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 conventional 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, allows for dyeing at atmospheric pressure and lower temperatures, enabling simultaneous dyeing with cotton.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
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 combines the dyeing of cotton and polyester into a single simultaneous dyeing process using a unified dye composition. The dye composition contains multiple dye components that can selectively dye both fiber types under the same processing conditions, eliminating the need for separate dyeing steps and reducing manufacturing complexity while maintaining effective dyeing of both fibers
Solution Approach 2:
The patent modifies the chemical parameters of the dye composition by incorporating specific dye components and auxiliaries that enable both cotton and polyester to be dyed under identical conditions. This parameter change in the dyeing system allows a single process to achieve what previously required separate processes
2Manufacturing precision
If high temperature dyeing is used for polyester, then dye receptivity is improved, but fiber elasticity deteriorates
Solution Approach 1:
The patent changes the chemical parameters of the dye composition to include components and auxiliaries that enable effective polyester dyeing at lower temperatures. This parameter modification allows the dyeing process to occur at temperatures that preserve fiber elasticity while still achieving adequate dye receptivity in polyester
3Reliability
If multiple dyeing steps are implemented, then colorfastness is improved, but production time increases
Solution Approach 1:
The patent merges multiple dyeing steps into a single simultaneous dyeing operation. The unified dye composition is applied in one step to both cotton and polyester, achieving the colorfastness that would otherwise require multiple steps while significantly reducing production time
Solution Approach 2:
The patent enables continuous dyeing of both fiber types in a single uninterrupted process. The dye composition and processing conditions are designed to allow both cotton and polyester to be dyed simultaneously in one continuous operation, eliminating the time loss associated with multiple sequential steps
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.