Polyester composition with improved dyeing properties
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Solution Overview
Problem
The challenge lies in developing a polyester composition that can be dyed with cotton in a single step, as current methods require separate dyeing processes for cotton and polyester due to differences in dyeing conditions, leading to increased costs and degradation of elasticity in stretch fibers.
Innovation Solution
A polyester copolymer composition comprising terephthalic acid, adipic acid, pentaerythritol, polyethylene glycol, and diethylene glycol, maintained at specific temperature and intrinsic viscosity ranges, allowing for dyeing at atmospheric pressure and temperatures below 212°F (100°C), enabling simultaneous dyeing with cotton.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyester is dyed using conventional high-temperature methods, then dye penetration is improved, but elasticity of stretch fibers deteriorates
Solution Approach 1:
The patent modifies the chemical composition parameters of polyester by incorporating specific comonomers (carboxylic acid groups) to change the dyeing mechanism. This allows dyeing at lower temperatures (below 212°F/100°C) while maintaining adequate dye penetration, thereby preserving the elasticity of stretch fibers that would otherwise be degraded by conventional high-temperature dyeing processes.
2Reliability
If separate dyeing processes are used for cotton and polyester, then dyeing effectiveness is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent creates a polyester variant with carboxylic acid groups that can be dyed using the same low-temperature, atmospheric pressure process as cotton. This universal dyeing approach eliminates the need for separate high-temperature dyeing equipment and processes for polyester, allowing both fibers to be dyed simultaneously in a single batch process, thereby reducing manufacturing complexity and cost.
3Reliability
If high-temperature dyeing is used for polyester, then color fastness is improved, but energy consumption increases
Solution Approach 1:
By changing the chemical parameters of polyester (incorporating carboxylic acid groups), the patent enables effective dyeing at lower temperatures. This parameter change maintains color fastness through chemical bonding mechanisms while significantly reducing the thermal energy required for the dyeing process, thereby lowering energy consumption compared to conventional high-temperature polyester dyeing.
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 9.5 and 10.5 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.