Dyed Polyester Fiber Composition for Low-Temperature Spinning
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Solution Overview
Problem
Existing polyester fiber production methods require complex polymerization steps, high temperatures for dyeing, and often rely on carriers or copolymers, resulting in inflexible fibers with limited spinnability and variation in fiber thickness, as well as high energy consumption and equipment requirements.
Innovation Solution
A process involving the mixing and melting of terephthalate polyester with a polyester-containing additive, allowing for the production of spinnable and dyed fibers without complex polymerization, at temperatures below 130°C, using disperse dyes and eliminating the need for carriers, with the additive facilitating melt spinning and enabling uniform coloration and good fastness to rubbing and washing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If complex copolymers are used for low-temperature dyeing, then dyeing temperature can be reduced below 130°C, but fiber spinnability decreases and fiber thickness variation is limited
Solution Approach 1:
The patent uses a composite system consisting of standard polyester fibers combined with a small amount of polyester-containing additive (1-20 wt%), where the additive provides dyeing functionality while the main polyester component maintains spinnability. This avoids the need for complex copolymer structures.
Solution Approach 2:
The polyester-containing additive acts as an intermediary substance that enables low-temperature dyeing without requiring the entire polymer structure to be complex. The additive contains the necessary functional groups for dye interaction while the bulk polyester remains simple and easy to process.
2Temperature
If complex copolymers are used for low-temperature dyeing, then dyeing temperature can be reduced, but device complexity and equipment requirements increase
Solution Approach 1:
The patent employs a simple additive approach rather than complex copolymer synthesis, using readily available polyester-containing additives that can be mixed with standard polyester. This eliminates the need for specialized polymerization equipment and complex production facilities.
Solution Approach 2:
The invention changes the chemical composition parameter by adding a small amount of polyester-containing additive with specific functional groups, which enables dyeing at lower temperatures without requiring changes to the overall polymer structure or specialized equipment.
3Ease of manufacture
If standard polyester fibers are used, then spinnability is excellent, but dyeing requires temperatures of 130°C or more
Solution Approach 1:
The patent merges standard polyester fibers (providing excellent spinnability) with polyester-containing additives (providing low-temperature dyeing capability). The combination maintains the advantages of both components without requiring complex copolymerization.
Solution Approach 2:
The polyester-containing additive serves multiple functions: it maintains the polyester matrix structure for good spinnability while simultaneously providing functional groups that enable low-temperature dyeing, making the system universally applicable to standard polyester production.
4Temperature
If carriers are used for low-temperature dyeing, then dyeing temperature can be reduced, but the process becomes more complex
Solution Approach 1:
The patent extracts the carrier function from a separate substance and integrates it directly into the polyester matrix through the polyester-containing additive. The additive itself provides the necessary functional groups for dye interaction, eliminating the need for separate carrier chemicals and simplifying the overall process.
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 process results in fibers with excellent spinnability, softness, and a wide range of color options, with reduced energy consumption and mechanical simplicity, achieving light-fast and wash-fast results at lower temperatures, while maintaining fiber flexibility and allowing for various fiber thicknesses.
Implementation Method 1
mixing and melting of terephthalate polyester with a polyester-containing additive, allowing for the production of spinnable and dyed fibers
Implementation Method 2
The action of heat creates a melt that is extruded through spinnerets
Implementation Method 3
The coloring of polymer compositions which, in addition to the standard polyesters, such as PET or PBT, also contain at least one of the polyester-containing additives (B) mentioned, has the effect of using a disperse dye using the exhaust method at temperatures below 130 °C
Data Source
AI summary
The present invention relates to a method for producing dyed polyester fibers (C) from a terephthalate polyester (A), at least one additive (B) containing polyester, and optionally at least one component (G). The additive contining polyester can be obtained by condensing the monomers of an aliphatic 1, ?-dicarbolic acid and an aromatic 1, ?-dicarbolic acid. Chain lengtheners (V) are optionally also used in the production of the additive (B) containing polyester. The components (A, B) and optionally (G) are mixed, melted in an extruder, and extruding by means of spinnerets for generating fiber. Said polyester fibers (C) are preferably used in the production of dyed textile material webs (F).