Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
  • D01F6/46—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyolefins
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
  • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
  • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
  • D01D5/30—Conjugate filaments; Spinnerette packs therefor
  • D01D5/34—Core-skin structure; Spinnerette packs therefor
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F1/00—General methods for the manufacture of artificial filaments or the like
  • D01F1/02—Addition of substances to the spinning solution or to the melt
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
  • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
  • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
  • D06P1/16—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using dispersed, e.g. acetate, dyestuffs
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
  • D06P3/79—Polyolefins
  • D06P3/794—Polyolefins using dispersed dyes

Definitions

• the present invention relates to textile fabrics manufactured using olefin fibers or yarns modified to dye using disperse dyes. These fabrics are conventionally colored using existing disperse dye or printing systems. Either solid shades or multiple tones of a shade are achieved in a single dye bath or print application.
• the fabrics in this invention are manufactured into greige goods produced by the knitting, weaving or non-woven process. Solid shades are achieved by grafting into the olefin yarn or fiber with one level of dye additive and subjecting the fabric to a disperse dye bath. Multiple ends of yarn each containing differing percentages of dye additives are manufactured into fabrics. The fabric will dye to multiple tones in a single dye bath.
• the affinity for disperse dye increases accordingly.
• the fabrics manufactured according to this invention are stored at the dye house undyed. Color is then added using conventional disperse dye machines or print dye methods. Surprising and novel effects are achieved using economical conventional disperse dye systems known to those skilled in the art.
• This invention is of particular usefulness in the apparel and home furnishings industry. The fabrics produced feel and, appear as conventional fabrics but are approximately 30-38% lighter in weight. This is due to the fact that the specific gravity of olefin is .91 while the specific gravity of cotton or polyester is 1.38. In addition, the light fastness and wash fastness properties are similar to those of polyester.
• Knitted and woven fabrics and textile articles are an enormous worldwide enterprise.
• Cotton is the predominant choice of fiber used to make woven or knitted textile fabrics. Cotton has been used through the ages to make yarn and textile articles. Cotton is a natural fiber and is grown in many parts of the world. Many cotton-spinning systems exist worldwide. Cotton yarns are easily produced for both apparel and home furnishings using the cotton spinning system. Egyptian and United States cotton staple is the most widely used cotton to produce yarn and fabrics.
• the cotton spinning system starts with bales of cotton picked from the fields.
• the fiber is called "staple” and is usually 3/4" to 1.5" in length.
• the longer length cotton is more expensive than the shorter length staple.
• Longer length staple will result in a superior spun yarn.
• Machines clean, card, and make roving to various sizes.
• Cotton is made into yarn of various sizes by twisting or "spinning" the roving on machines well known in this art.
• a yarn is produced to be either knitted or woven to create fabric for apparel or home furnishings. By using varying sizes of large or small yarns the knitting or weaving manufacturer can make various types of garments or furnishings. If the cotton fabric is manufactured and kept in the undyed state the fabric is called a greige fabric.
• the most common system of putting color on cotton apparel fabric is to dye the woven, knitted or non-woven fabric.
• the fabric is placed in a machine containing water, vat or direct dyes and chemicals.
• the temperature of the liquor or dye bath is adjusted to the desired degree.
• the skilled operator will use this process to produce the desired shade on the cotton fabric.
• the fabric is dried, and finished according to the customer's specifications.
• the dye house is a capital-intensive operation that contains expensive dye and finishing equipment.
• a dye house in addition to dyeing will have drying and finishing equipment such as compactors, chemical applicators and rolling or folding equipment.
• a good substitute for cotton would ideally be able to be processed using present cotton spinning, dyeing and finishing equipment systems to dye and finish cotton are in place worldwide.
• Cloth knitted or woven of cotton has standard nomenclature and is purchased as a commodity from most parts of the world. A manufacturer can buy a standard cotton fabric from anywhere in the world. Then the manufacturer sends the cloth to a dye house to be stored as uncolored greige cloth awaiting orders for colored cloth. The dyed cloth is cut and sewn into apparel garments or home furnishing items such as draperies, bedspreads, or upholstery.
• Synthetic fiber made using the acrylonitrile process is also used to make a soft fiber. Brands such as Acrilan from the Solutia Co., Creslan from American Cyanamid and Mannacryl from Mann Industries are examples. This fiber is not easily dyed and is mostly produced in large pigment dyed lots. Additionally acrylic is more expensive than cotton. It has a specific gravity of 1.17, which makes it ideal for a blend with wool for sweaters and for use in hosiery. Because it is solution dyed the yarn made from acrylic fibers is suited ideally for outdoor use in awnings, lawn and garden upholstery. Acrylic fiber is not a good substitute for cotton.
• Synthetics the majority being polyester, account for almost one half of all fibers used to produce textile fabrics.
• polyester staple was introduced by the Dupont Company to be a replacement for cotton. It did not replace cotton but it is commonly used to mix or blend with cotton. Initially polyester was harsh and coarse. It did not absorb moisture well and is very difficult to dye. Over a long period of years polyester fibers were engineered to feel soft, and to blend with cotton so that a yarn could be made using the cotton spinning system. The most popular polyester is called "micro denier". Micro denier is extruded through spinneret holes that make a size of fiber that is smaller than cotton. It is very common to find blends of 60% cotton with 40% polyester. There are many blends of cotton/polyester. These blends are found in knitted and woven textile fabrics.
• Polyester has many drawbacks. It is difficult to dye and great skill is needed to dye a uniform shade of polyester and cotton.
• the polyester fibers require high temperatures under pressure to absorb high energy disperse dyes.
• Polyester is a very large enterprise. Approximately 33 billion pounds of polyester are produced world wide for application in apparel and home furnishings. While polyester is widely used world wide, it has many disadvantages. Polyester has the following disadvantages:
• the synthetic fiber could be used to make a yarn for a fabric that would be similar to a fabric made from 100% cotton. Polyester does not meet these standards
• Olefin polypropylene, polyethylene
• Olefin is a manufactured fiber, which is composed of at least 85% ethylene, propylene or other olefin units.
• Olefin is an ideal substitute for cotton except for the fact that is not easily dyed on conventional dyeing or printing systems.
• Olefin is easy and economical to produce into fiber that feels just like cotton. I have found that an olefin of 1.8 denier per filament and a 1.5" to 2" staple length is an ideal substitute for cotton.
• olefin fiber has the following characteristics:
• olefin is a fiber that is not dyeable by conventional dye systems. Almost all olefin fiber and yarn is pigment or solution dyed. Fabric made from pigment dyed yarn cannot be dyed to fashion shades as orders, are received. This makes fabric manufacture prohibitively expensive and inventories too large to manage in the apparel and home furnishings industry. Polypropylene is presently used mainly for making carpet and rugs.
• US patent US-5 576 366 relates to a dyeable polyolefin composition.
• the object of the present invention is to create a novel knitted woven or non-woven fabric using synthetic yarn that has most of the characteristics of cotton fabrics and overcomes the disadvantages of polyester fabrics.
• the fabrics has to be available in greige goods, be easy to dye on conventional systems, be soft to touch; the fabric must "breathe” and wick moisture away from the body.
• the fabrics made using the synthetic yarns of the invention will be easy to wash either by hand or machine and will not stain by ordinary household food stains.
• the fabrics made using the invention are lighter in weight using standard size yarns and dry faster than cotton fabrics at room temperature.
• the fabrics made using this invention have superior light and wash fastness.
• cotton spinning system is the most widely used system, one skilled in the art can produce fiber that can be made into yarn using any conventional spinning system. Worsted, woolen and modified worsted are some of the more common spinning methods. The fiber length and denier can be varied to fit any spinning system.
• the present invention relates to a method (not claimed) of using disperse dyeable synthetic olefin yarn and fibers to manufacture knitted woven and non woven fabric greige goods that are easy to dye and process using commercially available disperse dye systems.
• disperse dyeable synthetic olefin yarn and fibers to manufacture knitted woven and non woven fabric greige goods that are easy to dye and process using commercially available disperse dye systems.
• This invention also shows the preferred novel additives to be grafted onto Olefin to make it disperse dyeable.
• the invention provides a disperse dyeable fiber or filament comprising a melt blend of a polyolefin and amorphous PETG.
• the present invention relates to manufacturing a knitted, woven or non-woven fabric using an olefin yarn or fiber that has been enhanced to accept disperse dye.
• the olefin does not dye but the additive that is grafted to the olefin of the present invention will accept any disperse dye that is used at dye facilities used to dye polyester or blends of polyester and cotton. No special dyes have to be purchased to achieve shades of all description.
• the olefin of the invention will only accepts disperse dyes.
• This invention uses grafted additives in olefin to create yarns that are made into woven, knitted or non-woven greige goods fabric.
• the fabric of this invention is stored as uncolored inventory.
• the greige goods are colored using disperse dyes usually used to dye polyester. Very high temperatures used to dye polyester are not necessary to dye the olefin fabrics. A temperature of 220°F - 250°F is ideal. Bright deep shades of any color are achieved when dyeing olefin fabrics using this invention.
• Multitones are dyed in addition to just one solid color.
• Olefin yarns with dye enhancer grafted of from 1% to 15% is used to make fabrics dye to multi-tones of the same shade in one dye bath containing disperse dyes. This is achieved by grafting varying strengths of the concentrate dye enhancer specified in this invention into the olefin fibers or yarns.
• I will call a yarn with 5% dye enhancer A, a yarn with 3% dye enhancer B and a yarn with 1.5% dye enhancer C.
• yarn A, B, and C are placed together on fabric forming machines, such as a weaving machine, the resultant fabric is dyed into novel three self tones of a color in a single dye bath. One will be dark, one medium and one light.
• the preferred range of concentrate grafted is from 1% to 7%.
• Fabric made from olefin yarn will dye a solid shade when made using yarn that has only one level of concentrate grafted.
• the preferred concentrate grafted should be 5% on the weight of the goods.
• Other concentrations can be used to vary the dye take up but I have found the preferred mixture to be 5% on the weight of the goods to make solid shades.
• a preferred method of rendering polyolefin disperse dyeable is as follows:
• Maleic anhydride is used to help the graft securely anchor onto the polyolefin.
• the maleic anhydride is not necessary to make the olefin disperse dyeable. However I found that if the maleic anhydride is eliminated, the amorphous PETG does not disperse evenly. This results in uneven dispersion and unlevel dyeing.
• Pellets containing 48% amorphous PETG (polyester) 2% Maleic Anhydride and 50% polypropylene are fed to an olefin fiber extruder using 10% owg (on weight of the goods).
• the result is a fiber containing 5% disperse dyeable mix grafted onto 95% olefin.
• One skilled in the art will vary the blend of graft to olefin to achieve the desired shade when subjected to a dye bath containing disperse dye. I have varied the mix and dyed the fiber and found the preferred enhancement to be 5% owg for deep solid shades and 2.5% owg for lighter shades.
• Pellets containing a blend of 50% olefin, 48% amorphous PETG and 2% Maleic Anhydride is preferred for the following reasons:
• the sweater will actually float in water.
• the sweater has the look and feel of cotton yet is substantially lighter in weight. It is understood by one skilled in the art that different weight fabrics using various sizes of yarn can be produced in the same manner.
• Pellets of olefin with a Melt Flow Index of 8-22 are intimately mixed and grafted with an olefin dye enhancement blend described above.
• the mixture is 95% olefin with 5% disperse dye enhancement concentrate consisting of PETG and Maleic Anhydride as described in this invention.
• the mixture is extruded into a staple mass using conventional staple extrusion equipment.
• the dpf is 1.8 and the staple is cut to 1.5".
• Approximately 1,000 pounds of staple are produced and baled.
• the denier per filament is close to that of cotton and so is the staple length. This batch is called "staple A”.
• Pellets of olefin with a Melt Flow Index of 8-22 are extruded and intimately mixed with the blend using the above-preferred mixture of PETG and Maleic Anhydride .
• the blend of 95% olefin and 5% PETG/Maleic is extruded into a continuous filament yarn using conventional extrusion equipment.
• the filament fiber dpf is 5.4. Approximately 1,000 pounds of yarn are produced and wound on perns.
• Example II The knitted fabric from Example I was fed to a 6 color aqueous continuous screen-printing machine. A standard dye paste using disperse dyes was prepared for each screen with thickener. The screens were made to allow a six color pleasing floral pattern to be produced. The print paste was screened on the fabric. The fabric was fed to a steam box to set the dyes. Two to four minutes of steam at 212°F is required to set the dye. The fabric is fed to the steam box and is taken up in a continuous system washed of excessive dyes and dried. The result was a pleasing 6-color floral printed sweater fabric.
• Pellets of olefin with a Melt Flow Index of 8-22 are extruded and intimately mixed with the blend using the above-preferred mixture of PETG and Maleic Anhydride .
• the blend of 95% olefin and 5% PETG/Maleic is extruded into a staple mass using conventional staple extrusion equipment.
• the fiber dpf is 1.8 and is cut to 1.5".
• Approximately 1,000 pounds of staple are produced and baled.
• the denier per filament is close to that of cotton and so is the staple length.
• space dye or print dyeing yarn can be used.
• One skilled in the art will adjust the various machines to the specifications that I outlined above. Warp printing or package impregnation are two other common methods use to space dye yarns.
• Spun yarns are usually made into 18's, 20's, 24's, 28's, 30's, 36's, 40's, either plied or in single form.
• Continuous filament yarn is usually made into 20/1, 70/1, 100/1, 150/1, 200/1 300/1, 500/1 or 1000/1.
• any size yarn or staple fiber could be made dyeable using the preferred mixture of the invention. From these yarns dyeable woven, non-woven or knitted fabrics of all types and descriptions will be made.
• Pellets of olefin with a Melt Flow Index of 8-22 are intimately mixed and grafted with an olefin dye enhancement blend described above.
• This machine has three extruders that will separately feed a single spinneret. Barmag, Plantex, Rieter make such machines. One extruder is fed a mix of 95% olefin and 5% Dye enhancer, another is fed 97% olefin and 3% dye enhancer, and the third is fed 99% olefin and 1 % dye enhancer.
• a single white yarn with a dpf of 5.4 consisting of three separate levels of dye affinity is taken up on three-pound packages.
• a fabric containing tri-tone yarns would be ideal to space dye or print, as the printed yarn would dye into separate tones within tones at each strike of color letdown.
• the printed yarn would dye into separate tones within tones at each strike of color letdown.
• This invention enables the yarn spinner, the fabric maker and the dyer to create novel lightweight colored fabrics. It enables a fabric to be held until the last moment before dyeing and shipping to be manufactured in shades that match the current time of year and season.
• Olefin yarn is made according to the invention. It is enhanced to accept a deep solid shade: of disperse dye.
• the size is 24/1 spun on the cotton spinning system taken up on three-pound cones. It contains a dyeable graft of 5% owg.
• the appropriate multiple ends are slashed and taken up on a weaving beam.
• the beam is set to feed a simple box loom.
• Olefin yarn made according to the invention containing 2.5% dyeable graft is made to feed the weft insertion on the box loom.
• the size is 24/1 spun on the cotton spinning system.
• a simple over and under woven fabric 60" wide is produced.
• one half of the yarn contains a 5% dye enhancer made according to the invention and one half contains a yarn that has a 2.5% dye enhancer made according to the invention.
• the woven greige cloth is dyed in a jet dyer set at 250°F with a Terasil Blue disperse dye using .005% on the weight of the goods.
• the warp or beamed yarn dyes a deep shade of blue and the weft yarn dyes to a medium shade of blue.
• the fabric is a two-tone tweed color.
• the fabric is dried in a relatively cool oven at 200°F to keep the temperature below the melt temperature of olefin.
• the fabric is tentered or held in a stretched position while it passes through drying oven. This "sets" the fabric so that it will not shrink in any further processing at a later time.
• the fabric is cut and sewn into a ladies jacket and skirt.
• the garment is a ladies suit made from 100% olefin fabric. This suit is easy care washable, stain resistant, and lightweight. It is 38% lighter than a similar suit made from polyester or wool/blends.
• the invention No. 6,136,436 claims a sheath of nylon or polyester on a core of olefin.
• I use a core and sheath of olefin.
• the outer sheath comprises 10% to 70% olefin grafted with the dye enhance of amorphous PETG.
• the core is 100% olefin.
• A.fabric is knitted or woven with one or more yarns containing differing dye levels.
• the fabric is dyed as per the examples above.
• Great cost savings result because the sheath comprises only 10% to 70% of the total composition.
• One skilled in the art would vary the percentages of the sheath and the dye enhancer to achieve the effect desired.
• a variation of the above is to use a sheath of non-dyeable olefin and a core of dyeable olefin.
• the result is a yarn with a clear outer shell with color in the core.
• One skilled in the art can manipulate this yarn or fiber to create the effect desired.
• Example IX Fabric knitted or Woven using Dyeable Olefin Blended with Polyester
• a novel and surprising effect is achieved when blending polyester and dyeable olefin fiber to make yarn.
• the resultant yarn has an outer cover consisting mostly of polyester and a core mostly of dyeable olefin. There is minor crossover in both the sheath and core.
• Olefin fiber is made according to the invention.
• the fiber is enhanced with the additive of this invention to accept a solid shade of disperse dye
• Woven, knitted or non-woven fabrics can be produced using this blend.
• Example X Fabric Woven or knitted using Dyeable Olefin Blended with Nylon
• the resultant yarn has an outer cover consisting mostly of nylon and a core mostly of dyeable olefin. There is minor crossover in both the sheath and core.
• the resultant yarn has a sheath mostly of Nylon and a core mostly of dyeable olefin.
• Olefin fiber is made according to the invention.
• the fiber is enhanced to accept a solid shade of disperse dye.
• Nylon is very easy to dye using an aqueous dye system.
• the fabrics made of nylon and olefin blends will print using any acid system commonly used to dye nylon or silk.
• the fabric can be printed using any aqueous dye system commonly used to print nylon, silk or polyester.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Dispersion Chemistry (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Coloring (AREA)
• Woven Fabrics (AREA)
• Artificial Filaments (AREA)
• Knitting Of Fabric (AREA)
• Multicomponent Fibers (AREA)

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• 2005
  • 2005-03-11 DE DE602005026460T patent/DE602005026460D1/de active Active
  • 2005-03-11 BR BRPI0519035-5A patent/BRPI0519035A2/pt not_active IP Right Cessation
  • 2005-03-11 WO PCT/US2005/008390 patent/WO2006098730A1/en active Application Filing
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  • 2005-03-11 CN CN2005800497441A patent/CN101175774B/zh active Active
  • 2005-03-11 KR KR1020077023284A patent/KR101235118B1/ko active IP Right Grant
  • 2005-03-11 EP EP05725506A patent/EP1861430B1/en active Active
  • 2005-03-11 CA CA002603865A patent/CA2603865A1/en not_active Abandoned
  • 2005-03-11 JP JP2008500694A patent/JP4873754B2/ja active Active
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  • 2008-10-16 HK HK08111420.9A patent/HK1116204A1/xx not_active IP Right Cessation

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