gaseous carbon dioxide can enter the condenser. The wormwood extract and the violet dye can be remained in the separator. Therefore, the wormwood extract and the violet dye in the pipelines can be cleaned up.

The wormwood extract and the violet dye are used to dye and modify the natural fibers including natural cotton fiber, natural linen fiber, natural silk fiber, and natural wool fiber that have same fineness, breaking strength and other physical indicators.

The specific properties of the functional modified natural fibers can be shown in Table 3 below. It is noted that, in the testing groups the supercritical carbon dioxide is used in the dyeing and modification process, while in the reference groups (‘Ref group’ in Table 3) the water is used as a solvent in the dyeing and modification process.

As shown in the testing groups of Table 3, the natural cotton fiber, natural linen fiber, natural silk fiber, and the natural wool fiber containing the wormwood extract can be processed respectively by using the supercritical carbon dioxide. In the reference groups of Table 3, the natural cotton fiber, natural linen fiber, natural silk fiber, and the natural wool fiber containing the wormwood extract can be processed respectively by using the water as the solvent.

Comparing the properties of the modified natural fibers shown in the testing groups and the reference groups of Table 3, it is noted that, the physical properties of the modified natural fibers including the dry breaking strength, the wet breaking strength, and the dry breaking elongation, are proximately same. Further, the antibacterial rates toEscherichia coli, Staphylococcus aureus, andCandida albicansare also close to each other. The color washing fastness of the violet dye of the textile fibers processed by using the supercritical carbon dioxide can be up to level five, while the color washing fastness of the violet dye of the textile fibers processed by using the water as the solvent is only level three.

It is noted that, when the fabric including at least 30% of the textile fibers modified by using the wormwood extract, and less than 70% of Modal fiber, the performance indicators of the fabric can achieve the properties described above.

The lavender extract and safflower dye are used to dye and modify yarns made by the natural fibers, including natural cotton fiber, natural linen fiber, natural silk fiber, and natural wool fiber that have same fineness, breaking strength and other physical indicators. The dyeing and functional modification process can be referred to Example 1 described above.

The specific properties of the functional modified natural fibers can be shown in Table 4 below. It is noted that, in the testing groups the supercritical carbon dioxide is used in the dyeing and modification process, while in the reference groups (‘Ref group’ in Table 4) the water is used as a solvent in the dyeing and modification process.

As shown in the testing groups of Table 4, the natural cotton fiber, natural linen fiber, natural silk fiber, and the natural wool fiber containing the lavender extract can be processed respectively by using the supercritical carbon dioxide. In the reference groups of Table 4, the natural cotton fiber, natural linen fiber, natural silk fiber, and the natural wool fiber containing the lavender extract can be processed respectively by using the water as the solvent.

Comparing the properties of the modified natural fibers shown in the testing groups and the reference groups of Table 4, it is noted that, the physical properties of the modified natural fibers including the dry breaking strength, the wet breaking strength, and the dry breaking elongation, are proximately same. Further, the antibacterial rates toEscherichia coli, Staphylococcus aureus, andCandida albicansare also close to each other. The color washing fastness of the safflower dye of the textile fibers processed by using the supercritical carbon dioxide can be up to level five, while the color washing fastness of the safflower dye of the textile fibers processed by using the water as the solvent is only level three.

Comparing the properties of the natural fibers modified by using different natural plant extracts and/or natural plant dyes as shown in Tables 2-4, the natural fibers modified by using the mint extract and/or the rose dye have a significant improvement to the wet breaking strength as shown in Table 2. The modified natural cotton fiber by using the mint extract and/or the rose dye can have a wet breaking strength as about 3.5 cN/dtex. The modified natural silk fiber by using the mint extract and/or the rose dye can have a wet breaking strength as about 32.2 cN/dtex. The modified natural wool fiber by using the mint extract and/or the rose dye can have a wet breaking strength as about 2.61 cN/dtex. Further, the natural fibers modified by using the mint extract and/or the rose dye have a significant improvement to the antibacterial rates ofEscherichia coli, Staphylococcus aureus, andCandida albicans.

It is noted that, when the fabric including at least 30% of the textile fibers modified by using the lavender extract, and less than 70% of the ordinary viscose fiber, Modal fiber, or Tencel fiber, the performance indicators of the fabric can achieve the properties described above.

The wormwood extract and the violet dye are used to dye and modify yarns made by the natural fibers, including natural cotton fiber, natural linen fiber, natural silk fiber, and natural wool fiber that have same fineness, breaking strength and other physical indicators. The dyeing and functional modification process can be referred to Example 3 described above.

The specific properties of the functional modified natural fibers can be shown in Table 5 below. It is noted that, in the testing groups the supercritical carbon dioxide is used in the dyeing and modification process, while in the reference groups (‘Ref group’ in Table 5) the water is used as a solvent in the dyeing and modification process.

As shown in the testing groups of Table 5, the natural cotton fiber, natural linen fiber, natural silk fiber, and the natural wool fiber containing the wormwood extract and the violet dye can be processed respectively by using the supercritical carbon dioxide. In the reference groups of Table 3, the natural cotton fiber, natural linen fiber, natural silk fiber, and the natural wool fiber containing the wormwood extract and the violet dye can be processed respectively by using the water as the solvent.

Comparing the properties of the modified natural fibers shown in the testing groups and the reference groups of Table 5, it is noted that, the physical properties of the modified natural fibers including the dry breaking strength, the wet breaking strength, and the dry breaking elongation, are proximately same. Further, the antibacterial rates toEscherichia coli, Staphylococcus aureus, andCandida albicansare also close to each other. The color washing fastness of the violet dye of the textile fibers processed by using the supercritical carbon dioxide can be up to level five, while the color washing fastness of the violet dye of the textile fibers processed by using the water as the solvent is only level three.

It is noted that, when the fabric including at least 30% of the textile fibers modified by using the wormwood extract, and less than 70% of the ordinary viscose fiber, Modal fiber, Tencel fiber, or combinations thereof, the performance indicators of the fabric can achieve the properties described above.

The rose dye and/or the mint extract are used to dye and modify the cotton fabric.

About 200 Kg cotton fabric to be dyed or modified can be added into the dyeing and functional modification kettle. About 2 Kg rose dye and/or about 1 Kg mint extract can be added into the mixing kettle. The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The pressure of the liquid carbon dioxide in the carbon dioxide high pressure pump can be increased to about 30 Mpa, and the temperature of the liquid carbon dioxide can be heated to about 100° C. to obtain the supercritical carbon dioxide.

The supercritical carbon dioxide can be injected into the mixing kettle. A pressure of the mixing kettle can be increased to about 30 Mpa, and a temperature of the mixing kettle can be increased to about 100° C. The supercritical carbon dioxide can be fully contacted with the rose dye and/or the mint extract and to fully dissolve the rose dye and/or mint extract.

The dyeing and functional modification kettle can be heated and pressurized. A temperature of the dyeing and functional modification kettle can be set to about 100° C. A pressure of the dyeing and functional modification kettle can be set to about 30 MPa. The supercritical carbon dioxide carrying the rose dye and/or the mint extract in the mixing kettle can be injected into the dyeing and functional modification kettle. The supercritical carbon dioxide can be circulated in the dyeing and functional modification kettle to fully mix with the cotton fabric for about a time period.

After the process for dyeing and functional modification to the textile fibers, a post-process can be performed. The supercritical carbon dioxide carrying the rose dye and/or the mint extract can be transferred from the dyeing and functional modification kettle to the separating kettle. A temperature of the separating kettle can be set to about 90° C., and a pressure of the separating kettle can be set to about 2 MPa. The gaseous carbon dioxide can enter a condensing kettle, and the rose dye and/or the mint extract can be left in the separating kettle.

A temperature of the condensing kettle can be set as the room temperature, such as about 20° C. The pressure of the condensing kettle can be set as about 4 MPa. The gaseous carbon dioxide can be converted into the liquid carbon dioxide for recycling. The liquid carbon dioxide can then reflux from the condensing kettle into the carbon dioxide storage tank to participate in a next round of dyeing process or functional modification process.

A cleaning process can be performed after the dyed and modified cotton fabric can be taken out from the dyeing and functional modification kettle. The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The carbon dioxide in the high-pressure pump can be pressurized to about 7.382 MPa. A temperature of the carbon dioxide in the high-pressure pump can be heated to about 65° C. to about 70° C. by one preheater. A solubilizing agent can be added into the dyeing and functional modification kettle to dissolve the rose dye and/or mint extract.

In some embodiments, the solubilizing agent can be a mixture of anhydrous ethanol and ethyl acetate. A mass ratio of anhydrous ethanol and the ethyl acetate in the dissolving agent can be in a range from 1:9 to 5:13. A temperature of the dyeing and functional modification kettle can be heated to about 65° C. to about 70° C. by one preheater. A stirrer in the dyeing and functional modification kettle can be started to stir for about 5 minutes to about 10 minutes.

The stirred fluid can pass through the separator to separate the carbon dioxide from the rose dye and/or mint extract. A temperature of the separator can be heated to about 80° C. to about 100° C. by one preheater, and a pressure of the separator can be set to about 2 MPa to about 3 MPa. As such, the liquid carbon dioxide can be converted to gaseous carbon dioxide that is separated from the rose dye and/or mint extract. The gaseous carbon dioxide can enter the condenser. The rose dye and/or mint extract can be remained in the separator. Therefore, the rose dye and/or mint extract in the pipelines can be cleaned up.

The specific antibacterial rate of the functional modified cotton fabric can be related to the time period. The effects of the time period for functional modification process on the specific antibacterial rate can be shown in Table 6 below.

As shown in Table 6, with the increasing of the time period for functional modification process, the functional modified cotton fabric can have better antibacterial rates toEscherichia coli, Staphylococcus aureus, andCandida albicans. However, when the time period for functional modification process is more than 90 minutes, the increases of the antibacterial rates are not significant. Therefore, the time period for functional modification process for natural cotton fiber can be about 90 minutes.

According to GB/T3921.3-1997 standard, the color washing fastness of the dyed and modified cotton fabric can be tested. The color washing fastness of the rose dye of the cotton fabric processed by using the supercritical carbon dioxide can be up to level five, while the color washing fastness of the rose dye of the cotton fabric processed by using the water as the solvent is only level three. Further, the mechanical properties of the dyed and modified cotton fabric can be tested. The strength of the cotton fabric processed by using the supercritical carbon dioxide can be decreased by about 10%, while the strength of the cotton fabric processed by using the water as the solvent is decreased by about 40%.

The mint extract includes menthone, menthol and other chemical ingredients that can provide cool senses. The cotton fabric modified by using the mint extract can be tested on the instantly touching cool sensation (Q-max). The value of Q-max can indicate a maximum amount of heat loss on human skin surface when touches the fabric, which is also the maximum heat flow through the fabric. A testing result of Q-max of the cotton fabric is 0.390 W/cm2, which is much higher than the standard indicator of Q-max of 0.14 W/cm2.

The safflower dye and wormwood extract are used to dye and modify the cotton garments.

Ten sets of cotton garments to be dyed and modified can be added into the dyeing and functional modification kettle. About 1 Kg of wormwood extract can be added into the natural plant dyes and extracts kettle.

The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The pressure of the liquid carbon dioxide in the carbon dioxide high pressure pump can be increased to about 30 Mpa, and the temperature of the liquid carbon dioxide can be heated to about 90° C. to obtain the supercritical carbon dioxide.

About 5 Kg of safflower plant fresh petals and/or dry petals can be added into the natural plant dye extraction kettle. The natural plant dye extraction kettle can be pressured to about 30 Mpa, and be heated to about 90° C. The supercritical carbon dioxide can be injected into the natural plant dye extraction kettle. According to different temperatures and different pressures of the supercritical carbon dioxide, the effective components in the pigments of safflower plant may have different degrees of solubility in the supercritical carbon dioxide. As such, the pigments in the safflower plant petals can be dissolved in the supercritical carbon dioxide, and the safflower dye can be extracted.

The supercritical carbon dioxide can also be injected into the natural plant dyes and extracts kettle. A pressure of the natural plant dyes and extracts kettle can be increased to about 30 Mpa, and a temperature of the natural plant dyes and extracts kettle can be increased to about 90° C. The supercritical carbon dioxide can be fully contacted with the wormwood extract. As such, the wormwood extract can be evenly dispersed and then dissolved in the supercritical carbon dioxide.

The supercritical carbon dioxide carrying the wormwood extract and the supercritical carbon dioxide carrying the safflower dye can pass through one or more filters, and enter the mixing kettle through one or more pipelines, and be mixed together in the mixing kettle. As such, the wormwood extract and the safflower dye can be evenly dispersed and dissolved in the supercritical carbon dioxide.

The dyeing and functional modification kettle can be heated and pressurized. A temperature of the dyeing and functional modification kettle can be set to about 90° C. A pressure of the dyeing and functional modification kettle can be set to about 30 MPa. The supercritical carbon dioxide carrying the wormwood extract and the safflower dye in the mixing kettle can be injected into the dyeing and functional modification kettle. The supercritical carbon dioxide can be circulated in the dyeing and functional modification kettle to fully mix with the cotton garments for a period of time.

After the process for dyeing and functional modification to the cotton garments, a post-process can be performed. The supercritical carbon dioxide carrying the wormwood extract and the safflower dye can be transferred from the dyeing and functional modification kettle to the separating kettle. A temperature of the separating kettle can be set to about 80° C., and a pressure of the separating kettle can be set to about 2 MPa. The gaseous carbon dioxide can enter a condensing kettle, and the wormwood extract and the safflower dye can be left in the separating kettle.

A temperature of the condensing kettle can be set as the room temperature, such as about 20° C. to 25° C. The pressure of the condensing kettle can be set as about 4 MPa. The gaseous carbon dioxide can be converted into the liquid carbon dioxide for recycling. The liquid carbon dioxide can then reflux from the condensing kettle into the carbon dioxide storage tank to participate in a next round of dyeing process or functional modification process.

A cleaning process can be performed after the dyed and modified cotton garments can be taken out from the dyeing and functional modification kettle. The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The carbon dioxide in the high-pressure pump can be pressurized to about 7.382 MPa. A temperature of the carbon dioxide in the high-pressure pump can be heated to about 65° C. to about 70° C. by one preheater. A solubilizing agent can be added into the dyeing and functional modification kettle to dissolve the safflower dye and the mint extract.

In some embodiments, the solubilizing agent can be a mixture of anhydrous ethanol and ethyl acetate. A mass ratio of anhydrous ethanol and the ethyl acetate in the dissolving agent can be in a range from 1:9 to 5:13. A temperature of the dyeing and functional modification kettle can be heated to about 65° C. to about 70° C. by one preheater. A stirrer in the dyeing and functional modification kettle can be started to stir for about 5 minutes to about 10 minutes.

The stirred fluid can pass through the separator to separate the carbon dioxide from the wormwood extract and the safflower dye. A temperature of the separator can be heated to about 80° C. to about 100° C. by one preheater, and a pressure of the separator can be set to about 2 MPa to about 3 MPa. As such, the liquid carbon dioxide can be converted to gaseous carbon dioxide that is separated from the wormwood extract and the safflower dye. The gaseous carbon dioxide can enter the condenser. The wormwood extract and the safflower dye can be remained in the separator. Therefore, the wormwood extract and the safflower dye in the pipelines can be cleaned up.

The specific antibacterial rate of the functional modified cotton garments can be related to the time period. The effects of the time period for functional modification process on the specific antibacterial rate can be shown in Table 7 below.

As shown in Table 7, with the increasing of the time period for functional modification process, the functional modified cotton garments can have better antibacterial rates toEscherichia coli, Staphylococcus aureus, andCandida albicans. However, when the time period for functional modification process is more than 150 minutes, the increases of the antibacterial rates are not significant. Therefore, the time period for functional modification process for natural cotton garments can be about 150 minutes.

According to GB/T3921.3-1997 standard, the color washing fastness of the dyed and modified cotton garments can be tested. The color washing fastness of the safflower dye of the cotton garments processed by using the supercritical carbon dioxide can be up to level five, while the color washing fastness of the safflower dye of the cotton garments processed by using the water as the solvent is only level three. Further, the mechanical properties of the dyed and modified cotton garments can be tested. The strength of the cotton garments processed by using the supercritical carbon dioxide can be decreased by about 10%, while the strength of the cotton garments processed by using the water as the solvent is decreased by about 40%.

The rose dye and/or the mint extract are used to dye and modify the polyester fiber.

About 50 Kg polyester fiber to be dyed or modified can be added into the dyeing and functional modification kettle. About 2 Kg rose dye and/or about 1 Kg mint extract can be added into the mixing kettle. The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The pressure of the liquid carbon dioxide in the carbon dioxide high pressure pump can be increased to about 30 Mpa, and the temperature of the liquid carbon dioxide can be heated to about 120° C. to obtain the supercritical carbon dioxide.

The supercritical carbon dioxide can be injected into the mixing kettle. A pressure of the mixing kettle can be increased to about 30 Mpa, and a temperature of the mixing kettle can be increased to about 120° C. The supercritical carbon dioxide can be fully contacted with the rose dye and/or the mint extract and to fully dissolve the rose dye and/or mint extract.

The dyeing and functional modification kettle can be heated and pressurized. A temperature of the dyeing and functional modification kettle can be set to about 120° C. A pressure of the dyeing and functional modification kettle can be set to about 30 MPa. The supercritical carbon dioxide carrying the rose dye and/or the mint extract in the mixing kettle can be injected into the dyeing and functional modification kettle. The supercritical carbon dioxide can be circulated in the dyeing and functional modification kettle to fully mix with the polyester fiber for about a time period.

After the process for dyeing and functional modification to the polyester fiber, a post-process can be performed. The supercritical carbon dioxide carrying the rose dye and/or the mint extract can be transferred from the dyeing and functional modification kettle to the separating kettle. A temperature of the separating kettle can be set to about 100° C., and a pressure of the separating kettle can be set to about 2 MPa. The gaseous carbon dioxide can enter a condensing kettle, and the rose dye and/or the mint extract can be left in the separating kettle.

A temperature of the condensing kettle can be set as the room temperature, such as about 20° C. The pressure of the condensing kettle can be set as about 4 MPa. The gaseous carbon dioxide can be converted into the liquid carbon dioxide for recycling. The liquid carbon dioxide can then reflux from the condensing kettle into the carbon dioxide storage tank to participate in a next round of dyeing process or functional modification process.

A cleaning process can be performed after the dyed and modified polyester fiber can be taken out from the dyeing and functional modification kettle. The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The carbon dioxide in the high-pressure pump can be pressurized to about 7.382 MPa. A temperature of the carbon dioxide in the high-pressure pump can be heated to about 65° C. to about 70° C. by one preheater. A solubilizing agent can be added into the dyeing and functional modification kettle to dissolve the rose dye and/or mint extract.

In some embodiments, the solubilizing agent can be a mixture of anhydrous ethanol and ethyl acetate. A mass ratio of anhydrous ethanol and the ethyl acetate in the dissolving agent can be in a range from 1:9 to 5:13. A temperature of the dyeing and functional modification kettle can be heated to about 65° C. to about 70° C. by one preheater. A stirrer in the dyeing and functional modification kettle can be started to stir for about 5 minutes to about 10 minutes.

The stirred fluid can pass through the separator to separate the carbon dioxide from the rose dye and/or mint extract. A temperature of the separator can be heated to about 80° C. to about 100° C. by one preheater, and a pressure of the separator can be set to about 2 MPa to about 3 MPa. As such, the liquid carbon dioxide can be converted to gaseous carbon dioxide that is separated from the rose dye and/or mint extract. The gaseous carbon dioxide can enter the condenser. The rose dye and/or mint extract can be remained in the separator. Therefore, the rose dye and/or mint extract in the pipelines can be cleaned up.

The specific antibacterial rate of the functional modified polyester fiber can be related to the time period. The effects of the time period for functional modification process on the specific antibacterial rate can be shown in Table 1 below.

As shown in Table 8, with the increasing of the time period for functional modification process, the functional modified polyester fiber can have better antibacterial rates toEscherichia coli, Staphylococcus aureus, andCandida albicans. However, when the time period for functional modification process is more than 150 minutes, the increases of the antibacterial rates are not significant. Therefore, the time period for functional modification process for the polyester fiber can be about 150 minutes.

As shown in Table 8, when the rose dye and the mint extract are used to dye and modify the polyester fiber for about 150 minutes, the modified polyester fiber can have an inhibitory rate toEscherichia coliabout 94%, an inhibition rate toStaphylococcus aureusabout 92%, an inhibitory rate toCandida albicansabout 96%.

The safflower dye and wormwood extract are used to dye and modify the polyester garments.

Ten sets of polyester garments to be dyed and modified can be added into the dyeing and functional modification kettle. About 1 Kg of wormwood extract can be added into the natural plant dyes and extracts kettle.

The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The pressure of the liquid carbon dioxide in the carbon dioxide high pressure pump can be increased to about 30 Mpa, and the temperature of the liquid carbon dioxide can be heated to about 90° C. to obtain the supercritical carbon dioxide.

About 5 Kg of safflower plant fresh petals and/or dry petals can be added into the natural plant dye extraction kettle. The natural plant dye extraction kettle can be pressured to about 30 Mpa, and be heated to about 90° C. The supercritical carbon dioxide can be injected into the natural plant dye extraction kettle. According to different temperatures and different pressures of the supercritical carbon dioxide, the effective components in the pigments of safflower plant may have different degrees of solubility in the supercritical carbon dioxide. As such, the pigments in the safflower plant petals can be dissolved in the supercritical carbon dioxide, and the safflower dye can be extracted.

The supercritical carbon dioxide can also be injected into the natural plant dyes and extracts kettle. A pressure of the natural plant dyes and extracts kettle can be increased to about 30 Mpa, and a temperature of the natural plant dyes and extracts kettle can be increased to about 90° C. The supercritical carbon dioxide can be fully contacted with the wormwood extract. As such, the wormwood extract can be evenly dispersed and then dissolved in the supercritical carbon dioxide.

The supercritical carbon dioxide carrying the wormwood extract and the supercritical carbon dioxide carrying the safflower dye can pass through one or more filters, and enter the mixing kettle through one or more pipelines, and be mixed together in the mixing kettle. As such, the wormwood extract and the safflower dye can be evenly dispersed and dissolved in the supercritical carbon dioxide.

The dyeing and functional modification kettle can be heated and pressurized. A temperature of the dyeing and functional modification kettle can be set to about 90° C. A pressure of the dyeing and functional modification kettle can be set to about 30 MPa. The supercritical carbon dioxide carrying the wormwood extract and the safflower dye in the mixing kettle can be injected into the dyeing and functional modification kettle. The supercritical carbon dioxide can be circulated in the dyeing and functional modification kettle to fully mix with the polyester garments for a period of time.

After the process for dyeing and functional modification to the polyester garments, a post-process can be performed. The supercritical carbon dioxide carrying the wormwood extract and the safflower dye can be transferred from the dyeing and functional modification kettle to the separating kettle. A temperature of the separating kettle can be set to about 80° C., and a pressure of the separating kettle can be set to about 2 MPa. The gaseous carbon dioxide can enter a condensing kettle, and the wormwood extract and the safflower dye can be left in the separating kettle.

A temperature of the condensing kettle can be set as the room temperature, such as about 20° C. to 25° C. The pressure of the condensing kettle can be set as about 4 MPa. The gaseous carbon dioxide can be converted into the liquid carbon dioxide for recycling. The liquid carbon dioxide can then reflux from the condensing kettle into the carbon dioxide storage tank to participate in a next round of dyeing process or functional modification process.

A cleaning process can be performed after the dyed and modified polyester garments can be taken out from the dyeing and functional modification kettle. The liquid carbon dioxide stored in the carbon dioxide storage tank can be injected into the carbon dioxide high pressure pump. The carbon dioxide in the high-pressure pump can be pressurized to about 7.382 MPa. A temperature of the carbon dioxide in the high-pressure pump can be heated to about 65° C. to about 70° C. by one preheater. A solubilizing agent can be added into the dyeing and functional modification kettle to dissolve the safflower dye and the mint extract.

In some embodiments, the solubilizing agent can be a mixture of anhydrous ethanol and ethyl acetate. A mass ratio of anhydrous ethanol and the ethyl acetate in the dissolving agent can be in a range from 1:9 to 5:13. A temperature of the dyeing and functional modification kettle can be heated to about 65° C. to about 70° C. by one preheater. A stirrer in the dyeing and functional modification kettle can be started to stir for about 5 minutes to about 10 minutes.

The stirred fluid can pass through the separator to separate the carbon dioxide from the wormwood extract and the safflower dye. A temperature of the separator can be heated to about 80° C. to about 100° C. by one preheater, and a pressure of the separator can be set to about 2 MPa to about 3 MPa. As such, the liquid carbon dioxide can be converted to gaseous carbon dioxide that is separated from the wormwood extract and the safflower dye. The gaseous carbon dioxide can enter the condenser. The wormwood extract and the safflower dye can be remained in the separator. Therefore, the wormwood extract and the safflower dye in the pipelines can be cleaned up.

The specific antibacterial rate of the functional modified polyester garments can be related to the time period. The effects of the time period for functional modification process on the specific antibacterial rate can be shown in Table 9 below.

As shown in Table 7, with the increasing of the time period for functional modification process, the functional modified polyester garments can have better antibacterial rates toEscherichia coli, Staphylococcus aureus, andCandida albicans. However, when the time period for functional modification process is more than 150 minutes, the increases of the antibacterial rates are not significant. Therefore, the time period for functional modification process for natural polyester garments can be about 150 minutes.

According to GB/T3921.3-1997 standard, the color washing fastness of the dyed and modified polyester garments can be tested. The color washing fastness of the safflower dye of the polyester garments processed by using the supercritical carbon dioxide can be up to level five, while the color washing fastness of the safflower dye of the polyester garments processed by using the water as the solvent is only level three. Further, the mechanical properties of the dyed and modified polyester garments can be tested. The strength of the polyester garments processed by using the supercritical carbon dioxide can be decreased by about 10%, while the strength of the polyester garments processed by using the water as the solvent is decreased by about 40%.

Accordingly, methods and apparatuses for processing textile fibers, related kettle automatic operation devices, and related textile fiber products are provided.

In the disclosed methods for processing textile fibers, the textile fibers can be dyed and modified by using supercritical carbon dioxide, without using water or other reagents as a solvent. As such, there is no generation and emissions of waste water and waste byproducts during the entire processing. Therefore, the significant cost for processing solid waste and/or liquid waste can be saved. The disclosed methods for processing textile fibers are eco-friendly and environmental-friendly functional modification processes.

The disclosed methods used for natural fiber dyeing and modification can have a fast and short process. The operations of the kettles during the process can be automatic without any manual operations. And after the dyeing and modification process, the supercritical carbon dioxide can be rapidly gasified, thus there is no need to dry the dyed or functional modified fibers. Thus, the labor intensity can be reduced and the efficiency of the disclosed methods is high. The cost of post-processing can be saved, and the production costs can be reduced.

The raw materials used in the disclosed methods for natural fiber dyeing and modification using supercritical carbon dioxide, including carbon dioxide, natural plant dyes, and natural plant extracts, can be fully recycled for a repeated use. Carbon dioxide is non-toxic, tasteless, and nonflammable. The dyeing and modification process requires no dispersants, stabilizers or buffers. Therefore, the production costs can be decreased, and potential pollution can be reduced. The disclosed methods for processing textile fibers can have good social benefits and can be widely used in the textile industry.

The fabrics, garments, home textiles and other textile products manufactured by the disclosed methods do not go through a bleaching process, therefore have no chemical reagent residue, are highly secure to human skin. Further, the fabrics, garments, home textiles and other textile products manufactured by the disclosed methods can have excellent antibacterial and bacteriostatic properties.

It is noted that, the textile fibers dyed and/or functional modified by using the supercritical carbon dioxide can be used to produce non-woven fabrics. The non-woven fabrics can be used to make underwear, T-shirts, towels, bedding, and other textile products. Further, the one or more natural plant dyes and one or more natural plant extracts can be directly purchased from the market.

The natural fibers processed by the disclosed methods can have uniform colors and excellent color reproducibility. The disclosed methods used for natural fiber dyeing and modification using supercritical carbon dioxide do not damage the natural fibers. The fabric products manufactured by the disclosed methods can have good physical properties, and a color fastness up to five degree.

The natural fibers processed by the disclosed methods can have excellent physical properties. For example, a wet breaking strength of the modified natural cotton fiber can be in a range from about 2.87 cN/dtex to about 3.5 cN/dtex, a wet breaking strength of the modified natural silk fiber can be in a range from about 30.2 cN/dtex to about 32.2 cN/dtex, a wet breaking strength of the modified natural wool fiber can be in a range from about 1.91 cN/dtex to about 2.61 cN/dtex, and a wet breaking strength of the modified polyester fiber can be in a range from about 4.1 cN/dtex to about 5.0 cN/dtex.

The natural fibers processed by the disclosed methods can have excellent antibacterial and bacteriostatic properties. For example, the modified natural cotton fiber can have an inhibitory rate toEscherichia coliin a range from about 93% to about 95%, an inhibition rate toStaphylococcus aureusin a range from about 91% to about 95%, an inhibitory rate toCandida albicansin a range from about 87% to about 89%. As another example, the modified natural silk fiber can have an inhibitory rate toEscherichia coliin a range from about 90% to about 98%, an inhibition rate toStaphylococcus aureusin a range from about 92% to about 96%, an inhibitory rate toCandida albicansin a range from about 87% to about 88%. As yet another example, the modified natural wool fiber can have an inhibitory rate toEscherichia coliin a range from about 93% to about 97%, an inhibition rate toStaphylococcus aureusin a range from about 93% to about 95%, an inhibitory rate toCandida albicansin a range from about 87% to about 96%. As yet another example, the modified polyester fiber can have an inhibitory rate toEscherichia coliin a range from about 91% to about 94%, an inhibition rate toStaphylococcus aureusin a range from about 89% to about 92%, an inhibitory rate toCandida albicansin a range from about 87% to about 96%.

The fibers processed by the disclosed methods and apparatus, by supercritical fluid extraction and dyeing, may be modified by various other natural materials, thereby providing other improved properties, e.g., to fabric, textile, and/or clothes thereof. For example, the functionally modified the textile fibers include violet dye and/or the wormwood extract modified textile fibers, having a color washing fastness improved from level three, for the non-modified fibers thereof, to level five. In another example, the functionally modified the textile fibers include mint extract modified textile fibers, having an instantly touching cool sensation (Q-max) of about 0.390 W/cm2, while non-modified fibers thereof have the Q-max of about 0.140 W/cm2. In yet other examples, a fabric, made by grass coral extract modified textile fibers, has an increased moisture absorption and heating temperature by 8° C. increased based on the non-modified fibers thereof; and a fabric, made by apocynum modified textile fibers, provides a far infrared function with a phase emissivity of a normal phase up to about 89%. Such fabric may be used to make clothes for infant and/or children.

The provision of the examples described herein (as well as clauses phrased as “such as,” “e.g.,” “including,” or the like) should not be interpreted as limiting the disclosure to the specific examples; rather, the examples are intended to illustrate only some of many possible aspects.

Although the present disclosure has been described and illustrated in the foregoing illustrative embodiments, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the details of embodiment of the present disclosure can be made without departing from the spirit and scope of the present disclosure. Features of the disclosed embodiments can be combined and rearranged in various ways. Without departing from the spirit and scope of the present disclosure, modifications, equivalents, or improvements to the present disclosure are conceivable to those skilled in the art and are intended to be encompassed within the scope of the present disclosure.