Polyester Copolymer Composition for Single-Step Cotton-Blend Dyeing
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Solution Overview
Problem
Existing polyester compositions require separate dyeing processes for cotton and polyester fibers due to differences in dyeing conditions, leading to inefficiencies and higher costs, and existing formulations struggle to accept a wide range of dye colors without degrading elasticity or forming pills.
Innovation Solution
A polyester copolymer composition containing specific amounts of adipic acid, pentaerythritol, and polyethylene glycol, allowing for dyeing at atmospheric pressure and lower temperatures, enabling a single-step dyeing process with cotton while maintaining elasticity and reducing pill formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polyester is dyed using conventional disperse dyes, then dyeing can be achieved, but high temperature (above 250°F) and high pressure are required
Solution Approach 1:
The patent modifies the chemical parameters of polyester by incorporating specific comonomers (carboxylic acid groups and hydroxyl groups) that change the dyeing characteristics of the fiber, enabling dyeing at lower temperatures and atmospheric pressure while maintaining dye acceptance
Solution Approach 2:
The patent creates a composite polyester composition by blending multiple comonomers with specific functional groups (carboxylic acid and hydroxyl groups) in controlled ratios, resulting in a fiber with improved dyeing properties that combines the benefits of both functional groups
2Adaptability or versatility
If polyester composition is modified to accept more dye colors, then dyeability improves, but elasticity and pill resistance deteriorate
Solution Approach 1:
The patent precisely controls the concentration parameters of functional comonomers (0.1-5.0% carboxylic acid groups, 0.1-3.0% hydroxyl groups) to achieve optimal balance between dyeability enhancement and mechanical property preservation
Solution Approach 2:
The patent introduces specific functional groups at localized concentrations within the polyester chain, creating regions with enhanced dye affinity while maintaining the overall structural integrity and mechanical properties of the fiber
3Reliability
If separate dyeing processes are used for cotton and polyester, then each fiber can be dyed optimally, but production time and costs increase
Solution Approach 1:
The patent modifies polyester to possess dual functionality: it can be dyed with conventional disperse dyes under modified conditions while also accepting reactive dyes typically used for cotton, enabling a universal one-step dyeing process for cotton-polyester blends
Solution Approach 2:
The patent combines the dyeing capabilities of two different fiber types (cotton and polyester) into a single process by modifying polyester to accept both disperse and reactive dyes simultaneously, merging previously separate operations into one efficient step
Data Source
AI summary
A copolymer composition is disclosed with advantages for textile fibers, yarns, blended yarns, fabrics, and garments. The composition includes polyester copolymer, between about 4.5 and 5.5 percent adipic acid based on the amount of copolymer, between about 630 and 770 parts per million (ppm) of pentaerythritol based on the amount of copolymer, and between about 3.4 and 4.2 percent polyethylene glycol based on the amount of copolymer.