Hydrolysis-Resistant Polyester Film Dyeing Process
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Solution Overview
Problem
Conventional methods for dyeing polyester films are impractical for producing small quantities of colored films and pose safety hazards, while also resulting in poor hydrolysis resistance, especially when exposed to natural weather conditions.
Innovation Solution
A process involving a dye bath with coloring agents, polyhydric alcohols, and UV absorbers at controlled temperatures, followed by quenching, cleaning, and drying to produce a hydrolysis-resistant polyester film with controlled shrinkage and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dyeing methods (waterless or solvent-assisted) are used, then coloring efficiency is improved, but safety risk increases due to explosion and fire hazards
Solution Approach 1:
The patent changes the fundamental parameter of the dyeing medium from flammable solvents (waterless or organic solvents) to water-based dye bath, eliminating explosion and fire hazards while maintaining effective dyeing through controlled temperature (140-190°C) and chemical composition (polyhydric alcohols and UV absorbers)
Solution Approach 2:
The patent uses water as the dyeing medium instead of expensive and dangerous organic solvents. Water is inexpensive, non-flammable, and can be easily disposed of or recycled, replacing hazardous substances with a safe alternative
2Ease of manufacture
If conventional dyeing methods are used, then coloring is achieved, but hydrolysis resistance deteriorates when exposed to natural weather conditions
Solution Approach 1:
The patent incorporates UV absorbers and polyhydric alcohols into the dye bath before dyeing. These additives pre-provide protection against UV radiation and hydrolysis, so the film is already protected before exposure to natural weather conditions, preventing micro-cracking and degradation
Solution Approach 2:
The patent creates a composite dyeing system combining coloring agents with protective additives (UV absorbers and polyhydric alcohols) in the dye bath. This composite approach simultaneously achieves coloring and enhances hydrolysis resistance, making the film more durable under weather exposure
3Productivity
If dyeing is performed at high temperature to improve dye penetration, then coloring efficiency is improved, but film shrinkage increases
Solution Approach 1:
The patent optimizes the temperature parameter to a specific range (140-190°C) rather than using excessively high temperatures. This controlled temperature range achieves sufficient dye penetration while minimizing thermal shrinkage of the polyester film
Solution Approach 2:
The patent uses polyhydric alcohols in the dye bath that facilitate dye penetration at moderate temperatures, allowing effective coloring without relying solely on high temperature, thus reducing overall thermal stress and shrinkage on the film
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 a hydrolysis-resistant polyester film with enhanced mechanical properties, improved lightfastness, thermal stability, and controlled shrinkage, capable of withstanding harsh environmental conditions for extended periods.
Implementation Method 1
dyeing a hydrolysis resistant polyester film in a dye bath comprising at least one coloring agent (dye), at least one polyhydric alcohol, and optionally at least one UV absorber, at a temperature in the range of 140° C. to 190° C.
Implementation Method 2
The dyed film is quenched in a first fluid medium to obtain a quenched film. The quenching is required to precipitate the dissolved additives.
Implementation Method 3
The so obtained cleaned film is subjected to drying in an oven at a temperature in the range of 130° C. to 250° C. to obtain the dyed hydrolysis resistant polyester film.
Data Source
AI summary
The present disclosure relates to a process for dyeing a hydrolysis-resistant polyester film. The process comprises dyeing of a hydrolysis resistant polyester film in a dye bath comprising at least one coloring agent (dye), at least one polyhydric alcohol, and optionally at least one UV absorber to obtain a dyed film. The dyed film is subjected to quenching followed by cleaning and drying to obtain a dyed hydrolysis-resistant polyester film. The process of the present disclosure is simple, economical, improve hydrolysis resistance, and also retains the mechanical properties of the film when exposed to harsh environmental conditions.