Methods, processes, and apparatuses for producing dyed and welded substrates

Abstract

A dyeing and welding process may be configured to convert a substrate into a welded substrate having at least some color imparted thereto via a dye and/or coloring agent by applying a process solvent having a dye and/or coloring agent therein to the substrate, wherein the process solvent interrupts one or more intermolecular force between one or more component in the substrate. The substrate may be configured as a natural fiber, such as cellulose, hemicelluloses, and silk. The process solvent may include a binder, such as dissolved biopolymer (e.g., cellulose). After application of a process solvent comprised of a dye and/or coloring agent, the substrate may be exposed to a second application of a process solvent comprised of a binder, which second application may occur before or after a process temperature/pressure zone, process solvent recovery zone, and/or drying zone.

1 . A yarn comprising:
 a) a plurality of fiber substrates adjacent to one another to form said yarn, wherein said plurality of fiber substrates contain a biopolymer;   b) a pigment dispersed throughout at least an exterior portion of said yarn, wherein said pigment comprises a plurality of pigment particles;   c) a binder surrounding a portion of said plurality of pigment particles and a portion of said plurality of fiber substrates, wherein said binder affixes said portion of said plurality of indigo particles to a portion of said plurality of fiber substrates; and,   d) a binder shell surrounding a portion of said binder.   
     
     
         2 . The yarn according to  claim 1  wherein said binder shell does not include any pigment particles therein. 
     
     
         3 . The yarn according to  claim 1  wherein a modulus of said yarn is at least 50% greater than a modulus of a raw yarn substrate counterpart. 
     
     
         4 . The yarn according to  claim 1  wherein a modulus of said yarn is at least 100% greater than a modulus of a raw yarn substrate counterpart. 
     
     
         5 . The yarn according to  claim 1  wherein said pigment is further defined as comprising indigo. 
     
     
         6 . The yarn according to  claim 1  wherein a hairiness of said yarn is reduced by at least 30% compared to a raw yarn substrate counterpart. 
     
     
         7 . The yarn according to  claim 1  wherein a hairiness of said yarn is reduced by at least 65% compared to a raw yarn substrate counterpart. 
     
     
         8 . A yarn comprising:
 a) a plurality of fiber substrates adjacent to one another to form said yarn, wherein said plurality of fiber substrates contain a biopolymer;   b) a pigment dispersed throughout at least an exterior portion of said yarn, wherein said pigment comprises a plurality of pigment particles, wherein a first portion of said pigment dyes at least one of said fiber substrates, and wherein a second portion of said pigment results in pigment padding of at least one of said fiber substrates; and,   c) a binder surrounding said second portion of said plurality of pigment particles, wherein said binder affixes said second portion of said plurality of indigo particles to a portion of said plurality of fiber substrates.   
     
     
         9 . The yarn according to  claim 8  further comprising a binder shell positioned around a portion of said binder. 
     
     
         10 . The yarn according to  claim 9  wherein said binder shell does not include any pigment particles therein. 
     
     
         11 . The yarn according to  claim 8  wherein a modulus of said yarn is at least 50% greater than a modulus of a raw yarn substrate counterpart. 
     
     
         12 . The yarn according to  claim 8  wherein a modulus of said yarn is at least 100% greater than a modulus of a raw yarn substrate counterpart. 
     
     
         13 . The yarn according to  claim 8  wherein said pigment is further defined as comprising indigo. 
     
     
         14 . The yarn according to  claim 8  wherein a hairiness of said yarn is reduced by at least 30% compared to a raw yarn substrate counterpart. 
     
     
         15 . The yarn according to  claim 8  wherein a hairiness of said yarn is reduced by at least 65% compared to a raw yarn substrate counterpart. 
     
     
         16 . A dyeing and welding process comprising:
 a) creating a suspension of a plurality of indigo dye particles in a process solvent;   b) creating a solution of a plurality of indigo dye molecules in said process solvent;   c) applying said process solvent to a substrate, wherein said substrate comprises a biopolymer;   d) controlling a temperature of said process solvent and said substrate;   e) controlling a time for which said process solvent interacts with said substrate; and,   f) removing at least a portion of said process solvent.   
     
     
         17 . The dyeing and welding process according to  claim 16  further comprising the step of applying a second process solvent to said substrate, wherein said second process solvent comprises said biopolymer in a solution. 
     
     
         18 . The dyeing and welding process according to  claim 17  wherein said step of applying said second process solvent is further defined as occurring after said step of removing at least said portion of said process solvent. 
     
     
         19 . The dyeing and welding process according to  claim 17  wherein said step of applying said second process solvent is further defined as occurring before said step of removing at least said portion of said process solvent. 
     
     
         20 . The dyeing and welding process according to  claim 16  wherein said process solvent is further defined as being selected from a group consisting of: 1-ethyl-3-methylimidazolium acetate, 1-butyl-3-methylimidizolum chloride, dimethyl sulfoxide, dimethylformamide.