Cationic Dyeable Polyester Fiber via Heteropolyacid and Branched Diol
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Solution Overview
Problem
Conventional polyester fibers face challenges in dyeability due to their hydrophobic nature and tight molecular structure, requiring high temperature and pressure for dyeing, which increases energy consumption and costs, and also have slow natural degradation rates, posing environmental concerns.
Innovation Solution
The development of cationic dyeable polyester fibers with low SIPE loading and rapid natural degradation rates is achieved through the use of tert-butyl branched diol and high-temperature calcined solid heteropolyacid powders in the esterification and polycondensation reactions, enhancing dye uptake and degradation rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional disperse dyes are used at high temperature and high pressure to dye PET fiber, then dye uptake is ensured, but energy consumption and dyeing cost increase
Solution Approach 1:
The patent changes the chemical parameters of the polyester fiber by incorporating cationic monomers (SIPE and dimethylol propionic acid) into the polymer chain, transforming the fiber from hydrophobic to hydrophilic with cationic dyeing sites. This parameter change enables dyeing at lower temperatures and pressures while maintaining high dye uptake, directly resolving the contradiction between dye uptake and energy consumption
Solution Approach 2:
The patent creates a composite polyester structure by combining traditional PET chains with cationic monomer units (SIPE and DMPA) within the same polymer chain. This composite approach allows the fiber to retain PET's mechanical properties while gaining improved dyeability and reduced energy requirements for dyeing
2Quantity of substance
If SIPE modifier is added to polyester molecules to enable cationic dyeing, then dyeability is improved, but condensed particles and precipitates form reducing spinnability
Solution Approach 1:
The patent introduces dimethylol propionic acid (DMPA) as an intermediary substance that mediates between SIPE and the polyester chain. DMPA contains both hydroxyl groups that can react with SIPE and cationic groups that provide dyeing sites, acting as a bridge that prevents direct reaction between SIPE and metal ions that would cause precipitation, thus maintaining both dyeability and spinnability
Solution Approach 2:
The patent applies local quality by incorporating cationic functional groups (SIPE and DMPA) at specific locations within the polyester chain rather than uniformly throughout. This localized modification allows cationic dyeing sites to be present while maintaining the overall polymer structure's spinnability, preventing condensed particles and precipitates
3Strength
If conventional PET structure is used, then mechanical strength is maintained, but natural degradation rate is slow increasing environmental pressure
Solution Approach 1:
The patent changes the chemical composition parameters of polyester by incorporating hydrophilic cationic monomers (SIPE and DMPA) into the polymer chain. These modifications increase the polymer's hydrophilicity and create more accessible ester bonds, accelerating natural degradation rates while maintaining adequate mechanical strength through controlled monomer content
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 method improves dyeing performance with lower energy consumption and shorter dyeing times, while also accelerating the natural degradation of polyester fibers, reducing environmental impact.
Implementation Method 1
high-temperature calcined solid heteropolyacid powders in the esterification and polycondensation reactions
Implementation Method 2
the use of tert-butyl branched diol and high-temperature calcined solid heteropolyacid powders in the esterification and polycondensation reactions, enhancing dye uptake and degradation rates
Implementation Method 3
cationic dyeable polyester fiber... the polar sodium sulfonate group could be connected with cationic dyes
Implementation Method 4
accelerating the natural degradation of polyester fibers... rapid natural degradation rates
Data Source
AI summary
A type of cationic dyeable polyester fiber and preparing method thereof are disclosed. The preparing method is to manufacture a fiber from a cationic modified polyester through a fully drawn yarn (FDY) process, wherein the cationic modified polyester is composed of terephthalic acid segments, ethylene glycol segments, sodium salt of diethylene ester of 5-sulfoisophthalic acid segments and tert-butyl branched diol segments and a molecular formula of tert-butyl branched diol is as following:The cationic modified polyester is further dispersed with a high temperature calcined solid heteropolyacid. A final fiber has a dye uptake of 87.8-92.2% and a K/S value of 23.27-25.67 when dyed at 120° C., as well as an intrinsic viscosity drop of 13-17% when stored at 25° C. and R.H. 65% for 60 months.