Wool-like Polyester Filament Dyeing and Degradation
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Solution Overview
Problem
Polybutylene terephthalate (PBT) fibers face challenges with poor dyeability, high dyeing costs due to high temperature and pressure requirements, and slow degradation rates, which restrict their application and waste treatment efficiency.
Innovation Solution
A wool-like polyester filament is developed through a modified polyester production process using fluorinated dicarboxylic acid and tert-butyl branched hexanediol, which reduces dyeing temperature and energy consumption, and enhances degradation rates by modifying the molecular structure to improve dye uptake and hydrolysis efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional PBT fiber is dyed with disperse dyes at high temperature and high pressure, then dye uptake is ensured, but equipment requirements and energy consumption increase
Solution Approach 1:
The patent modifies the molecular structure of PBT by introducing fluorinated dicarboxylic acid and tert-butyl branched hexanediol, which changes the physical and chemical parameters of the fiber. This structural modification enables the fiber to achieve good dye uptake at lower temperatures and pressures, directly resolving the contradiction between dye uptake reliability and energy consumption
Solution Approach 2:
The patent creates a composite molecular structure by incorporating fluorinated dicarboxylic acid and tert-butyl branched hexanediol into the PBT polymer chain. This composite approach combines the advantages of PBT (elasticity, soft handle) with the dyeability improvements from the modified molecular structure, achieving both good dye uptake and reduced energy consumption
2Reliability
If conventional PBT fiber is dyed with disperse dyes at high temperature and high pressure, then dye uptake is ensured, but dyeing cost increases
Solution Approach 1:
By modifying the molecular structure with fluorinated dicarboxylic acid and tert-butyl branched hexanediol, the patent changes the dyeing parameters from high temperature and high pressure to milder conditions. This reduces equipment requirements and energy consumption, directly lowering dyeing costs while maintaining good dye uptake
Solution Approach 2:
The patent performs preliminary molecular structure modification during the fiber production stage, incorporating fluorinated dicarboxylic acid and tert-butyl branched hexanediol into the PBT polymer. This preliminary action prepares the fiber for easier and cheaper dyeing in subsequent processing, reducing the complexity and cost of the dyeing operation
3Ease of manufacture
If PBT waste is treated by landfill or incineration, then waste treatment is simple, but environmental pollution increases
Solution Approach 1:
The patent modifies the molecular structure of PBT by introducing fluorinated dicarboxylic acid, which contains hydrolyzable bonds. This structural change transforms the waste from being resistant to degradation to being more susceptible to chemical degradation, enabling more environmentally friendly treatment methods while maintaining simplicity
Solution Approach 2:
The patent converts the previously harmful effect of PBT's resistance to degradation (which caused accumulation and pollution) into a beneficial feature by introducing fluorinated dicarboxylic acid that enables controlled chemical degradation. This allows the waste to be broken down into less harmful substances, transforming the environmental harm into a benefit
4Strength
If PBT fiber structure is tight with high crystallinity, then mechanical strength is improved, but chemical degradation becomes difficult
Solution Approach 1:
The patent modifies the molecular structure by introducing fluorinated dicarboxylic acid with hydrolyzable bonds and tert-butyl branched hexanediol. This changes the chemical parameters of the polymer chain, creating vulnerable points that enable chemical degradation while maintaining the overall tight structure and mechanical strength through the PBT backbone
Solution Approach 2:
The patent applies local quality modification by introducing fluorinated dicarboxylic acid at specific positions in the polymer chain. This creates localized vulnerable points for chemical degradation without compromising the overall structural integrity and mechanical strength of the PBT fiber, resolving the contradiction between strength and degradability
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 modified wool-like polyester filament achieves improved dyeability with lower energy consumption, faster dyeing times, and enhanced natural degradation rates, addressing the limitations of traditional PBT fibers while maintaining mechanical properties.
Implementation Method 1
enhanced natural degradation rates, addressing the limitations of traditional PBT fibers
Implementation Method 2
improve dye uptake and hydrolysis efficiency
Data Source
AI summary
A type of wool-like polyester filament and preparing method thereof are disclosed. The preparing method is manufacturing filament from a modified polyester through a POY process and a successive DTY processes, wherein the modified polyester is the product of the esterification and the successive polycondensation reactions of evenly mixed terephthalic acid, 1,4-butanediol, fluorinated dicarboxylic acid, tert-butyl branched hexanediol and 2,5,6,6-tetramethyl-2,5-heptanediol. The obtained fiber has a dye uptake of 90.32-93.27% and a K/S value of 22.15-23.42 when dyed at 100° C., and has an intrinsic viscosity drop of 17-20% when stored at 25° C. and R.H. 65% for 60 months. This invention features a method with ease of application and a product with good dyeing and degradation performance.