Carrier system in dyeing polyester fabric

Abstract

The invention relates to a natural carrier substance used in the textile industry to enable dyeing of polyester fabrics at lower temperatures and to avoid generating environmentally harmful waste.

Description

[0001] DESCRIPTION

[0002] Carrier system in dyeing polyester fabric

[0003] FIELD OF THE INVENTION

[0004] The invention relates to a natural carrier substance used in the textile industry to enable dyeing of polyester fabrics at lower temperatures and to avoid generating environmentally harmful waste.

[0005] PRIOR ART

[0006] Polyester fabrics involve thermal or chemical dyeing processes using disperse dyes. The first main step of these processes is the preparation stage. In this stage, pretreatment is carried out to make the polyester fabric suitable for dyeing. This step includes cleaning the fabric, removing oils and dirt, and processing it if necessary. With this step, the polyester fabric fibers absorb the dye better. In the next step, disperse dyes are prepared for the dyeing process. Disperse dyes can usually be in powder or liquid form. These dyes are mixed with water to obtain a homogeneous mixture. The fabric is immersed in or injected with the dyeing mixture containing the disperse dyes. At this stage, it is ensured that the dye reaches the entire surface of the fabric. Heat and pressure are used during the dyeing process. Disperse dyes adhere to fabric fibers at temperatures above 130°C. In this process, heat and pressure are used to ensure that the dyes penetrate the fabric fibers. At lower temperatures, chemical reactions are used to bind disperse dyes to the fabric fibers. In this method, chemical binders are used to ensure that the dye adheres to the fabric. After the dyeing process, fixatives are used to set the dye on the fabric. Then, the fabric is washed and rinsed. This step removes excess dye residues and other chemicals from the fabric. Finally, the dyed fabrics are dried, and final processing steps are applied to achieve the desired fabric properties. In prior art, polyester fibers are dyed at high pressure and temperatures. By using a carrier substance, polyester fabrics can be dyed at temperatures between 100°C and 120°C. However, dyeing polyester at lower temperatures using a carrier substance has drawbacks such as higher dyeing costs, difficulty in removing carrier residues from the fabric after dyeing, and environmental pollution. Among the auxiliary substances used as carriers are butyl benzoate, methylnaphthalene, dichlorobenzene, diphenyl, and o-phenylphenol. The use of such substances also poses environmental risks in terms of pollution. The following documents were encountered during the preliminary patent search. In the document with the publication number W02018010356A1 , the method describes a dyeing process for cationically dyeable polyester / polyester / nylon / spandex fabrics. In this method, the fabric is immersed in a first dyeing liquor containing refined emulsifier, disperse dye, and cationic dye; the pH of the liquor is adjusted to 4.0-5.5 by adding acid, and the fabric is processed at 120-135°C for 20-60 minutes. Subsequently, the treated fabric undergoes hot washing, reducing cleaning, and acid neutralization, followed by immersion in a second dyeing liquor containing acid dye; the pH of this liquor is adjusted to 4.0-7.0 by adding acid, and the fabric is processed at 90-105°C for 20-60 minutes. Finally, the processed fabric is washed with water at room temperature, drained of liquid, and then subjected to acidic color fixation. This method ensures color fastness, reduces dyeing time, and saves energy and water consumption.

[0007] In the document with publication number of WO2018010357A1 The method describes a process for dyeing polyester / nylon / cationically dyeable polyester / spandex fabrics. In the first step, the fabric is immersed in a solution containing disperse dye and refined emulsifier, followed by adjusting the pH to 4.0 to 5.0 by adding acid and processing at high temperature. Subsequently, the fabric is washed with hot water, subjected to reducing cleaning, and acid neutralization is carried out. In the third step, the treated fabric is immersed in a solution containing cationic dye and acidic dye and processed again at a specified temperature. Finally, the fabric is washed at room temperature and subjected to acidic color fixation. This method reduces fabric dyeing time, minimizes water usage, and achieves high-quality and durable dyeing results while saving energy.

[0008] In the document with publication number of WO2015154155A1 , the invention describes a method and equipment for dyeing cellulosic fibers in a gas environment. Essentially, it involves a dyeing process using a base dye diluted in ethanol, citric acid, tannic acid, a water-ethanol solution, enzyme nanocapsules, and tetrafluoroethane gas among other components. The application process includes placing the textile product into a tank, evacuating the air with a vacuum pump, and pumping the dye and other components into the tank under pressure. During this process, the gas circulates inside the tank with the help of a circulation pump and is directed through return pipes to filters and storage cylinders. Special components like enzyme nanocapsules, the use of tetrafluoroethane gas, and controlled conditions are utilized to ensure a more effective dyeing process. This method enables dyeing of cellulosic fibers in a gas environment, offering a more efficient dyeing process compared to traditional methods.

[0009] As a result, all abovementioned problems have made it necessary to make an improvement in the relevant technical field.

[0010] AIM OF THE INVENTION

[0011] The present invention aims to eliminate the abovementioned problems and to make a development in the relevant technical field.

[0012] The main object of the invention is to replace environmentally impactful carrier substances commonly used in standard polyester fabric dyeing processes with eco- friendly tannic acid.

[0013] Another object of the invention is to perform the dyeing process at low temperatures without creating environmental pollution.

[0014] Another object of the invention is target the safe and natural use of plant-derived tannic acid as a carrier substance in dyeing polyester fabrics.

[0015] Another object of the invention is provide additional advantages on polyester fabric through the various functional groups present in the chemical structure of tannic acid, which confer anti-carcinogenic, antioxidant, antimutagenic, antimicrobial, anti-allergic, and anti-inflammatory properties.

[0016] Another object of the invention the practicality provided by tannic acid crystals being available in powder or flake form, commonly used in dyeing and leather tanning processes.

[0017] Another object of the invention is to offer a more environmentally friendly and practical dyeing process by eliminating the adverse effects of other carrier substances during the dyeing of polyester fabrics with disperse dye materials, through the use of tannic acid. BRIEF DESCRIPTION OF THE INVENTION

[0018] The invention is related to is a dye solution composition containing natural carrier chemicals used to reduce the required reaction temperature for dyeing polyester fabrics in the textile industry and prevent the formation of environmentally harmful waste so as to fulfil all aims mentioned above and will be obtained from the following detailed description. According to this, the dye composition includes by weight 0.01 - 1 % tannic acid to increase water solubility with its polyphenol structure, thereby preventing the formation of environmentally harmful waste, and 0.5-2.0% dyeing agent to facilitate dyeing of polyester fabrics in the temperature range of 110°C- 130°C. It also contains by weight 0.5-3% acidity regulator to maintain the pH of the dye composition in the range of 3.5-4, and acetic acid comprising 94-98.99% by weight pure water for performing the coloring process of polyester fabrics.

[0019] In a preferred embodiment of the invention, includes acetic acid as an acidity regulator, comprising 0.5-3% by weight.

[0020] In another preferred embodiment of the invention involves adding a dye solution composition to the tank as mentioned in method step A, to lower the required reaction temperature for dyeing polyester fabrics to the range of 110°C - 130°C and to enhance water solubility with its polyphenol structure, thereby preventing the formation of environmentally harmful waste. This dye solution composition comprises by weight 0.01 -1 % tannic acid, 0.5-2.0% dyeing agent, and 0.5-3% acidity regulator.

[0021] In a preferred embodiment of the invention, involves adding a dye solution composition containing acetic acid as an acidity regulator to the tank in method step A.

[0022] In another preferred embodiment of the invention is fabric endowed with antimicrobial properties.

[0023] BRIEF DESCRIPTION OF DRAWINGS

[0024] The SEM images of the raw fabric before dyeing are given in the In Figures 1 a, 1 b, and 1 c.

[0025] The SEM images of the fabric dyed at 110°C with a commercial carrier are given in Figures 2a, 2b ve 2c. The SEM images of the fabric dyed at 110°C with 0.5 g / L tannic acid are given in figures 3a, 3b, and 3c.

[0026] The SEM images of the fabric dyed at 120°C with a commercial carrier are given in figures 4a, 4b, and 4c,

[0027] The SEM images of the fabric dyed at 120°C with 0.5 g / L tannic acid are given in figures 5a, 5b, and 5c,

[0028] The SEM images of the fabric dyed at 130°C with a commercial carrier are given in figures 6a, 6b, and 6c.

[0029] The SEM images of the fabric dyed with 0.5 g / L tannic acid at 130°C are given in figures 7a, 7b, and 7c.

[0030] FT-IR analyses of the fabric dyed at 120°C are given in figures 8a, 8b, 8c, 8d, 8e, and 8f.

[0031] The figures are not required to be scaled and the details which are not necessary for understanding the present invention may be neglected. Moreover, the elements that are at least substantially identical or have at least substantially identical functions been shown by the same number.

[0032] DETAILED DESCRIPTION OF THE INVENTION

[0033] In this detailed description, the invention of the dyeing of polyester fabrics with a carrier systemis described by means of examples only for clarifying the subject matter such that no limiting effect is created.

[0034] The subject of the invention relates to the tannic acid, a natural carrier substance used in the textile industry to enable dyeing of polyester fabrics at lower temperatures and without creating harmful environmental waste.

[0035] In the textile industry, the use of natural carrier substances is increasingly gaining importance to enable eco-friendly and lower-temperature dyeing of polyester fabrics. The primary purpose of these carriers is to facilitate better adhesion of dispersing dye materials, especially those with low water solubility, to the fabric surface at lower temperatures. Polyester fabrics are dyed with dispersing dye materials at temperatures below 130°C using carriers that facilitate easy adsorption and diffusion. However, many existing carriers contribute to environmental issues such as poor light resistance, high toxicity, unpleasant odor, and high wastewater treatment costs. Additionally, they biodegrade weakly and contribute to environmental pollution. To address these issues, it is essential to prefer natural substances as carriers. In this context, natural materials like tannic acid can be cited as environmentally friendly carriers. The dyeing process with tannic acid, an environmentally friendly carrier substance, is approached step by step as follows:

[0036] Preparation of Tannic Acid Solution (A):

[0037] • Tannic acid is prepared at a concentration of 1.25 g / L as the main stock solution.

[0038] • Tannic acid is added to the tubes to be used for dyeing at different concentrations in the range of 0.01 -1% by weight.

[0039] Preparation of Polyester Fabrics (B):

[0040] • Polyester fabrics weighing 5 grams are prepared for dyeing.

[0041] Preparation of Dye (C):

[0042] • Six different dyes are prepared as 1% solutions.

[0043] Dyeing Process (D):

[0044] • Polyester fabrics are combined with a specified dye, acetic acid to achieve the desired pH level, and specified concentrations of tannic acid.

[0045] • Acetic acid is used to maintain the pH level required for the dyeing process.

[0046] • Tannic acid is used as a carrier agent to perform the dyeing process.

[0047] Application of Dye (E):

[0048] • Dyeing is carried out in a dyeing machine at temperatures of 110°C, 120°C, and 130°C under pre-determined conditions.

[0049] • Finally, the dyed fabrics are washed according to the conventional reductive washing method with 5 g / L hydrosulfite and 5 g / L sodium hydroxide. The temperature program for dyeing conditions at 110°C, 120°C, and 130°C is given in Table 1 , Table 2, and Table 3.

[0050] Table 1. 110°C Dyeing Diagram

[0051] Table 2. 120°C Dyeing Diagram

[0052] Table 3. 130°C Dyeing Diagram

[0053] Table 4. AE and K / S Results for Fabrics Dyed with Green Disperse Dye at 110°C, 120°C, and 130°C In Table 4, the AE and K / S values obtained from the analysis of fabrics dyed with green disperse dye at 110°C, 120°C, and 130°C using different tannic acid concentrations, as well as those dyed with a commercial carrier, are presented. According to the comparison values, fabrics dyed with different tannic acid concentrations exhibited higher K / S values. This indicates that tannic acid usage provides polyester fabrics with higher color strength and improves the retention of the disperse dye on the fabric. Additionally, when referring to the AE values of fabrics dyed with a commercial carrier, the AE values of fabrics dyed with different tannic acid concentrations are found to be similar. For a successful result, the AE value should be less than 1. The FT-IR analyses of the fabrics dyed with different tannic acid concentrations at 110°C, 120°C, and 130°C, as well as those dyed with a commercial carrier, are shown in Figures 8a, 8b, 8c, 8d, 8e, and 8f. The comparison values indicate that the structures of fabrics dyed with different tannic acid concentrations remain intact and preserved.

[0054] SEM images of fabrics dyed with tannic acid and those dyed with a commercial carrier have been obtained. Figures 1 a, 1 b, and 1 c show the SEM images of the raw fabric before dyeing. Figures 2a, 2b, and 2c display the SEM images of fabrics dyed with a commercial carrier at 110°C. Figures 3a, 3b, and 3c present the SEM images of fabrics dyed with 0.5 g / L tannic acid at 110°C. Figures 4a, 4b, and 4c show the SEM images of fabrics dyed with a commercial carrier at 120°C. Figures 5a, 5b, and 5c provide the SEM images of fabrics dyed with 0.5 g / L tannic acid at 120°C. Figures 6a, 6b, and 6c depict the SEM images of fabrics dyed with a commercial carrier at 130°C. Figures 7a, 7b, and 7c illustrate the SEM images of fabrics dyed with 0.5 g / L tannic acid at 130°C. According to the comparison values, it has been observed that the fiber structures of fabrics dyed with different concentrations of tannic acid remain intact and preserved compared to the raw fabric, and tannic acid adheres to the fabric.

[0055] Table 5 shows the zone diameters obtained from the antibacterial activity analysis of fabrics dyed with different concentrations of tannic acid at 110°C, 120°C, and 130°C, as well as those dyed with a commercial carrier. According to the analysis, the zone diameters of fabrics dyed with different tannic acid concentrations are larger. This indicates that tannic acid provides antibacterial properties to polyester fabrics. The raw fabric in Table 5 has not been subjected to any dyeing. The fabric labeled "T" is a sample obtained by impregnating a 1 x1 cm raw fabric with a solution containing 0.25 g / 100 mL tannic acid.

[0056] Table 5.

[0057] Table 6. Fastness test results for fabrics dyed with black disperse dye at 110°C

[0058]

[0059] Table 7. Fastness test results for fabrics dyed with black disperse dye at 120°C

[0060]

[0061] Table 8. Fastness test results for fabrics dyed with black disperse dye at 130°C

[0062]

[0063] Table 9. Fastness test results for fabrics dyed with green disperse dye at 110°C

[0064]

[0065] Table 10. Fastness test results for fabrics dyed with green disperse dye at 120°C

[0066]

[0067] Table 11. Fastness test results for fabrics dyed with green disperse dye at 130°C

[0068]

[0069] Table 12. Fastness test results for fabrics dyed with orange disperse dye at 110°C

[0070]

[0071] Table 13. Fastness test results for fabrics dyed with orange disperse dye at 120°C

[0072]

[0073] Table 14. Fastness test results for fabrics dyed with orange disperse dye at 130°C

[0074]

[0075] Table 15. Fastness test results for fabrics dyed with yellow disperse dye at 110°C

[0076]

[0077] Table 16. Fastness test results for fabrics dyed with yellow disperse dye at 120°C

[0078]

[0079] Table 17. Fastness test results for fabrics dyed with yellow disperse dye at 130°C

[0080]

[0081] Table 18. Fastness test results for fabrics dyed with red disperse dye at 110°C

[0082]

[0083] Table 19. Fastness test results for fabrics dyed with red disperse dye at 120°C

[0084]

[0085] Table 20. Fastness test results for fabrics dyed with red disperse dye at 130°C

[0086]

[0087] Table 21. Fastness test results for fabrics dyed with blue disperse dye at 110°C

[0088]

[0089] Table 22. Fastness test results for fabrics dyed with blue disperse dye at 120°C

[0090]

[0091] Table 23. Fastness test results for fabrics dyed with blue disperse dye at 130°C

[0092] Tables 6-23 present the fastness test results for fabrics dyed with different tannic acid concentrations at 110°C, 120°C, and 130°C, as well as for fabrics dyed with a commercial carrier. According to these fastness values, dyeing with tannic acid is considered a successful alternative that could replace the commercial carrier.

[0093] The scope of protection of the invention is stated in the attached claims and cannot be limited to what is explained in this detailed description for exemplary purposes. Because it is obvious that a person skilled in the art can produce similar structures in the light of those described above, without deviating from the main theme of the invention.

Claims

CLAIMS1. A dye solution composition containing natural carrier chemicals used to reduce the required reaction temperature for dyeing polyester fabrics in the textile industry and to prevent the formation of environmentally harmful waste and to impart antimicrobial properties to the applied fabric, the composition is characterized by comprising;• 0.01 -1 % by weight of tannic acid to increase water solubility with its polyphenol structure, thereby preventing the formation of environmentally harmful waste and enabling the dyeing of polyester fabrics at a temperature range of 110°C-130°C,• 0.5-2.0% by weight of dye to perform the coloring process of the polyester fabric,• 0.5-3% by weight of acidity regulator to stabilize the pH level of the dye composition in the range of 3.5-4,• 94-98.99% by weight of pure water.

2. The composition of claim 1 , wherein the composition comprises 5-3% by weight of acetic acid as the acidity regulator.

3. A polyester fabric dyeing method comprising the process steps ofA. Adding the dye solution to the tank,B. Adding the fabric to be dyed into the tank containing the dye solution,C. Dyeing the fabric by allowing the dye solution to penetrate the fabric through mixing and / or shaking at the required reaction temperature of 130°C for 130 minutes,D. Adding sodium hydroxide at a concentration of 3-6% by weight to perform reductive washing after the dyeing process,E. Adding hydrosulfite at a concentration of 3-6% by weight during the addition of sodium hydroxide, in order to enable the reaction temperature required for dyeing polyester fabrics characterized in that it comprises to be reduced to the range of 110°C - 130°C,and by increasing water solubility with its polyphenol structure to prevent the formation of environmentally harmful waste the dye solution is added to the tank in step A includes: 0.01 -1% by weight of tannic acid,0.5-2.0% by weight of dye,0.5-3% by weight of acidity regulator.

4. The method of claim 3, characterized in that the dye solution containing acetic acid as the acidity regulator is added to the tank in step A.

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