Blended textile composition with improved dyeing properties

Abstract

Disclosed is a copolymer composition having advantages for textile fibers, yarns, blended yarns, fabrics and garments, and methods of making and using same. The copolymer composition can include 84-86% terephthalic acid, 13-16% ethylene glycol, 0.5-1.5% caprolactone monomer, 0.1-2% pentaerythritol and / or 0.5-2% polyethylene glycol.

Description

Technical Field

[0001] Cross-Reference to Related Applications

[0001] This application is a PCT application claiming the priority benefit of U.S. Provisional Patent Application No. 63 / 194,234, filed May 28, 2021, entitled POLYESTER COMPOSITION FOR FILAMENT, YARNS, AND FABRICS.

[0002]

[0002] Disclosed are copolymer compositions having advantages for textile fibers, yarns, blended yarns, fabrics and garments, as well as methods of making and using the same. Background Art

[0003]

[0003] Synthetic compositions can be used to produce filaments and fibers. Such filaments and fibers are used in articles including fabrics. Working backwards starting from one such article, a garment, provides information regarding the role of filaments, fibers and yarns in the production of the final product. Garments are typically formed from fabric woven or knitted from yarns. Yarns, in turn, are formed from individual fibers that are bonded together, for example, by a spinning process.

[0004]

[0004] There are two main types of manufacturing processes for synthetic fibers: batch processes and continuous processes. Continuous production processes are generally economically preferred over batch processes and can be carried out on a continuous polymerization line.

[0005]

[0005] Natural fibers (in particular, such as cotton and wool) may have inherent properties that give yarns, fabrics, and garments specific properties, depending on the type of natural fiber used. For example, wool has excellent thermal properties and maintains its insulating properties when wet. However, unless properly treated, wool is abrasive and therefore can be uncomfortable when in contact with the skin for extended periods. Similarly, various synthetic fibers may have some properties that are more desirable than natural fibers. One of the goals in the production, design, and development of synthetic compositions for use as fibers, yarns, and fabrics is to produce products that have properties desirable for the intended purpose of the fabric. This often requires combining properties often found in certain natural fibers with complementary properties found in certain synthetic fibers. It is common to blend synthetic and natural fibers in proportions that result in finished garments with the most desirable properties for a particular purpose.

[0006]

[0006] In the apparel industry, the ability to produce garments with desired colors is a fundamental goal. This can be achieved through the dyeing process. Depending on the situation, fibers can be dyed as fibers, filaments, yarns, fabrics, or garments themselves. Fundamentally, the color of a garment is based on the chemical composition of the underlying fibers, as well as the chemical composition and process of a suitable dye composition.

[0007]

[0007] However, the properties of the two different fibers present practical problems when dyeing blended fabrics. One such problem is that the color of a dye is based on the functional groups in the dye molecule. In other words, different colors in textiles are the result of the action of dye molecules with different compositions. However, not all dye colors (i.e., the underlying molecules) function the same way in natural and synthetic fibers, yarns and garments. Therefore, additional steps are introduced into the dyeing process of fabrics made from blended fibers and yarns in order to ensure the desired color properties.

[0008]

[0008] Therefore, there is a need for a composition that can produce synthetic fibers having desirable colorfastness properties when dyed at lower temperatures and / or pressures than conventional dyes. Furthermore, it would be economically ideal if such fibers could be produced in a continuous polymerization process. [Overview of the project]

[0009]

[0009] One or more aspects of the present invention can address one or more of the above-mentioned problems.

[0010] In one aspect of the present invention, a method for spinning polyester copolymer filaments is provided, comprising polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol to form a polyester copolymer melt; and spinning the polyester copolymer melt into polyester copolymer filaments.

[0010] This specification includes the disclosure of the following inventions. [Item 1] A method for spinning polyester copolymer filaments, Terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol are polymerized to form a polyester copolymer melt; and A polyester copolymer molten material is spun into a polyester copolymer filament; The method, including the above. [Item 2] The method according to Item 1, wherein the polymerization of terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol to form a polyester copolymer melt is carried out in a continuous polymerization line. [Item 3] The method according to Item 1, wherein polymerization of terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol to form a polyester copolymer melt is carried out in a batch reactor. [Item 4] The method according to any one of Items 1 to 3, wherein polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol comprises polymerizing 84% to 86% terephthalic acid by weight of the polyester copolymer melt. [Item 5] The method according to any one of Items 1 to 4, wherein polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol comprises polymerizing 13 to 16% by weight of ethylene glycol in a polyester copolymer melt. [Item 6] The method according to any one of Items 1 to 5, wherein polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol comprises polymerizing 0.5 to 1.5% by weight of caprolactone monomer in a polyester copolymer melt. [Item 7] The method according to any one of Items 1 to 6, wherein polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol comprises polymerizing 0.1 to 2% pentaerythritol based on the total amount of the polyester copolymer melt. [Item 8] The method according to any one of Items 1 to 7, wherein polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol comprises polymerizing 0.5 to 2% by weight of polyethylene glycol in a polyester copolymer melt. [Item 9] The method according to any one of Items 1 to 8, wherein the polyester copolymer molten contains less than 3% diethylene glycol. [Item 10] The method according to any one of Items 1 to 9, wherein polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol comprises polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol at an intrinsic viscosity of about 0.58 to 0.82 and a temperature of about 275°C to 295°C. [Item 11] The method described in Item 9, wherein the temperature is 285°C to 295°C. [Item 12] A method for forming a textured polyester copolymer filament, comprising texture a polyester copolymer filament produced by the method described in any one of Items 1 to 11 to form a textured polyester copolymer filament. [Item 13] A method for forming textured polyester copolymer staple fibers, comprising cutting a textured polyester copolymer filament described in Item 12 to form textured polyester copolymer staple fibers. [Item 14] A method for forming a blended yarn, comprising spinning a textured polyester copolymer staple fiber described in Item 13 together with a plurality of cotton fibers to form a blended yarn. [Item 15] A method for forming a dyed blended yarn, comprising dyeing the blended yarn described in Item 14 to form a dyed blended yarn. [Item 16] The method according to Item 15, wherein the dyeing of the blended yarn comprises dyeing the cellulose component of the blended yarn with a reactive dye at atmospheric pressure. [Item 17] A method for forming a fabric from the blended yarn described in Item 14. [Item 18] A method for forming a dyed fabric, comprising dyeing the fabric described in Item 17. [Item 19] The method of Item 18, wherein the dyeing of the fabric comprises dyeing the fabric with a reactive dye at atmospheric pressure. [Item 20] A method for forming a dyed fabric from dyed blended yarn as described in Item 15 or 16. [Item 21] A method for forming garments from the fabrics described in Item 17. [Item 22] A method for forming garments from dyed fabrics as described in any one of items 18-20. [Item 23] A method for forming dyed yarn, This includes dyeing yarn blended from cotton and textured polyester copolymer staple fibers. The yarn contains approximately 10-90% cotton; and The textured polyester copolymer staple fiber comprises terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol; The aforementioned method. [Item 24] The method according to Item 23, wherein the textured polyester copolymer staple fibers contain 84-86% by weight of terephthalic acid in the polyester copolymer molten material. [Item 25] Textured polyester copolymer staple fibers containing 0.5-1.5% by weight of caprolactone monomer in the polyester copolymer melt, as per item 23 or 24. Method of description. [Item 26] The method according to any one of Items 23 to 25, wherein the textured polyester copolymer staple fibers contain 13 to 16% by weight of ethylene glycol in the polyester copolymer molten material. [Item 27] ​​The method according to any one of Items 23 to 25, wherein the textured polyester copolymer staple fibers contain 0.1 to 2% pentaerythritol based on the total amount of the polyester copolymer molten material. [Item 28] The method according to any one of Items 23 to 25, wherein the textured polyester copolymer staple fibers contain 0.5 to 2% by weight of polyethylene glycol in the polyester copolymer molten material. [Item 29] The method according to any one of Items 23 to 28, wherein the textured polyester copolymer staple fiber contains less than 2.5% diethylene glycol. [Item 30] The method according to any one of items 23 to 29, wherein the dyeing of a yarn blended from cotton and textured polyester copolymer staple fibers is carried out at atmospheric pressure and at a temperature below 100°C. [Item 31] The method according to any one of Items 23 to 30, wherein the dyeing of the cotton component of the yarn includes dyeing the yarn with a reactive dye. [Item 32] The method according to any one of Items 23 to 31, wherein dyeing the polyester component of the yarn comprises dyeing the yarn with a disperse dye. [Item 33] A method for forming a knitted fabric, the method comprising knitting the dyed yarn according to any one of Items 23 to 32 to form the knitted fabric. [Item 34] A method for forming a knitted garment from the knitted fabric according to Item 33. [Item 35] A method for forming a woven fabric, the method comprising weaving the dyed yarn according to any one of Items 23 to 32 to form the woven fabric. [Item 36] A method for forming a woven garment from the woven fabric according to Item 35. [Item 37] A textile composition comprising: terephthalic acid; ethylene glycol; caprolactone monomer; pentaerythritol; and polyethylene glycol. [Item 38] The textile composition according to Item 35, wherein the textile composition comprises 84 to 86% of terephthalic acid. [Item 39] The method according to any one of Items 37 or 38, wherein the textile composition comprises 13 to 16% by weight of ethylene glycol based on the polyester copolymer melt. [Item 40] The composition according to any one of Items 38 to 39, wherein the textile composition comprises 0.5 to 1.5% of caprolactone monomer. [Item 41] The composition according to any one of Items 39 to 40, wherein the textile composition comprises 0.1 to 2% of pentaerythritol. [Item 42] The composition according to any one of Items 37 to 41, wherein the textile composition comprises 0.5 to 2% of polyethylene glycol. [Item 43] A polyester copolymer filament produced from the textile composition according to any one of Items 37 to 42. [Item 44] A textured polyester copolymer filament made from the polyester copolymer filament of Item 43. [Item 45] A textured polyester copolymer staple fiber made from the textured polyester copolymer filament of Item 44. [Item 46] A blended yarn comprising: the textured polyester copolymer staple fiber of Item 45; and a plurality of cotton fibers. [Item 47] A dyed knit fabric comprising the blended yarn of Item 46. [Item 48] A dyed woven fabric comprising the blended yarn of Item 46. [Item 49] A textile fabric comprising: spandex; and the polyester copolymer filament of Item 43. [Item 50] A polyester copolymer filament comprising: terephthalic acid; ethylene glycol; caprolactone monomer; pentaerythritol; and polyethylene glycol. [Item 51] The polyester copolymer filament of Item 50, wherein the polyester copolymer filament comprises 84 to 86% of terephthalic acid. [Item 52] The polyester copolymer filament of Item 4 or 51, wherein the polyester copolymer filament comprises 13 to 16% of ethylene glycol. [Item 53] The polyester copolymer filament of any one of Items 50 to 52, wherein the polyester copolymer filament comprises 0.5 to 1.5% of caprolactone monomer. [Item 54] The polyester copolymer filament of any one of Items 50 to 53, wherein the textile composition comprises 0.1 to 2% of pentaerythritol. [Item 55] A polyester copolymer filament according to any one of items 50 to 54, wherein the polyester copolymer filament contains 0.5 to 2% polyethylene glycol. [Item 56] A textured filament made from a polyester copolymer filament as described in any one of items 49-55. [Item 57] Textured polyester copolymer staple fibers made from the textured filaments described in Item 56. [Item 58] Blended yarns containing the following: Textured polyester copolymer staple fibers as described in item 57; and Multiple cotton fibers. [Item 59] A fabric formed from a blended yarn as described in Item 60, wherein the yarn is a woven or knitted fabric. [Item 60] Multiple staple fibers cut from the textured filament described in Item 56. [Item 61] Blended yarns containing the following: Multiple cotton or rayon fibers; and Multiple staple fibers as described in item 60. [Item 62] Blended yarn as described in Item 61, wherein the blended yarn contains approximately 10-90% cotton or rayon. [Item 63] Colorfast yarns including the following: Blended yarns as described in item 61 or 62; and Reactive dye. [Item 64] A fabric formed from the blended yarns described in Item 61 or 62. [Item 65] Fabrics as described in Item 64, where the fabric is a woven fabric or a knitted fabric. [Item 66] Fabric formed from colorfast yarn as described in Item 63. [Item 67] Fabrics as described in Item 66, wherein the fabric is a woven fabric or a knitted fabric. [Item 68] Dyed fabrics including the following: Reactive dyes; Blended yarns containing approximately 10% to 90% cotton or rayon; and Multiple textured polyester copolymer staple fibers, including the following: Terephthalic acid; Ethylene glycol; Caprolactone monomer; Pentaerythritol; and Polyethylene glycol. [Item 69] Dyed fabrics containing 84-86% terephthalic acid, as described in Item 68 Brick. [Item 70] The dyed fabric according to Item 68 or 69, wherein the dyed fabric contains 13-16% by weight of ethylene glycol in a polyester copolymer molten material. [Item 71] A dyed fabric according to any one of items 68 to 70, wherein the dyed fabric contains 0.5 to 1.5% caprolactone monomer. [Item 72] A dyed fabric as described in any one of items 68-71, wherein the dyed fabric contains 0.5-2% pentaerythritol. [Item 73] A dyed fabric as described in any one of items 68 to 72, wherein the dyed fabric contains 0.5 to 2% polyethylene glycol. [Item 74] A dyed fabric as described in any one of items 68-73, wherein the dyed fabric is a woven fabric or a knitted fabric. [Item 75] Garments made from dyed fabrics as described in any one of items 68-74.

[0011] In another aspect of the present invention, a method for forming a dyed yarn comprises dyeing a yarn blended from cotton and textured polyester copolymer staple fibers, the yarn comprising about 10 to about 90% cotton, and the textured polyester copolymer staple fibers comprising terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol.

[0011]

[0012] In other respects, the present invention provides a dyed fabric. The dyed fabric comprises a reactive dye, a blended yarn containing about 10% to about 90% cotton or rayon, and a plurality of textured polyester copolymer staple fibers containing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol.

[0012]

[0013] In yet another embodiment, a polyester copolymer filament is provided, comprising terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol.

[0013]

[0014] In a final aspect of the present invention, a textile composition is provided, comprising terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol. [Brief explanation of the drawing]

[0014]

[0015] Having described the present invention in general terms, we now refer to the accompanying drawings. These drawings are not necessarily drawn to a specific scale: [Figure 1]

[0016] Figure 1 illustrates the concentration of caprolactone monomer present in a fiber produced according to one aspect of the disclosed invention, as well as the concentrations of caprolactone monomer in overhead and in vacuum. [Figure 2]

[0017] Figure 2 shows a table illustrating the components and their respective masses in a 1000g sample before esterification. [Figure 3]

[0018] Figure 3 illustrates the color characteristics of fabrics made from both standard polyester and the proposed invention when dyed at approximately 210°F (99°C) to approximately 220°F (103°C). [Modes for carrying out the invention]

[0015]

[0019] As described herein, the object of the present invention is to produce a synthetic fiber that can be dyed together with natural fibers. Specifically, a polyester (polyethylene terephthalate) fiber that can be dyed together with cotton or rayon at temperatures below 100°C.

[0016]

[0020] As used herein, “dye” is defined as “a coloring agent that is molecularly dispersed at some point during application to a substrate and exhibits some degree of durability.” See Tortora, FAIRCHILD'S DICTIONARY OF TEXTILES, 7th edition, 2009 Fairchild Publications.

[0017]

[0021] As used herein, "dyeability" means "the ability of a fiber to accept dye." See Tortora above. Dyeability is a property of the fiber itself.

[0022] As used herein, in the context of synthetic fibers and their manufacture, the term “melt viscosity” refers to the resistivity of a molten polymer to deformation or flow under any given conditions. The term “intrinsic viscosity” is used to describe a property that is directly proportional to the average molecular weight of the polymer. Intrinsic viscosity is calculated based on the viscosity of the polymer solution (in the solvent) extrapolated to zero concentration. Thus, while intrinsic viscosity is a property that affects melt viscosity, melt viscosity is also related to other factors, particularly the temperature of the molten material.

[0018]

[0023] In textile technology, terms such as “texturing” and “crimping” are used broadly and specifically. In its broadest sense, texturing and crimping are used as synonyms for processes that mechanically, heatfully, or bother synthetic filaments, staple fibers, or yarns to have a larger volume than the untreated filaments, staples, or yarns. In a narrower sense, the term crimping is used to describe the process of creating a two-dimensional sawtooth orientation in filaments, fibers, or yarns, while the term texturing is used to describe the process of creating loops and curls. This meaning is usually clear from the context. As used herein, the term “texture” is used broadly to encompass all possibilities of producing a desired effect on filaments, staple fibers, or yarns.

[0019]

[0024] When "between" is used to indicate a range of numbers, that range encompasses the numbers used. For example, "between approximately 10% and approximately 13%" includes both 10% and 13%, as well as all numbers between 10% and 13%.

[0020]

[0025] As used herein, "percent" or "%" means weight percentage unless otherwise specified. Furthermore, concentration and proportion refer to the concentration or proportion in the finished copolymer unless otherwise specified.

[0021]

[0026] As used herein, the term “pilling” is used to describe undesirable small entanglements (“piles”) of fibers that may occur when the surface of a fabric is worn (including normal abrasion).

[0022]

[0027] This paper describes polyester (polyethylene terephthalate) fibers that possess desirable colorfastness characteristics when dyed at lower temperatures and pressures than conventional synthetic fibers.

[0028] Typically, cotton, rayon, and various other natural fibers are dyed with reactive or direct dyes at a temperature of approximately 66°C and atmospheric pressure. Furthermore, the dyeing of cotton tends to be accelerated by the pH of the dye solution or composition (typically a basic environment), while the dyeing of polyester tends to be accelerated by temperature, requiring the addition and performance of auxiliary chemicals commonly referred to as "carriers" or "leveling agents."

[0023]

[0029] In contrast, polyester is dyed with disperse dyes, which typically require much higher temperatures (most often 130°C), and therefore may also require pressurized equipment (above atmospheric pressure) to penetrate the dye dispersion into the polyester. From an economic standpoint, the use of disperse dyes is more expensive than the use of reactive dyes, especially when using high-energy disperse dyes. High-energy dyes are larger dyes at the molecular level. They are used to give fabrics brighter colors, for example, the colors used in clothing for safety purposes. Higher temperatures and pressures are required to penetrate these larger molecules into the polymer chains of conventional synthetic fabrics.

[0024]

[0030] With respect to the fibers disclosed herein, disperse dyes, including high-energy dyes, can be used at lower temperatures and pressures than conventional synthetic fibers, resulting in a reduction of 50% or more in dyeing costs. This is at least partially due to a reduction in water and energy use, which represent a 20% and 25% reduction per dyeing cycle, respectively.

[0025]

[0031] Due to these differences in dyeing compositions and conditions, it is conventional practice to dye cotton and polyester separately. For example, a blended cotton-polyester fabric can be dyed in two separate steps. In the first step, the fabric is dyed in a slightly acidic bath at a temperature of about 132°C or higher (e.g., using disperse dyes) to allow the polyester to accept the dye. The partially dyed fabric is then rinsed by scrubbing, and subsequently dyed in a dye suitable for cotton (e.g., direct dyes or reactive dyes) at a basic pH and a temperature of about 66°C. Since many cotton dyes decompose at polyester dyeing temperatures, the two steps cannot be combined.

[0026]

[0032] Common compositions and methods for producing polyester filaments, fibers, and yarns, as well as the limitations arising from such compositions and methods, contribute to many of the problems in facilitating the dyeing of fibers together with natural fibers. One example is the frequent use of additives to control or modify the properties of polymer melts, the characteristics of which are likely to alter either the dyeing properties or the spinning properties, or both.

[0027]

[0033] Another such example is synthetic fibers—and certainly polyester—which are produced by typically polymerizing starting materials and then extruding the polymer molten material through a small opening in a device called a spinneret, a process known as “spinning.” Anyone familiar with synthetic and natural fibers will immediately recognize that the term “spinning” is used to refer to two completely different processes. In one sense (and since ancient times), spinning refers to the process of twisting individual fibers together and pulling them into a yarn. In the production of synthetic fibers, extruding filaments from a molten material into solidified polymer filaments is also called “spinning.” The difference is usually clear from the context. Typically, the solidification of the extruded filaments is accelerated or propelled using a quenching process, in which a carefully controlled airflow is directed towards the extruded filaments.

[0028]

[0034] However, the properties required for a composition that can be melted and spun in this way are either unrelated to, or unfavorable in combination with, properties that result in good dyeing properties. For example, in order to be properly “spun,” the molten polymer must have a certain fluidity (viscosity) that allows it to produce a cohesive liquid filament (i.e., one that does not separate) at the spinneret by extrusion, while avoiding a viscosity (“watery”) that is too low to control the spinning process for its intended purpose. The spinning temperature must also be appropriate, as the viscosity of the polymer molten is proportional to the temperature, degree of polymerization, and other polymer properties. In other words, the molten polymer must be able to function at the indicated temperature. Furthermore, the synthetic fiber arises as a filament and must be cut and textured (not necessarily in this order) to obtain other desirable properties for the finished yarn, fabric, or garment. In most cases, the textured process requires the synthetic filament or fiber to be shaped mechanically or thermally into a form other than a linear extruded filament. Therefore, the need to texture polyester must be considered, and a range of other properties may be added that may compete with properties that enhance polymerization, spinning, or dyeing.

[0029]

[0035] The limited solutions known in the art for dyeing blended fiber fabrics require specialized equipment, and the resulting fabrics are ultimately expensive to produce. Furthermore, they are difficult to process under certain conditions, such as high heat and low humidity.

[0030]

[0036] This application discloses a dyeing process and recipe which can be used in textile machinery with significant modifications to the apparatus, enabling lower temperatures and pressures during production and requiring reduced amounts of components. The disclosures contained herein further result in dyed mixed fiber fabrics that provide enhanced pilling performance and reduce cost.

[0031]

[0037] In one aspect of the present invention, a method for spinning polyester copolymer filaments is provided, comprising polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol to form a polyester copolymer melt; and spinning the polyester copolymer melt into polyester copolymer filaments. In some embodiments, the polymerization of terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol to form a polyester copolymer melt is carried out in a continuous polymerization line. Those skilled in the art will recognize that the continuous polymerization process can have various configurations with respect to the size, number, and specifications of the machinery used.

[0032]

[0038] Referring to Figure 1, a table is provided showing the caprolactone monomer concentrations in the resulting fibers, as well as the caprolactone monomer concentrations in the overhead and vacuum of one continuous polymerization process configuration used to produce a particular exemplary embodiment of the present invention. In such production, the amount of each additive was varied within the parameters disclosed herein. As shown, only trace amounts of caprolactone monomer were present in the fibers, overhead, and vacuum, thus supporting the high product yield in the continuous process line.

[0033]

[0039] Referring to Figure 2, a table is shown showing the masses of caprolactone monomer, polyethylene glycol 400, and pentaerythritol in five successful tests in which 1000g of sample was produced in each test. The concentrations of the components can vary depending on several factors, for example, the color of the dye applied, but not limited to these factors.

[0034]

[0040] The polymerization steps for terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol may include polymerizing 84% to 86% terephthalic acid by weight of the polyester copolymer melt. Additionally or alternatively, the polymerization of terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol may include polymerizing 13 to 16% by weight of ethylene glycol of the polyester copolymer melt. Additionally or alternatively, the polymerization of terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol may include polymerizing 0.5 to 1.5% by weight of caprolactone monomer of the polyester copolymer melt. Alternatively or additionally, the polymerization of terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol may include polymerizing 0.1 to 2% pentaerythritol based on the total amount of polyester copolymer melt. Additionally or alternatively, polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol may include polymerizing 0.5 to 2% by weight of polyethylene glycol in the polyester copolymer melt.

[0035]

[0041] In some embodiments, the polyester copolymer melt contains less than 2.5% diethylene glycol. In some embodiments, polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol involves polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol at an intrinsic viscosity of about 0.58 to 0.82. Given that conventional copolymers tend to flow at lower intrinsic viscosities, the higher intrinsic viscosity of the present invention is counterintuitive and novel. Furthermore, the lower intrinsic viscosity in conventional polymers requires lower spinning temperatures for proper spinning and quenching. However, the range of intrinsic viscosity of the present invention allows polymerization at about 275°C to 295°C. More specifically, the temperature can be 285°C to 295°C.

[0036]

[0042] In some embodiments, the filaments produced by this method are textured and cut into staple fibers. Textured filaments are well understood in the art, and for the time being, we will not describe in particular detail other than pointing out that the compositions of the present invention produce filaments that can be textured using conventional processes (e.g., by heat curing while in the twisted position).

[0037]

[0043] In some embodiments, staple fibers are spun together with cotton or rayon to form a blended yarn. Optionally, the blended yarn may be dyed to form a dyed yarn. The dyed yarn can then be used to form a fabric that can be used to make textiles such as clothing. Alternatively, the blended yarn can be woven or knitted into a fabric, which is then dyed and formed into clothing. In some situations, the dyeing process is carried out on the clothing itself. Reactive dyes or disperse dyes can be used. Furthermore, the dyeing process may be carried out at atmospheric pressure, if desired.

[0038]

[0044] In another aspect of the present invention, a method for forming a dyed yarn comprises dyeing a yarn blended from cotton and textured polyester copolymer staple fibers, the yarn comprising about 20 to about 80% cotton; the textured polyester copolymer staple fibers comprising terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol. In some embodiments, the textured polyester copolymer staple fibers comprise 84 to 86% by weight of terephthalic acid in the polyester copolymer molten material. Additionally or alternatively, the textured polyester copolymer staple fibers may comprise 0.5 to 1.5% by weight of caprolactone monomer in the polyester copolymer molten material. Additionally or alternatively, the textured polyester copolymer staple fibers may comprise 13 to 16% by weight of ethylene glycol in the polyester copolymer molten material. Additionally or alternatively, the textured polyester copolymer staple fibers may comprise 0.5 to 2% pentaerythritol based on the total amount of the polyester copolymer molten material. Additionally or alternatively, textured polyester copolymer staple fibers may contain 0.5 to 2% by weight of polyethylene glycol in the polyester copolymer molten material. Additionally or alternatively, textured polyester copolymer staple fibers may contain less than 2.5% diethylene glycol.

[0039]

[0045] In some embodiments, the dyeing of yarns blended from cotton and textured polyester copolymer staple fibers is carried out at atmospheric pressure and a temperature below 212°F (100°C). In certain embodiments, the dyeing of the cotton component of the yarn includes dyeing the yarn with a reactive dye. In other embodiments, the dyeing of the polyester component of the yarn includes dyeing the yarn with a disperse dye. The yarn produced by this method can be knitted or woven to form knitted or woven fabrics. Knitted or woven fabrics can be used to make textiles such as clothing.

[0040]

[0046] In another aspect of the present invention, a textile composition comprising terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol is provided. The textile may contain 84-86% terephthalic acid. Additionally or alternatively, the textile composition may contain 13-16% by weight of ethylene glycol in the polyester copolymer melt. Additionally or alternatively, the textile composition may contain 0.5-1.5% caprolactone monomer. Additionally or alternatively, the textile composition may contain 0.1-2% pentaerythritol. Additionally or alternatively, the textile composition may contain 0.5-2% polyethylene glycol.

[0041]

[0047] In some embodiments, a polyester copolymer filament is produced using a textile composition. The polyester copolymer filament can be textured to produce a textured polyester copolymer filament, from which, optionally, a textured polyester copolymer staple fiber may be produced. The textured polyester copolymer fiber can then be used to form a blended yarn containing the textured polyester copolymer staple and a plurality of cotton fibers. In some embodiments, a dyed knitted fabric formed from the blended yarn is provided. In other embodiments, a dyed woven fabric formed from the blended yarn is provided. In yet another embodiment, a textile fabric containing spandex and polyester copolymer filament is provided.

[0042]

[0048] In yet another aspect of the present invention, a polyester copolymer filament is provided, comprising terephthalic acid; ethylene glycol; caprolactone monomer; pentaerythritol; and polyethylene glycol. The polyester copolymer filament may contain 84-86% terephthalic acid. Additionally or alternatively, the polyester copolymer filament may contain 13-16% ethylene glycol. Additionally or alternatively, the polyester copolymer filament may contain 0.5-1.5% caprolactone monomer. Additionally or alternatively, the polyester copolymer filament may contain 0.1-2% pentaerythritol. Additionally or alternatively, the polyester copolymer filament may contain 0.5-2% polyethylene glycol.

[0043]

[0049] In some embodiments, a textured polyester copolymer filament made from polyester copolymer filaments is provided. The textured polyester copolymer filament can be used to form a textured polyester copolymer staple fiber, or a plurality thereof, which can be used to form a blended yarn containing one or more textured polyester copolymer staple fibers and a plurality of cotton or rayon fibers. In some embodiments, the blended yarn contains about 10 to about 90 percent cotton or rayon. In some embodiments, a colorfast yarn containing a blended yarn and a reactive dye is provided. If desired, the fabric may be formed from the blended yarn and / or the colorfast yarn. The fabric can be made using several textile processing methods, resulting in woven fabrics containing the blended yarn or colorfast yarn, knitted fabrics containing the blended yarn or colorfast yarn, and so on.

[0044]

[0050] In another view, the present invention provides a dyed fabric comprising a reactive dye and a blended yarn comprising about 10% to about 90% cotton or rayon and a plurality of textured polyester copolymer staple fibers, wherein the plurality of textured polyester copolymer staple fibers comprises terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol. Additionally or alternatively, the plurality of textured polyester copolymer staple fibers may contain 13 to 16% ethylene glycol. Additionally or alternatively, the plurality of textured polyester copolymer staple fibers may contain 0.5 to 1.5% caprolactone monomer. Additionally or alternatively, the plurality of textured polyester copolymer staple fibers may contain 0.1 to 2% pentaerythritol. Additionally or alternatively, the plurality of textured polyester copolymer staple fibers may contain 0.5 to 2% polyethylene glycol.

[0045]

[0051] In some embodiments, the dyed fabric is a woven fabric. In other embodiments, the dyed fabric is a knitted fabric. In some embodiments, a garment comprising the dyed fabric is provided.

[0046]

[0052] In another aspect of the present invention, a textile composition comprising terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol is provided. The textile may contain 84-86% terephthalic acid. Additionally or alternatively, the textile composition may contain 13-16% by weight of ethylene glycol in the polyester copolymer melt. Additionally or alternatively, the textile composition may contain 0.5-1.5% caprolactone monomer. Additionally or alternatively, the textile composition may contain 0.1-2% pentaerythritol. Additionally or alternatively, the textile composition may contain 0.5-2% polyethylene glycol.

[0047]

[0053] In embodiments disclosing terephthalic acid at a concentration of 84-86%, the concentrations of terephthalic acid are approximately 84%-84.1%, 84%-84.2%, 84%-84.3%, 84%-84.4%, 84%-84.5%, 84%-84.6%, 84%-84.7%, 84%-84.8%, 84%-84.9%, 84%-85%, 84%-85.1%, 84%-85.2%, 84%-85.3%, 84%-85.4%, 84%-85.6%, 84%-85.7%, 84%-85.8%, and 84%. It can be approximately 85.9%, 84% to 86%, 85.9% to 86%, 85.8% to 86%, 85.7% to 86%, 85.6% to 86%, 85.5% to 86%, 85.4% to 86%, 85.3% to 86%, 85.2% to 86%, 85.1% to 86%, 85% to 86%, 84.9% to 86%, 84.8% to 86%, 84.7% to 86%, 84.6% to 86%, 84.3% to 86%, 84.2% to 86%, 84.1% to 86%, and / or approximately 84% to 86%.

[0048]

[0054] In embodiments disclosing ethylene glycol at a concentration of 13-16%, the concentrations of ethylene glycol are approximately 13%-13.1%, 13%-13.2%, 13%-13.3%, 13%-13.4%, 13%-13.5%, 13%-13.6%, 13%-13.7%, 13%-13.8%, 13%-13.9%, 13%-14%, 13%-14.1%, and 13%-1 4.2%, approximately 13% to 14.3%, approximately 13% to 14.4%, approximately 13% to 14.5%, approximately 13% to 14.6%, approximately 13% to 14.7%, approximately 13% to 14.8%, approximately 13% to 14.9%, approximately 13% to 15%, approximately 13% to 15.1%, approximately 13% to 15.2%, approximately 13% to 15.3%, approximately 13% to 15.4%, approximately 13% to 15.5%, approximately 13% to 15.6%, approximately 13% to 15.7%, approximately 13% to 15. 8%, approximately 13% to 15.9%, approximately 13% to 16%, approximately 13.1% to 16%, approximately 13.2% to 16%, approximately 13.3% to 16%, approximately 13.4% to 16%, approximately 13.5% to 16%, approximately 13.6% to 16%, approximately 13.7% to 16%, approximately 13.8% to 16%, approximately 13.9% to 16%, approximately 14% to 16%, approximately 14.1% to 16%, approximately 14.2% to 16%, approximately 14.3% to 16%, approximately 14.4% to 16%, approximately It can be 14.5% to about 16%, about 14.6% to about 16%, about 14.7% to about 16%, about 14.8% to about 16%, about 14.9% to about 16%, about 15% to about 16%, about 15.1% to about 16%, about 15.2% to about 16%, about 15.3% to about 16%, about 15.4% to about 16%, about 15.5% to about 16%, about 15.6% to about 16%, about 15.7% to about 16%, about 15.8% to about 16%, and / or about 15.9% to about 16%.

[0049]

[0055] In embodiments disclosing caprolactone monomers in concentrations of 0.5-1.5%, the concentrations of caprolactone monomers are approximately 0.5-0.6%, 0.5-0.7%, 0.5-0.8%, 0.5-0.9%, 0.5-1.0%, 0.5-1.1%, 0.5-1.2%, and 0.5-1.3%. It can be approximately 0.5% to 1.4%, approximately 0.5% to 1.5%, approximately 0.6% to 1.5%, approximately 0.7% to 1.5%, approximately 0.8% to 1.5%, approximately 0.9% to 1.5%, approximately 1.0% to 1.5%, approximately 1.1% to 1.5%, approximately 1.2% to 1.5%, approximately 1.3% to 1.5%, and / or approximately 1.4% to 1.5%.

[0050]

[0056] In the manner in which 0.1-2% pentaerythritol is disclosed, the concentrations of pentaerythritol are approximately 0.1%-0.3%, 0.1%-0.4%, 0.1%-0.5%, 0.1%-0.6%, 0.1%-0.7%, 0.1%-0.8%, 0.9%-1.0%, 0.1%-1.1%, 0.1%-1.2%, 0.1%-1.3%, 0.1%-1.4%, 0.1%-1.5%, 0.1%-1.6%, 0.1%-1.7%, and 0.1%- It can be 1.8%, approximately 0.1% to 1.9%, approximately 0.1% to 2%, approximately 0.2% to 2%, approximately 0.3% to 2%, approximately 0.4% to 2%, approximately 0.5% to 2%, approximately 0.6% to 2%, approximately 0.7% to 2%, approximately 0.8% to 2%, approximately 0.9% to 2%, approximately 1.0% to 2%, approximately 1.1% to 2%, approximately 1.2% to 2%, approximately 1.3% to 2%, approximately 1.4% to 2%, approximately 1.5% to 2%, approximately 1.6% to 2%, approximately 1.7% to 2%, approximately 1.8% to 2%, and / or approximately 1.6% to 2%.

[0051]

[0057] In embodiments disclosing polyethylene glycol in concentrations of 0.5-2%, the concentrations of polyethylene glycol are approximately 0.5%-0.6%, 0.5%-0.7%, 0.5%-0.8%, 0.5%-0.9%, 0.5%-1.0%, 0.5%-1.1%, 0.5%-1.2%, 0.5%-1.3%, 0.5%-1.4%, 0.5%-1.5%, 0.5%-1.6%, 0.5%-1.7%, and 0.5%- It can be 1.8%, approximately 0.5% to approximately 0.6%, approximately 0.5% to approximately 2.0%, approximately 0.6% to approximately 2.0%, approximately 0.7% to approximately 2.0%, approximately 0.8% to approximately 2.0%, approximately 0.9% to approximately 2.0%, approximately 1.0% to approximately 2.0%, approximately 1.1% to approximately 2.0%, approximately 1.2% to approximately 2.0%, approximately 1.3% to approximately 2.0%, approximately 1.4% to approximately 1.5%, approximately 1.6% to approximately 2.0%, approximately 1.7% to approximately 2.0%, approximately 1.8% to approximately 2.0%, and / or approximately 1.9% to approximately 2.0%. [Examples]

[0052]

[0058] Example 1

[0059] Dyeing tests were conducted at temperatures of approximately 99°C to approximately 103°C on both 10 grams of fabric produced in a manner consistent with standard polyester and 10 grams of the fabric of the present invention. In each test, 30 mL of a 1% dye solution, 2 mL of a 10% DLS Leveler solution, 2 mL of a 10% Albatex-45 solution, and 2 mL of acetic acid were applied to the fabric. The results of these tests are shown in Figure 3. The temperature variations used may be to adjust the coloration of the dye or various other factors. Preferred embodiments of the present invention are described herein, and certain terms have been adopted, but they are used only in a general and descriptive sense and not for limiting purposes, and the scope of the present invention is defined in the claims.

Claims

1. A method for spinning polyester copolymer filaments, Terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol are polymerized to form a polyester copolymer melt; and A polyester copolymer molten material is spun into a polyester copolymer filament; The method, including the above.

2. The method according to claim 1, wherein the polymerization of terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol to form a polyester copolymer melt is carried out in a continuous polymerization line.

3. The method according to claim 1, wherein the polymerization of terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol to form a polyester copolymer melt is carried out in a batch reactor.

4. Polymerization of terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol is 84% to 85.9% terephthalic acid by weight of the polyester copolymer molten; 13-14.9% ethylene glycol by weight of the polyester copolymer molten material; 0.5–1.5% by weight of the polyester copolymer molten caprolactone monomer; 0.1–2% pentaerythritol by weight of the polyester copolymer molten material; The method according to claim 1, comprising polymerizing polyethylene glycol at a weight of 0.5 to 2% of a polyester copolymer molten.

5. The method according to claim 1, wherein the polyester copolymer molten material contains less than 3% diethylene glycol.

6. The method according to claim 1, wherein polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol is performed to obtain a polymer having an intrinsic viscosity of 0.58 to 0.82 by polymerizing terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol at a temperature of 275°C to 295°C.

7. A method for forming dyed yarn, This includes dyeing yarn blended from cotton and textured polyester copolymer staple fibers. The yarn contains 10-90% cotton; and The textured polyester copolymer staple fiber comprises terephthalic acid, ethylene glycol, caprolactone monomer, pentaerythritol, and polyethylene glycol; the method described above.

8. Textured polyester copolymer staple fibers, 84–85.9% terephthalic acid by weight of the polyester copolymer molten; 0.5–1.5% by weight of the polyester copolymer molten caprolactone monomer; 13-14.9% ethylene glycol by weight of the polyester copolymer molten material; 0.1–2% pentaerythritol by weight of the polyester copolymer molten material; The method according to claim 7, comprising 0.5 to 2% by weight of the polyester copolymer molten polyethylene glycol.

9. The method according to claim 7, wherein the textured polyester copolymer staple fiber contains less than 2.5% diethylene glycol.

10. The method according to claim 7, wherein the dyeing of a yarn blended from cotton and textured polyester copolymer staple fibers is carried out at atmospheric pressure and a temperature below 100°C.

11. The method according to claim 7, wherein the dyeing of the cotton component of the yarn includes dyeing the yarn with a reactive dye.

12. The method according to claim 7, wherein the dyeing of the polyester component of the yarn includes dyeing the yarn with a disperse dye.

13. Textile compositions comprising: terephthalic acid; ethylene glycol; caprolactone monomer; pentaerythritol; and polyethylene glycol.

14. Textile composition 84–85.9% by weight of terephthalic acid; 13-14.9% by weight of ethylene glycol; 0.5 to 1.5% by weight of caprolactone monomer; 0.1–2% by weight of pentaerythritol; The textile composition according to claim 13, comprising 0.5 to 2% by weight of polyethylene glycol.

15. A polyester copolymer filament prepared from the textile composition described in claim 13.

16. A textured polyester copolymer filament made from the polyester copolymer filament described in claim 15.

17. A textured polyester copolymer staple fiber made from a textured polyester copolymer filament as described in claim 16.

18. A blended yarn comprising: textured polyester copolymer staple fibers as described in claim 17; and a plurality of cotton fibers.

19. A dyed knit fabric comprising the blended yarn described in claim 18.

20. A dyed woven fabric comprising the blended yarn described in claim 18.

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