Modified Polyester Fiber Dye Penetration via Silicated Diol
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Solution Overview
Problem
The difficulty in dyeing porous PET fibers due to their high crystallinity and dense structure, which restricts the diffusion of dye molecules, and the environmental concerns associated with high antimony catalyst usage in polyester synthesis.
Innovation Solution
Introducing main chain silicated diol and doped Sb2O3 into the polyester synthesis process, which increases the free volume of the fiber and enhances the catalytic activity of the antimony trioxide catalyst, allowing for easier dye penetration and reducing the amount of antimony required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature and high pressure method is used for PET fiber dyeing, then dye penetration is improved, but energy consumption increases and dye uptake rate remains low
Solution Approach 1:
The patent introduces main chain silicated diol to modify the polyester molecular structure, changing the physical parameters of the fiber including increasing free volume and reducing glass transition temperature. This structural modification enables effective dyeing at lower temperatures (reducing from conventional high temperature/pressure conditions) while maintaining good dye penetration, thus resolving the contradiction between dye penetration and energy consumption
Solution Approach 2:
The patent creates a composite modified polyester fiber by incorporating main chain silicated diol into the polyester molecular chain. This composite structure combines the properties of polyester with silicated components, producing a fiber that has both the original strength properties and enhanced dyeability at lower energy input, effectively addressing the energy consumption vs. dye penetration contradiction
2Power
If large amount of antimony catalyst is added in polyester synthesis, then catalytic activity is improved, but environmental harm increases and fiber brightness decreases
Solution Approach 1:
The patent introduces main chain silicated diol as a catalyst modifier that changes the catalytic system parameters. The silicated diol interacts with the antimony catalyst to enhance its activity, allowing reduction of antimony dosage while maintaining or improving catalytic performance. This reduces environmental harm from antimony waste and prevents excessive antimony incorporation that would darken the fiber
Solution Approach 2:
The main chain silicated diol acts as an intermediary substance between the antimony catalyst and the polyesterification reaction. It modifies the catalyst's interaction with reactants, enhancing catalytic efficiency and allowing lower antimony loading. This intermediary role enables the system to achieve high catalytic activity with reduced environmental impact and improved fiber brightness
3Reliability
If main chain silicated diol is introduced to increase free volume, then dyeing performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines the functions of catalyst modifier and molecular structure modifier into a single component - the main chain silicated diol. This unified approach achieves both enhanced catalytic activity (improving manufacturing efficiency) and increased free volume (improving dyeing performance) through one additive, rather than requiring separate complex processing steps for each function
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
This approach improves the dyeing performance of polyester fibers by reducing dyeing temperature, shortening dyeing time, and lowering energy consumption while minimizing antimony usage, resulting in environmentally friendly production.
Implementation Method 1
Introducing main chain silicated diol and 2,2,3,4,5,5-hexamethyl-3,4-hexanediol, and doped Sb2O3 into the polyester synthesis process, which increases the free volume of the fiber
Implementation Method 2
doped Sb2O3 powder... enhances the catalytic activity of the antimony trioxide catalyst
Implementation Method 3
The dye molecules are difficult to enter into the fiber... promote the diffusion of dye molecules to the fiber
Data Source
AI summary
A type of easy-to-dye porous modified polyester fibers and preparing method thereof are disclosed. The preparing method is using the modified polyester melt through a porous spinneret with FDY process; wherein the modified polyester is a product of an esterification and successive polycondensation reactions of an evenly mixed terephthalic acid, ethylene glycol, main chain silicated diol, 2,2,3,4,5,5-hexamethyl-3,4-hexanediol, and metal oxide doped Sb2O3 powder; wherein the main chain silicated diol is selected from the group consisting of dimethylsiloxane diol, dimethyldiphenyldisiloxane glycol and tetramethyldisiloxane diol. The structural formula of 2,2,3,4,5,5-hexamethyl-3,4-hexanediol is as follows:The dye uptake and the K/S value of the prepared easy-to-dye porous modified polyester fiber are high. This invention features a method with ease of application and a product with good dyeing performance and good quality.