Modified polyester masterbatch for textile applications and manufacturing process thereof
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Solution Overview
Problem
Current polyester dyeing processes, particularly for PET, PBT, and PTT, are inefficient due to high energy consumption, incomplete dye bath exhaustion, and deterioration of other fibers' properties, with challenges in achieving deep and dark shades at ambient conditions.
Innovation Solution
A polyester masterbatch comprising high molecular weight polyalkylene glycol, DMSIP or SIPA, and additives, allowing for deep and dark dyeing at atmospheric pressure and temperatures below 100°C, compatible with various polyester matrices, and enabling simultaneous use with disperse and reactive dyes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-temperature and high-pressure dyeing methods are used for PET fibers, then disperse dye can enter the polymer matrix, but energy consumption increases and the process becomes expensive
Solution Approach 1:
The patent modifies the chemical structure of polyester by incorporating comonomers with reactive end groups (carboxyl, hydroxyl, or amine groups) that can form ionic or covalent bonds with dye molecules. This chemical modification enables dyeing at lower temperatures and pressures by changing the interaction mechanism from physical diffusion to chemical bonding, thereby reducing energy consumption while maintaining effective dye penetration
Solution Approach 2:
The patent introduces carrier substances with reactive end groups that act as intermediaries between the dye and the polyester matrix. These carriers facilitate dye penetration by forming temporary complexes with dye molecules and releasing them into the polymer matrix, enabling effective dyeing at reduced temperature and pressure conditions
2Manufacturing precision
If high-temperature and high-pressure dyeing methods are used for PET fibers, then dye penetration is achieved, but dyeing time increases
Solution Approach 1:
The patent changes the chemical parameters of polyester by incorporating comonomers with reactive end groups that enable rapid chemical bonding with dyes. This chemical modification accelerates the dyeing kinetics, allowing deep and uniform dye penetration to be achieved in shorter times at lower temperatures, thereby reducing overall dyeing cycle time
Solution Approach 2:
The patent performs preliminary chemical modification of the polyester structure during fiber production by incorporating comonomers with reactive end groups. This pre-preparation creates ready-to-bond sites in the polymer matrix that can rapidly accept and bind dye molecules during the dyeing process, eliminating the need for prolonged heating and pressure treatment
3Manufacturing precision
If high-temperature and high-pressure dyeing methods are used for PET fibers, then dye penetration is achieved, but dye bath exhaustion is incomplete
Solution Approach 1:
The patent modifies the chemical structure of polyester to include comonomers with reactive end groups that form strong ionic or covalent bonds with dye molecules. This chemical bonding mechanism ensures complete uptake of disperse dyes from the dye bath, achieving near-total exhaustion and eliminating residual dyes that would otherwise remain in the effluent with conventional physical diffusion methods
Solution Approach 2:
The patent converts the traditionally harmful environmental issue of incomplete dye bath exhaustion and residual dye discharge into a benefit by using comonomers with reactive end groups that ensure complete dye uptake. The reactive groups act as traps that completely capture dye molecules, transforming the waste problem into an environmentally friendly dyeing process with minimal effluent contamination
4Manufacturing precision
If high-temperature and high-pressure dyeing methods are used for PET fibers in combination with other fibers, then PET dyeing is achieved, but physical properties of other fibers deteriorate
Solution Approach 1:
The patent changes the dyeing mechanism from physical diffusion requiring high temperature and pressure to chemical bonding that can occur at ambient or mild conditions. By incorporating comonomers with reactive end groups in the polyester structure, the patent enables effective dyeing at lower temperatures that do not adversely affect the physical properties of blended fibers such as acrylic, cotton, or wool
Solution Approach 2:
The patent introduces dynamic adaptability in the dyeing process by using comonomers with different types of reactive end groups (carboxyl, hydroxyl, amine) that can selectively interact with various dye molecules. This chemical flexibility allows differential dyeing of polyester in blends at mild conditions, preserving the integrity of other fiber types while achieving effective dye uptake in polyester
5Strength
If conventional PET fibers are used, then mechanical strength is maintained, but dyeability is poor
Solution Approach 1:
The patent modifies the chemical parameters of polyester by incorporating comonomers with reactive end groups that enable chemical bonding with dyes. This chemical modification improves dyeability without significantly affecting mechanical strength because the comonomers are incorporated in controlled amounts (typically 5-30 mol%) that maintain the structural integrity of the polyester chains while providing sufficient reactive sites for dye attachment
Solution Approach 2:
The patent creates a composite polyester structure by combining conventional polyester units with comonomer units containing reactive end groups. This composite approach allows the material to exhibit both the mechanical properties of conventional polyester and the improved dyeability of chemically modified polyester, achieving a synergistic combination of strength and dyeability
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 solution provides a cost-effective, time-saving, and environmentally friendly dyeing process with >90% dye bath exhaustion, maintaining mechanical properties and achieving soft feel and deep color penetration, suitable for various polyester applications.
Implementation Method 1
The masterbatch produced in the present invention provides an environment friendly, cost effective, superior and easy dye ability solution for various polyesters... achieving >90% dye bath exhaustion
Data Source
AI summary
The present invention provide a polyester masterbatch comprising: at least one dicarboxylic acid or ester thereof; at least one diol; at least one high molecular weight polyalkylene glycol up to 60%; optionally DMSIP/SIPA up to 40%; at least one antioxidant up to 1.0%; and at least one or more additives up to 20%; which provides an environment friendly, cost effective, superior and easy dye ability solution for various polyesters.