Branched-Diol Modified Polyester Fiber for Low-Energy Dyeing
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Solution Overview
Problem
Polyester fibers, particularly PET fibers, face challenges in dyeing due to their high crystallinity and lack of functional groups, leading to poor dye uptake and uneven dyeing, along with high energy consumption in the dyeing process, which affects their quality and processing efficiency.
Innovation Solution
The development of a modified polyester fiber with a branched diol chain segment that increases the space gap between molecular chains, allowing for better dye diffusion and reduced melt viscosity, combined with an elliptical spinneret arrangement for uniform cooling, enhancing dyeing uniformity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high temperature and high pressure are used for dyeing PET fibers, then dye uptake rate improves, but energy consumption increases and production cost increases
Solution Approach 1:
The invention changes the molecular structure parameter of PET by introducing branched chain segments, which fundamentally alters the dyeing mechanism from high-temperature diffusion to low-temperature interaction, thereby reducing energy consumption while maintaining dye uptake rate
Solution Approach 2:
The invention creates a composite molecular structure combining linear PET chains with branched chain segments, achieving both improved dyeability and maintained mechanical properties through structural composition optimization
2Quantity of substance
If high temperature and high pressure are used for dyeing PET fibers, then dye uptake rate improves, but production cost increases
Solution Approach 1:
The invention modifies the chemical structure parameter of PET by incorporating branched chain segments, which enables effective dyeing at lower temperatures and pressures, thereby reducing production costs while achieving adequate dye uptake rate
3Strength
If cooling and blowing rate is increased to improve fiber quality, then tensile properties improve, but energy consumption increases
Solution Approach 1:
The invention changes the molecular architecture parameter by introducing branched chains, which inherently improve tensile properties through enhanced molecular entanglement and intermolecular forces, reducing the need for intensive cooling and blowing operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The modified polyester fibers exhibit improved dyeing performance, reduced energy consumption, and maintained excellent mechanical properties, with enhanced uniformity and efficiency in the dyeing process, addressing the issues of poor dye uptake and uneven dyeing in traditional PET fibers.
Implementation Method 1
the space gap between molecular chains of modified polyester fibers is much larger than that of ordinary polyester fibers without branched chains at the same temperature, which is beneficial to the degree of tiny particles such as dye into the interior
Implementation Method 2
strengthen the convection of air around the yarn strip, make the inner and outer layer yarn strip cool evenly
Implementation Method 3
The melt viscosity of the modified polyester fiber is reduced, the processing temperature is reduced, and the degradation rate is reduced
Data Source
AI summary
A different shrinkage composite yarn and preparation method. The modified polyester is spun with a porous spinneret to produce a different shrinkage composite yarn, and the spinneret holes on the porous spinneret are arranged in an elliptical arrangement. The different shrinkage composite yarn is obtained by winding modified polyester POY yarn and FDY yarn, network recombining, and coiling them. The preparation method of modified polyester is as follows: terephthalic acid reacts with ethylene glycol to produce ethylene terephthalate. The modified polyester is obtained by the reaction of terephthalic acid with branched diol. The fiber of the invention has good properties and the deviation rate of fiber density. The CV value of breaking strength is ≤4.0%, the CV value of elongation at break is ≤8.0%, the CV value of coefficient of variation of coiling shrinkage is ≤8.0%.