JP2008533315A - Dyed olefin yarn and fiber fabric using the yarn - Google Patents

Abstract

A disperse dyeable fiber or filament is comprised principally of polyolefin modified with PETG to accept the disperse dyes. The combining of maleic anhydride with the PETG provides good dispersion of the PETG for uniform dye results. Novel textile fabric, knitted, woven and non-woven, can be formed with yarns or fibers formed in accordance with the invention. In one aspect of the invention, fabric can be disperse dyed to a light, medium or deep solid shade. In another aspect, the textile fabrics are manufactured using olefin yarns that contain variable amounts of dye acceptor additives. A fabric with more than one tone of a color thus can be dyed in a single dye bath. The fabrics and yarn according to this invention can be processed using conventional spinning, weaving, knitting, web formingl machines and will dye using existing dyeing and finishing systems. This invention is of particular value in the apparel and home furnishings industry.

Description

(Background of the Invention)
The present invention relates to a textile fabric produced using olefin fibers or yarns modified for dyeing using disperse dyes. These fabrics have traditionally been colored using existing disperse dyes or printing systems. Either identical shades or multi-tone shades are achieved in a single dyebath or printing application. The fabric in the present invention is manufactured as a fabric produced by a knitting process, a weaving process or a non-woven process. The same shade is achieved by joining the olefin yarn or fiber to one level of dye additive and exposing the fabric to a disperse dye bath. Multiple ends of yarn, each containing different percentages of dye additives, are made into the fabric. The fabric can be dyed in multiple colors in a single dye bath. By increasing the amount of dispersible dye additive in the olefin yarn or fiber, the affinity for the disperse dye is increased accordingly. The fabric produced according to the present invention is stored undyed in a dyeing factory. The color is then added using conventional disperse dyeing machines or print dyeing methods. A surprising new effect is achieved using economically conventional disperse dyeing systems known to those skilled in the art. The present invention is particularly useful in the clothing and furniture industry. The fabric produced feels and looks like a conventional fabric, but is about 30-38% lighter in weight. This is due to the fact that the specific gravity of cotton or polyester is 1.38 while the specific gravity of olefin is 0.91. In addition, the characteristics of sunlight fastness and wash fastness are similar to those of polyester.

(Simple explanation of related technology)
Knitted fabrics and woven fabrics and fabric products are a very large worldwide business. Cotton is a leading option for fibers used to make woven or knitted fiber fabrics. Cotton has long been used to make yarn and fabric products. Cotton is a natural fiber and is cultivated in many parts of the world. There are many cotton spinning devices all over the world. Cotton yarn is easily produced for both clothing and furniture using cotton spinning equipment. Egyptian and United States cotton staples are the most widely used cotton for producing yarns and fabrics.

  The cotton spinning machine starts with a large amount of cotton harvested from the field. The fibers are called "staples" and are usually from 3/4 inch to 1.5 inch long. Longer length cotton is more expensive than shorter length staples. Longer length staples result in advanced spinning. The machine is cleaned, fired and moved to various sizes. Cotton is made into yarn by twisting or “rotating” rovings on machines known in the art. Yarn is manufactured either knitted or woven to produce fabric for clothing or furniture. By using yarns of various sizes, large and small, the knitting or weaving manufacturer can make various types of clothing or apparel. If the cotton fabric is manufactured and maintained in an undyed state, the fabric is called a greige fabric. This is the most common and economical method of manufacture most widely used for cotton fabrics. Typically, the fabric is dyed or printed after an order is received from the end consumer of the fabric. The dyed cotton fabric is then cut into the appropriate shape and any garment garment is sewn together from these parts. Cotton is used to make underwear, socks, sweaters, shirts, slacks, casual athletic clothes and dresses. Cotton is not usually used to make sports jackets, men's or women's suits or jackets.

  Many of the common devices that color cotton garment fabrics are for dyeing woven, knitted or non-woven fabrics. The fabric is placed in water, a tank or a machine containing direct dyes and chemicals. The temperature of the liquid or dyebath is adjusted to the desired temperature. A skilled operator will use this process to produce the desired shade on the cotton fabric. The fabric is dried and finished according to customer specifications. The dye factory is a capital intensive operation involving expensive dyes and finishing equipment. Dyed dye factories can have dried and finished equipment such as compressors, chemical applicators and rotating or folding equipment. A good substitute for cotton could ideally be processed using current spinning, dyeing and finishing equipment systems for dyeing and finishing cotton located throughout the world.

  Cotton is selected in the fabric for the following reasons.

Cotton is easily grown in many parts of the world.
Cotton grows to standard staple lengths, so it can be easily turned into yarn.
Cotton yarn should be processed well on most knitting and weaving machines.
Cotton fabric should be comfortable to the user's body and soft to the touch.
Cotton should absorb and absorb moisture.
Cotton should be dyed very easily.
Cotton should go well with other synthetic fibers.

  Cotton knitted or woven garments have standard terms and are purchased as goods from many parts of the world. Manufacturers can purchase standard cotton fabric from anywhere in the world. The manufacturer then sends the garment to a dye factory to be stored as uncolored fabric garment waiting for an order for colored garment. Dyed garments are cut and sewn into furniture items such as clothing garments or cloths, bedclothes or upholstery.

(Synthetic fibers)
Many attempts have been made to produce acceptable synthetic fibers or yarns that are good substitutes for cotton and can be processed on conventional spinning equipment.

  Worldwide demand for cotton is introduced because there is not enough available land area to produce enough worldwide cotton to meet the demands of affordable fabrics and garments for the growing large population It will be like a synthetic substitute. It is highly desirable to produce synthetic substitutes for cotton.

(Rayon)
Many attempts have been made to produce synthetic substitutes for cotton. Rayon and rayon acetate were the first successful attempts to produce a substitute for cotton. Fiber from wood is used in rayon processing. Rayon and rayon acetate are widely used in the clothing and furniture industry. However, producing the yarns and fibers causes great pollution and they are not manufactured in the United States. Rayon processing uses large amounts of corrosives and anhydrides. Rayon has a very desirable quality. It is easy to dye and the garments produced are bright and soft and a good substitute for cotton. Many rayons are imported and manufactured by specialized manufacturers, so they are not expensive and not an option except for expensive high fashion clothing. Rayon is further mixed with cotton or other synthetic fibers to make fabrics having desirable properties such as feel or texture. Rayon or acetate has the same specific gravity as cotton. While these fibers are used in place of cotton, they do not provide a weight advantage. Their specific gravity is the same as that of cotton.

(acrylic)
Synthetic fibers made using acrylonitrile processing are further used to make soft fibers. Examples include brands such as Acrilan from Solutia Co., Creslan from American Cyanamid and Mannacryl from Mann Industries. It is. This fiber does not dye easily and is mostly produced in large quantities of dye in the lot to be dyed. In addition, acrylic is more expensive than cotton. It has a specific gravity of 1.17, which is ideal for use in socks and for mixing with wool for sweaters. Since it is a dyed solution, yarns made from acrylic fibers are ideally suited for outdoor use in awnings, lawn fabrics and garden furniture. Acrylic fibers are not a good substitute for cotton.

(polyester)
Synthetic fibers, the majority of which are polyester, account for approximately half of all fibers used to make fabrics.

  About 60 years ago, polyester staples were introduced by the Dupont Company to become a cotton substitute. It did not replace cotton, but was commonly used to harmonize or mix with cotton. The initial polyester was rough and poor. It did not absorb enough moisture and was very difficult to dye. Over the years, the polyester fibers felt soft and were designed to mix with cotton so that the yarn could be made using a cotton spinning machine. The most popular polyester is called "micro denier". The micro denier is extruded through a spinneret hole that is the size of a fiber smaller than cotton. It is very common to find a blend of 60% cotton and 40% polyester. There are many cotton / polyester blends. These blends are found in textile fabrics that are knitted and woven. Many expensive modifications are made to be able to rotate, and then the dye fabric is made from a blend of polyester and cotton. In today's modern dye and finishing equipment, undyed fabrics made from yarns mixed with cotton and polyester are dyed, finished and shipped to the end consumer in the same color. Matching the color of cotton dyed by a kind of dyeing with the color of polyester dyed using disperse dyes requires great skill. When dyeing blends of this nature, a two-stage process is used, which is more expensive than using a one-stage process.

  Polyesters have a number of drawbacks. It is difficult to dye and great skill is required to dye the same shades of polyester and cotton. Polyester fibers require high temperatures under pressure to absorb high energy disperse dyes. Cotton dyeing directly or with a tank dyes without the need for pressure or high temperature. Dye factories that dye cotton / polyester blends have advanced technology. Fabrics made from a mixture of cotton and polyester must be dyed using a two-step process. One is stained first and then the other is stained. Most technical dye factories maintain a large amount of shade to disperse for the purpose of dyeing polyester and polyester and cotton blends.

  There are numerous businesses in the production of polyester. Approximately 33 billion pounds of polyester are manufactured worldwide for application in apparel and furniture. While polyester is widely used in the world, it has many disadvantages.

Polyester has the following disadvantages.
Mixing polyester with cotton requires great skill.
Polyester is difficult to dye.
Polyester is warm against the body.
Fabrics made from 100% polyester should feel heavy.
High temperature and pressure are required to dye or print polyester.
Polyester should not let moisture escape.

  In the garment and furniture industry, it is highly desirable to have available synthetic yarns or fabrics with new properties. Ideally synthetic fibers can be used to make yarns for fabrics that can resemble fabrics made from 100% cotton. Polyester does not achieve these criteria.

(Olefin)
Olefin (polypropylene, polyethylene) is a manufactured fiber made up of at least 85% composed of ethylene, propylene or other olefin units. Olefin is an ideal substitute for cotton, except for the fact that it is not easily dyed on conventional dyeing or printing equipment. It is simple and economical to make olefins into fibers that feel like cotton. It has been discovered that 1.8 denier olefins and 1.5 to 2 inch staple lengths for each fiber are ideal substitutes for ideal cotton. In addition, the “feel” of the olefin fiber has the following properties:

Olefin fibers can be easily converted into yarn using existing spinning equipment.
Olefin yarn can be processed sufficiently on knitting and weaving machines.
Olefin yarn should be soft to the touch.
Olefin staples should be processed thoroughly on a non-woven machine.
Feel that olefin fabric is similar to cotton.
Olefin can dry quickly.
Olefin passes moisture, but can retain body heat.
Olefin is very resistant to contamination.

(Disadvantages of olefin fiber and yarn)
The main disadvantage of olefins is the fact that they are fibers that are not dyeable by conventional dyeing equipment. Almost all olefin fibers and yarns are pigments or dyed solutions. Fabrics made from dyed yarn cannot be dyed to create shades when an order is received. This makes fabrics inventories that are very expensive and too much to manage in the clothing and furniture industry. Polypropylene is currently mainly used to make carpets and rugs.

(Summary of the Invention)
The object of the present invention is to create new knitted fabrics, woven fabrics or non-woven fabrics using synthetic yarns that have most of the properties of cotton fabrics and overcome the disadvantages of polyester fabrics. In order to qualify as a good substitute for cotton fabrics, the fabrics must be available in fabric goods, easily dyed on conventional equipment, and soft to the touch. The fabric must “breath” and let the moisture escape from the body. Fabrics made using the synthetic yarns of the present invention are easily washed either by hand or machine and cannot be dyed by ordinary household food stains. Fabrics made using the present invention are lighter in weight using standard size yarns and dry faster than cotton fabrics at room temperature. Fabrics made using the present invention have a high level of lightness and do not fade when washed.

  Further objects and further scope of the invention will become apparent from the detailed description given herein below. However, it should be understood that the detailed description and examples are given for purposes of illustration, as various changes and innovations within the spirit of the invention will be apparent to those skilled in the art.

  Cotton spinning equipment is the most widely used machine by which those skilled in the art can produce fibers that can be made into yarn using any conventional spinning equipment. Eyelashes, wool and modified eyelashes are some of the more common spinning methods. The fiber length and denier can be varied to suit any spinning device.

  In addition to the short fibers spun into the yarn, there is a mass production of continuous long fiber yarns. The present invention can be applied to either fibers or continuous long fiber yarns.

  As briefly described, the present invention uses dispersed dye equipment available commercially to produce knitted, woven and non-woven fabric articles that are easy to dye and process. The present invention relates to a method using a dyeable synthetic olefin yarn and fiber. The new advantages of these fabric products over cotton and blends of cotton and polyester can become apparent from the detailed description. The present invention also shows suitable novel additives to be joined onto the olefin to make it dispersible.

(Detailed description of the invention)
The present invention relates to the manufacture of knitted fabrics, woven fabrics or non-woven fabrics using olefin yarns or fibers that are improved to receive disperse dyes. Although the olefins are not dyed, the additive conjugated to the olefin of the present invention accepts any disperse dye used in dyeing equipment used to dye polyester or polyester and cotton blends. In order to achieve all kinds of shades, no special dyes need to be purchased. The olefins of the present invention accept only disperse dyes. The present invention uses joined additives in olefins to make woven, knitted or non-woven fabric yarns. The fabrics of the present invention are stored as uncolored stock. The fabric fabric is colored using disperse dyes that are usually used to dye polyester. The very high temperatures used to dye polyester are not required to dye olefin fabrics. A temperature of 220 ° F to 250 ° F is ideal. When dyeing olefin fabrics using the present invention, a brilliant dark shade of any color is achieved.

(Multicolored)
In addition to only one identical color, a multi-tone is dyed. Olefin yarn with 1% to 15% joined dye promoter is used to dye fabrics in multiple shades of the same shade in one dyebath containing disperse dyes. This is accomplished by joining the varying strength concentrated dye promoters identified in the present invention to olefin fibers or yarns. For example, a yarn having 5% dyeing accelerator is named A, a yarn having 3% dyeing accelerator is B, and a yarn having 1.5% dyeing accelerator is named C. When yarns A, B and C are placed together on a fabric forming machine such as a loom, the resulting fabric is dyed in three new uniform shades in a single dyebath. One is dark, one is middle, and one is light. A suitable bonded concentrate range is 1% to 7%.

  When the fabric is made with yarns containing two dye levels and one yarn without any concentrate, the result can be a fabric with two shades and one white. This embodiment creates a new and surprising effect. One skilled in the art can find many attractive ways to make new fabrics using the present invention.

(Same color)
Fabrics made from olefin yarns can dye the same shade when made using yarns that have only one level of concentrate joined. A suitable joined concentrate should be 5% of the dough anti-weight. While other concentrates can be used to change the dye take up, the inventors have discovered that a suitable mixture to make the same shade is 5% of the fabric anti-weight.

  Surprisingly new effects can be achieved using the 100% olefin yarns of the present invention. The benefits of using olefins were made according to the present invention as follows.

1. Olefin fabric should not fade in warm water.
2. The olefin fabric can be naturally dried or quickly machine dried at cold temperatures.
3. The disperse dyed olefin fabric does not stretch or shrink during the washing process.
4). The olefin fabric should dry substantially without wrinkles.
5. Olefin fabric is not easily soiled.
6). Soft touch of olefin fabric.
7). Olefin fabric is 38% lighter than cotton.
8). Olefin fabric will release moisture and exhalation.
9. Olefin fabric is resistant to mold stains and algae growth.
10. Olefins have a larger volume than most fibers.
11. The olefin yarn can be produced either by spinning or continuous long fibers.
12 Characterized by the fact that the olefin fabric is easy to care for and travel.

(Olefin dyeing accelerator)
There are various ways to produce or strengthen olefins to accept dyes.

(Related patents)
6,420,482 Domingguez et al. 4,320,046 Havens
6,146,574 Henkee et al. 3,926,553 Fuest
6,126,701 Calogero
3,652,198 Farber et al. 5,576,366 Sheth
3,622,264 Brown et al. 5,550,192 Sheth et al. 3,315,014 Coover et al. 5,169,405 Hoyt et al. 3,256,362 Claubuer Et

  All of the above patents teach one skilled in the art how to join when joining on a polyolefin can produce a dyeable polyolefin. Reference is made to chemical reactions that are all completely different from the chemical reactions of the present invention. Clover's patent number 3,256,362 refers to unsaturated polyesters that are different from other above-mentioned inventions. The Cloveer patent requires difficulty to blend with unrelated types of polyesters. In said patent, unsaturated polyesters are amorphous and do not mix well at the lower temperatures required to produce olefins.

  Each of the methods described in the above patents creates the problem of spinning or extruding to the small size required for garments. Dyeing the yarns or fabrics of the prior patent requires special equipment or dyeing options. No inventor's knowledge has been applied on a large scale to make garment or woven furniture fabric items. The carpet industry uses yarn in a limited manner. It is desirable to have a dyeable olefin that can be used for the clothing and furniture industry and is not limited to carpet manufacturing. In addition, dyeable olefins can be used when dyers can adapt shades in laboratories where unmodified dispersible dyeing elements can be transferred to the production of dyeing machines with little or no modification. Is the only practical to use. The present invention allows dyeers to adapt shades in laboratories that are easily moved to the manufacturing machine.

  A preferred method for providing dispersible dyeable polyolefins is as follows.

  A mixture of amorphous PETG (polyethylene terephthalate modified with glycol) is a suitable component used to bond to polyolefins. Amorphous PETG is selected because it melts at the same temperature as polypropylene. This allows one skilled in the art to make dyeable polyolefins using conventional olefin fiber extruders. No special equipment is required to perform this task. The advantage of this additive is the fact that no drying and moisture absorption reduction is required to add a bond. In addition to amorphous PETG, the present invention used maleic anhydride to improve dispersion and graft cohesion within the olefin fibers. Preferred products are amorphous PETG 1428 from Eastman Chemical and maleic anhydride 3200 from Uniroyal. A blend using 96% PETG 1428 and 4% maleic anhydride is ideal (percentages are by weight unless otherwise specified). By providing the blend in polypropylene, a 50% active compound is made. 50% is polypropylene, 48% is amorphous PETG, and 2% is maleic anhydride. One skilled in the art will select an appropriate method to make the compound. Of course this is the best suggestion, but experimentation will change the percentage to suit those needs. The compound is in pellet form and is packaged in Gayload's or drums without the need for special gas sealants.

  Maleic anhydride is used to help secure the bond securely on the polyolefin. Maleic anhydride is not required to make dispersed dyeable olefins. However, when maleic anhydride is erased, amorphous PETG does not disperse uniformly. This results in non-uniform dispersion and unleveled staining.

(Dyeable olefin fiber and yarn)
Pellets containing 48% amorphous PETG (polyester), 2% maleic anhydride and 50% polypropylene are fed to the olefin fiber extruder using 10% of the dough anti-weight. The result is a fiber containing 5% dispersible dyeable mixture joined to 95% olefin. Those skilled in the art will vary the blend of the olefin bond to achieve the desired shade when exposed to a dye bath containing disperse dyes. The inventor changes the mixture to dye the fibers, 5% of the fabric anti-weight is the preferred improvement for the same dark shade, and 2.5% of the fabric anti-weight is the preferred improvement for the lighter shades. I discovered that there is. When 5% of the fabric anti-weight fiber and 2.5% of the fabric anti-weight fiber were exposed to a single dye bath, an attractive two-tone shade resulted from the single dye bath. The inventor uses the term “dye promoting olefin” to describe the joined product.

  Pellets containing a blend of 50% olefin, 48% amorphous PETG and 2% maleic anhydride are preferred for the following reasons.

The disperse dye must be the only dye absorbed by the bond.
The blend should melt at the olefin processing temperature.
The blend is bound and easily extruded into pellets.
The mixed pellets need not be absolutely dry to be fed to the olefin fiber extruder.
The blend should be uniformly mixed and well dispersed within the olefin being extruded.
The dyeable joint shall be stable when any dyeing conditions are provided.
The spliced yarn or fabric will be dyed or printed using standard disperse dyes.
Printing is easily accomplished and requires only exposure to steam at a temperature of 212 ° F. for 2-4 minutes.
The color should not fade by washing at a warm temperature of 175 ° F.
Joining should improve the “feel” of olefins.

  The invention is described in more detail below.

(Monochromatic fiber)
a. ) Pellets of olefins having a melt flow index of 8-22 are extruded and intimately mixed with the blend using a mixture of suitable PETG and maleic anhydride as described above. A blend of 95% olefin and 5% PETG / maleic acid is extruded into a staple mass using conventional staple extrusion equipment. Its denier per long fiber (dpf) is 1.8 and is cut to 1.5 inches. Approximately 1,000 pounds of staples are produced and packaged. The denier per long fiber is close to the denier per cotton long fiber, as is the staple length.

  b. ) The dye-promoted olefin packaging of staple fibers is mixed together in the carding process and brought into an intimate blend of rovings. Rovings made using conventional cotton making equipment are ring-spun 10/1 and wound into a 3 pound package. Approximately 1000 pounds of yarn are produced.

  c. ) The 10/1 olefin yarn is knitted on a 10 cut circular knitting machine. This manufacturing process forms an undyed fabric that is ideal for making cut and sewn sweaters.

  d. ) Sweater fabric anti-fabric is dyed in a conventional jet dyeing machine which is usually used to dye polyester. The temperature is kept at 250 ° F. to avoid damage to the olefin. A disperse dye Terasil Blue BRL of 0.005% by weight of the dough is used with a standard dye disperse chemical and water. The resulting woven fabric is a new and attractive brilliant shade of dark blue. The fabric is dried in a relatively cool dryer. The temperature is below the melting temperature of the olefin or is kept at 200 ° F. The water cleans the olefin leaving a dry, brilliant fabric that is rolled and packaged for transport. Since olefins retain only a limited amount of water, drying time is greatly reduced compared to cotton or cotton polyester blends.

  f. ) Sweater fabric is cut and sewn and is surprisingly new. The fabric is at least 30% lighter in weight than a cotton sweater made to the same specifications. This is because the specific gravity of olefin is 0.91 compared to 1.38 for cotton or cotton polyester.

  The new sweater will actually float on the water. The sweater has a cotton look and feel, but is nevertheless substantially lighter in weight. It will be appreciated by those skilled in the art that different weight fabrics using different sizes of yarn can be produced by the same method.

(Color tone Color on olefin fabric)
Olefin pellets having a melt flow index of 8-22 are intimately mixed and joined with the olefin dye-promoting blend described above. Said mixture is 5% disperse dyeing accelerating concentrate composed of PETG and maleic anhydride as described in the present invention and 95% olefin. The mixture is extruded into staple masses using conventional staple extrusion equipment. Its dpf is 1.8 and the staple is cut to 1.5 inches. Approximately 1,000 pounds of staples are produced and packaged. The denier per long fiber is close to the denier per cotton long fiber, as is the staple length. This group is called “staple A”.

  b) Olefin pellets having a melt flow index of 8-22 are intimately mixed and joined with the olefin dye-promoting blend described above. Said mixture is 3% disperse dyeing accelerating concentrate composed of PETG and maleic anhydride as described in the present invention and 97% olefin. The mixture is extruded into staple masses using conventional staple extrusion equipment. Its dpf is 1.8 and the staple is cut to 1.5 inches. Approximately 1,000 pounds of staples are produced and packaged. The denier per long fiber is close to the denier per cotton long fiber, as is the staple length. This group is called “staple B”.

  c. Aside from the above, the olefin packaging of staple fibers is mixed and roved in a carding process. Roving made using conventional cotton making equipment is spun to 10/1 and wound into a 3 pound package. Approximately 1000 pounds of each yarn produced for a total of 1,000 pounds of olefin (yarn A) with 5% concentrate and 1,000 pounds of olefin joined by 3% concentrate (yarn B) Is done. Both accept disperse dyes.

  d. ) Olefin yarn A containing 5% concentrate and olefin yarn B containing 3% concentrate are placed side by side on a 10-cut knitting machine. Both yarns are 10/1. The olefin yarn is knitted in a 10-cut circular knitting machine. This manufacturing process forms an undyed fabric that is ideal for making sweaters when cut and sewn.

  e. ) The sweater fabric is dyed in a conventional jet dyeing machine, which is usually used to dye polyester. The temperature is kept at 250 ° F. to avoid damage to the olefin. Disperse dye Terasil Blue BRL of 0.005% by weight of the dough is used with standard dye disperse chemicals and water. The resulting sweater fabric is a new and attractive two-tone shade of dark blue. Only one dyebath is used to obtain more than one shade on the fabric. The fabric is dried in a relatively cool dryer. The temperature is below the melting temperature of the olefin or is kept at 200 ° F. Compared to cotton or cotton polyester blends, the drying time is greatly reduced. The water cleans the olefin, leaving a dry, brilliant two-tone blue fabric that is rolled and packaged for transport.

  f. ) Two-color sweater fabric is cut and sewn and is surprisingly new. The two-tone effect is new and looks natural, similar to hair or linen. The fabric is at least 30% lighter in weight than a cotton sweater made to the same specifications. This is because the specific gravity of olefin is 0.91 compared to 1.38 for cotton or cotton polyester. This new sweater will actually float on the water.

  Numerous outbreaks made from other olefin and olefin blends or olefins fed to various knitting or looms by varying the number of olefin yarns fed to the knitting or loom and the amount of concentrate And it should be understood that new fabric anti-fabrics can be made by those skilled in the art. It will be appreciated by those skilled in the art that different weight fabrics using different sizes of yarn can be produced by the same method.

(Same color of continuous long fiber fabric)
Olefin pellets having a melt flow index of 8-22 are extruded and intimately mixed with the blend using a suitable mixture of PETG and maleic anhydride as described above. A blend of 95% olefin and 5% PETG / maleic acid is extruded into a continuous long fiber yarn using conventional extrusion equipment. The long fiber has a dpf of 5.4. About 1,000 pounds of yarn are produced and wound on a polymer electrolyte membrane (pems).

  b. ) Undrawn yarn is drawn 3.0 to 1 and false twisted on a conventional texturing machine. The processed yarn has 277 long fibers of 1.8 denier each. The yarn is soft and feels like cotton. The yarn is not brightly colored and is put up on a 3 pound cone. In this process, an appropriate spinning finish is applied.

  c. ) The processed yarn is knitted on a 10-cut knitting machine. The result is an undyed sweater fabric with a brilliant soft appearance.

  d. ) A brilliant processed continuous long fiber sweater fabric anti-fabric is dyed in a conventional jet dyeing machine which is usually used to dye polyester. In order to avoid damage to the olefin, the temperature is kept below 250 ° F. A disperse dye Terasil Blue BRL of 0.005% by weight of the dough is used with a standard dye dispersal chemical. The resulting sweater fabric is a new and attractive brilliant shade of dark blue that is identically colored. The fabric is dried in a relatively cool dryer. The temperature is below the melting temperature of the olefin or is kept at 200 ° F. Compared to cotton or cotton polyester blends, the drying time is greatly reduced. The water cleans the olefin leaving a soft, soft fabric that fits dry and shining body lines, and the fabric is rolled and packaged for transport.

  e. ) Continuous long fiber sweater fabric is cut and sewn and is surprisingly new. The fabric is brilliant, “fits well with the lines of the body” and is fashionable. Although the fabric is the same color, by using the same technique as in Example 2 above, one skilled in the art can change the olefin yarn to achieve a new effect in two or three tones from one dye bath. can do. The fabric is at least 30% lighter in weight than a sweater made from polyester. This is because the specific gravity of olefin is 0.91 compared to 1.38 for polyester. This new sweater will actually float on the water. The sweater does not require ironing and would be ideal as travel clothing.

  It should be understood by those skilled in the art that the same technique can be used to produce finer filaments of 20, 70, 120, 150 denier. The above examples are intended to show that continuous long fiber yarns can be made dyeable using the same PETG and maleic anhydride blends used to make dyeable staple fibers. is there. Woven fabrics can also be made using the yarn.

(Printed olefin fabric)
Screen printing-The knitted fabric from Example 1 was fed to a 6 color aqueous continuous screen printing machine. A standard dyeing paste using disperse dyes was prepared for each screen with thickener. The screen was made to allow 6 colors of attractive floral patterns to be generated. The print thickener was covered on the fabric. The fabric was fed into a steam chamber to fix the dye. Two to four minutes of 212 ° F. steam is required to fix the dye. The fabric is fed into a steam chamber, where excess dye is washed and dried and wound up in a continuous system. The result was a sweater fabric printed with attractive six-colored flowers.

  This new effect has been achieved without bleeding or excessive pick up. Drying time was significantly reduced and the dryer was set to allow contact with the fabric at 200 ° F. It will be appreciated that woven fabrics can also be processed using the same technique.

(Spatial dye printing of color on yarn using knit denit processing)
Olefin pellets having a melt flow index of 8-22 are extruded and intimately mixed with the blend using a suitable mixture of PETG and maleic anhydride as described above. A blend of 95% olefin and 5% PETG / maleic acid is extruded into a staple mass using conventional staple extrusion equipment. Its fiber dpf is 1.8 and is cut to 1.5 inches. Approximately 1,000 pounds of staples are produced and packaged. The denier per long fiber is close to the denier per cotton long fiber, as is the staple length.

  b. ) Staple fiber olefin packaging is mixed and roving together in a carding process. The roving is made using conventional cotton making equipment, spun to 10/1 and wound into a 3 pound package. Approximately 1000 pounds of yarn are produced. The 10/1 conjugated olefin is plied to make a 10/2 dyeable olefin.

  c. ) Knitted sleeve-10/2 olefin yarn is knitted into a single endless sleeve.

  d. ) Spatial dye prints-Three colors are printed on the sleeve using a knit denit process well known in the prior art. This is a continuous process in which the undyed sleeve passes through the squeegee roller and is submerged in the disperse dye tank to give the first shade. The sleeve follows a second patterned roller, the roller prints over a second shade, then follows a third roller, and the third roller is a patterned third Print with overlapping colors. Each shade contains a disperse dye. The colored knitted sleeve is exposed to steam for at least 2 minutes, preferably 4 minutes. As a result, the disperse dye is fixed to a color depth that can be demanded. The knitted sleeve has a beige identical background shade printed overlaid with dark brown and dark gray. The sleeve is then washed and dried for a continuous area. The dryer is set to a low temperature of 200 ° F. and washed with water. The dried sleeve is collected in a can and moved to a take-up chamber.

  e. The resulting sleeve is wound or denited into a yarn package using a winding operation well known to those skilled in the art. The yarn is an attractive beige color with dark brown and dark dark gray dots and is stored in a 3 pound cone.

  f. ) Space dyed 10/2 olefins are knitted on a 10 cut knitting machine. The result is a fascinating three-tone space-dyed fabric. Spatially dyed olefin fabrics are surprisingly free of patterns usually associated with sweater skein or dyeing. The fabric is washed with hot water in a jet dyeing or winch dyeing machine to add bulk and clarify the color. This also ensures the fact that the finished sweater will not shrink when washed by the end user. The fabric is dried in a cold dryer at 200 ° F. Although it is not necessary to wash the fabric, it is worth performing additional steps to perform a fabric shrinkage test.

  g. ) Spatially dyed sweater fabric is cut and sewn and is surprisingly new. The fabric is 30% lighter in weight than a cotton sweater made to the same specifications. This is because the specific gravity of olefin is 0.91 compared to 1.38 for cotton or cotton polyester. This new sweater will actually float on the water.

  Although this example uses 10/2 yarn, it should be noted that any size of dyeable olefin that would be practical to pass through a knit denit system would be suitable. A number of attractive color effects can be achieved, and this should not be limited to the embodiments described above. Those skilled in the art should experiment to find an attractive effect with either spun yarn or long fiber yarn.

  Other methods of space dyeing or print dyeing yarns can be used. Those skilled in the art will adjust the various machines to the specifications outlined above. Warp yarn printing or package injection is two other common methods used to spatially dye yarns.

  There are a number of yarn sizes used to make fabrics. Spun yarns are usually made into # 18, # 20, # 24, # 28, # 30, # 36, and # 40, which are in the form of double yarn or single yarn respectively. Continuous continuous yarns are usually made 20/1, 70/1, 100/1, 150/1, 200/1, 300/1, 500/1 or 1000/1. These are common yarn sizes used to make woven or knitted fabrics. It should be understood that any size yarn or staple fiber can be made dyeable using a suitable mixture of the present invention. From these yarns all types and types of dyeable woven, non-woven or knitted fabrics will be made.

  It should be noted that there are continuous long fiber machines that use multiple extrusions to supply the yarn projections and extrude more than one color. When the dye promoter composition is introduced into each extruder in a different percentage configuration instead of the dye, the result is a continuous long fiber yarn that accepts different shades of shade from a single dye bath. Will.

(Tricolor long fiber fabric)
Olefin pellets having a melt flow index of 8 to 22 are intimately mixed and joined with the olefin dye-promoting blend described above. This machine has three extrusion parts that supply a single yarn projection separately. Barmag, Plantex and Rieter make such machines. One extrusion is fed with a mixture of 95% olefin and 5% dye promoter, the other is fed 97% olefin and 3% dye promoter, and the third is fed to the third extrusion. Is supplied with 99% olefin and 1% dye promoter. A single white yarn having a denier per long fiber (dpf) of 5.4 composed of three separate levels of dyeability is wound into a 3 pound package.

  b. ) The yarn at this stage is drawn and woven. The yarn is drawn at 3: 0 on a conventional draw-twisting machine known to those skilled in the art and woven in false twist. The result is a continuous long fiber yarn with 300 ends of 1.8 dpf. One third of the yarn has 5% additive, one third has 3% additive, and one third has 1% additive.

  c. ) The yarn is knitted on a 30 inch rubber knitting machine. The tubular fabric produced is a white fabric anti-tube that is transported to a dyeing factory.

  d. ) The tube is dyed with 0.005% disperse dye of the fabric weight. The surprising result is a dyed fabric that simulates a tweed fabric with dark, medium and light blue shades. One third of the yarn receives one level of disperse dye, one third of the yarn receives a second level of disperse dye, and one third of the yarn receives a third level of disperse dye. Accepted.

  e. ) The fabric is opened, dried at a low temperature of 200 ° F. and wound for transport.

  f. ) The fabric is cut and sewn into a full-fashioned heeled spring coat with dress buttons. One skilled in the art will vary both the bonded dispersible dyeable compound and the size of the extrusion to achieve the desired effect.

  Variations for knitting a dyeable trichromatic yarn with a dyeable light colored yarn will exist to those skilled in the art. When the fabric is dyed, the fabric will have stripes of the same tone with tritone stripes. This is only an example and should serve to show that many variations are now made using the present invention. It would be desirable to supply two extrudates with additives while the third extrudate produces an undyable part. When exposed to a Terraseal Blue disperse dye bath, the two ends will dye blue and the third end will remain white.

  Fabrics containing tri-colored yarns would be ideal for spacing between dyeings or prints, as the printed yarns will dye separate tones within the tone in each strike of color reduction. Of course, those skilled in the art should not be limited to the above examples, but should be guided by the above examples.

  The present invention enables spinning machines, fabric making machines and dyeing machines to create new lightweight colored fabrics. The present invention allows the fabric to be held until the last moment before dyeing and transporting to be produced with a shade consistent with the current year and season.

(Olefin woven fabric)
Olefin yarn is made according to the present invention. The olefin yarn is improved to accept the same dark shade of disperse dye. Its size is 24/1 spun on a cotton spinning machine wound up on a 3 pound cone. The olefin yarn includes a dyeable joint of 5% of the weight of the fabric.

  Appropriate multiple terminations are cut and wound on the woven beam. The beam is set up to supply a simple box loom.

  Olefin yarns made in accordance with the present invention containing 2.5% dyeable joints are made to supply weft inserts on a box loom. Its size is 24/1 span on a cotton spinning machine. Simple 60 inch wide over and under fabrics are produced. By composition, half of the yarn contains 5% dye promoter made according to the present invention, and half contains yarn with 2.5% dye promoter made according to the present invention.

  The woven fabric is dyed with Telaseal Blue disperse dye using 0.005% of the fabric weight in a jet dyeing machine set at 250 ° F.

  The warp or beamed yarn is dyed in a deep blue shade and the weft is dyed in an intermediate blue shade. The fabric is a two-tone tweed color.

  The fabric is dried at 200 ° F. in a relatively cool dryer to maintain the temperature below the melting temperature of the olefin.

  The fabric passes through the dryer while being held in a stretched or stretched position on the tenter. This “sets” the fabric so that it does not shrink in any further processing at a later time.

  The fabric is cut and sewn into a women's jacket and skirt. When the garment is combined, it is a women's suit made from 100% olefin fabric. This suit is easy to clean, washable, resistant to dirt and lightweight. The suit is 38% lighter than a similar suit made from polyester or hair / blend.

  The above is an example. Using the present invention, one of ordinary skill in the art can make many types of dyeable woven fabrics for use in the clothing or furniture industry. There are some possibilities for patterns and prints such as bird's eyes, jacquard and twill. Each is lightweight, stain resistant and can be disperse dyed in any shade that the market will demand.

(Cover-core long fiber or thread)
Kennedy et al., U.S. Pat. No. 6,136,436, discloses a method for producing continuous wick-core fibers or yarns. This process is incorporated into the present invention with the following additions.

  No. 6,136,436 claims a nylon or polyester covering on an olefinic core. The outer covering contains 10% to 70% olefin joined by dye-promoted amorphous PETG. The core is 100% olefin.

  The fabric is knitted or woven with one or more yarns containing different dye levels. The fabric is dyed as in the above example. Because the covering contains only 10% to 70% of the total composition, significant cost savings occur. Those skilled in the art will vary the cover and the percentage of dye promoter to achieve the desired effect.

  A variation of the above is to use a dyeable olefin cover and a dyeable olefin core. The result is a thread with a transparent outer shell and core color. One skilled in the art can manipulate the yarn or fiber to create the desired effect.

(Knitted fabric or woven fabric using dyeable olefin mixed with polyester)
A new and surprising effect was achieved when mixing polyester and dyeable olefin fibers to make yarn. The resulting yarn has an outer covering composed mostly of polyester and a core composed mostly of dyeable olefins. There is a small overlap on both the cover and the core.

  In accordance with the present invention, olefin fibers are made. The fibers are enhanced with the additives of the present invention to accept disperse dyes of the same shade.

  a. ) Pellets of olefins having a melt flow index of 8-22 are extruded and intimately mixed with the blend using a suitable PETG and maleic anhydride mixture of the present invention. A blend of 95% olefin and 5% PETG / maleic acid is extruded into staple masses using conventional staple extrusion equipment. The denier (dpf) per long fiber of the fiber is 1.8 and cut to 1.5 inches. Approximately 650 pounds of staples are produced and packaged. The denier per long fiber is close to the denier per long cotton fiber, as is the staple length.

  b. ) Improved dyeing olefin staple fiber is mixed with polyester staple fiber having 1.35 denier per long fiber and cut to 1.5 inch staple length in carding process, 65% dyeable A close blend of rovings containing olefin and 35% polyester. The roving is made using conventional cotton making equipment, ring-spun to 28/1, and then wound on a 3 pound package.

  c. ) About 1000 pounds of unique yarn is produced. The heavier polyester with a specific gravity of 1.38 moves to the outside of the yarn due to centrifugal force and becomes a covering that surrounds the lighter weight olefin that remains mostly in the center.

  d. ) The yarn is twist plied into 28/2 twin yarns. Both ends contain 65% dyeable olefin and 35% polyester.

  e. ) The yarn is then converted to a woven fabric on a conventional box loom using 40 ends per inch for warp yarns and 40 ends per inch for weft yarns. The fabric is woven to a width of 67 inches.

  f. ) The fabric fabric is dyed in a conventional jet dyeing machine which is usually used for dyeing polyester. The temperature is maintained at 250 ° F. to avoid damage to the olefin. Disperse dye Terasil Blue BRL of 0.005% by weight of the dough is used with standard dye dispersal chemical and water. The resulting woven fabric is a new and attractive brilliant shade of dark blue. The fabric is dried in a relatively cool dryer. The temperature is kept below the melting temperature of the olefin, but is raised to 255 ° F. because the olefin core is protected by a polyester sheath. The water is washed leaving a dry, brilliant fabric that is wound and packaged for transport. Since olefins retain only a limited amount of water and only 35% of the fabric is polyester, drying time is greatly reduced compared to cotton or cotton polyester blends.

  g. ) The new result is a fabric that shrinks to 61.5 inches after finishing. The fabric then stabilizes and does not shrink more than 1% after washing. This effect makes the fabric easy to maintain without ironing.

  h. ) The dyed woven fabric is cut and sewn and is surprisingly new. The woven fabric is at least 20% lighter in weight than a polyester garment made to the same specifications. This is because the specific gravity of the polyester / olefin is 1.07 compared to 1.38 for the polyester. The fabric has a soft hand feel of cotton but is nevertheless substantially light in weight. It will be appreciated by those skilled in the art that different weight fabrics using different yarn sizes can be produced by the same method. In addition, the yarn can be used to knit fabric using a conventional knitting machine.

  Woven, knitted and non-woven fabrics can be produced using the blends described above.

  The advantages of fabrics and yarns made from blends of polyester and dyeable olefins are:

1. ) Weaving, knitting and dyeing processes are fully developed in all parts of the world.
2. ) A deeper dyed polyester can be used as a cover.
3. ) The fabric can be post-dyed or printed using conventional equipment.
4). ) Sublimation prints using heat transfer processes can be used.
5. ) The fabric is lighter in weight than 100% polyester, 100% cotton or a blend of both.
6). ) Permanent press should be easily implemented.
7). ) The fabric is washable and can be line or machine dried.
8). ) Flexible fabric can be made by using very small denier polyester.
9. ) The fabric is sewn on any conventional sewing machine.
10. ) The dyed fabric should not shrink more than 1-5%.

(Woven or knitted fabric using dyeable olefin mixed with nylon)
A new and surprising effect is achieved when nylon and dyeable olefin fibers are mixed to make yarn. The resulting yarn has an outer covering composed mostly of nylon and a core composed mostly of dyeable olefins. There is a small overlap in both the cover and the core. The resulting yarn has a covering composed mostly of nylon and a core composed mostly of dyeable olefins.

  Olefin fibers are made according to the present invention. The fibers are enhanced to accept the same shade of disperse dyeing.

  a. ) Pellets of olefins having a melt flow index of 8-22 are extruded and intimately mixed with the blend using a mixture of suitable PETG and maleic anhydride as described above. A blend of 95% olefin and 5% PETG / maleic acid is extruded into staple masses using conventional staple extrusion equipment. The denier (dpf) per long fiber of the fiber is 1.8 and cut to 1.5 inches. Approximately 650 pounds of staples are produced and packaged. The denier per long fiber is close to the denier per long cotton fiber, as is the staple length.

  b. ) Improved dyed olefin staple fibers are mixed with nylon staple fibers having a 1.35 denier per long fiber and cut to a staple length of 1.5 inches in the carding process and 65% dyeable A close blend of rovings containing olefin and 35% nylon. Rovings made using conventional cotton making equipment are ring spun to 28/1 and the yarn is wound on a 3 pound package.

  c. ) About 1000 pounds of unique yarn is produced. The heavier nylon with a specific gravity of 1.14 moves to the outside of the yarn due to centrifugal force and becomes a covering that surrounds the lighter weight olefin that remains mostly in the center.

  c. ) The yarn is twisted into 28/2 twin yarns.

  c. ) The yarn is then converted to a woven fabric on a conventional box loom using 40 ends per inch for warp yarns and 40 ends per inch for weft yarns. The fabric is woven to a width of 67 inches.

  d. ) The fabric fabric is dyed in a conventional jet dyeing machine which is usually used to dye the fabric. The temperature is maintained at 250 ° F. to avoid damage to the olefin. Disperse dye Terasil Blue BRL of 0.005% by weight of the dough is used with standard dye disperse chemicals and water. The resulting woven fabric is a new and attractive brilliant shade of dark blue. The fabric is dried in a relatively cool dryer. The temperature is kept below the melting temperature of the olefin, but is raised to 255 ° F. because the olefin core is protected by a nylon sheath. The water is washed leaving a dry, brilliant fabric that is wound and packaged for transport. Since olefins retain only a limited amount of water and only 35% of the fabric is nylon, drying time is greatly reduced compared to cotton or cotton polyester blends.

  e. ) When acid dyes are used to dye fabrics, only nylon is dyed. When disperse dyes and acid dyes are used, nylon can be dyed in one shade and olefins are dyed in another shade, creating a noticeable blending effect. The new result is a fabric that shrinks to 61.5 inches after finishing. The fabric then stabilizes and does not shrink more than 1-5% after washing. This effect makes the fabric easy to maintain without ironing.

  f. ) The dyed woven fabric is cut and sewn and is surprisingly new. The woven fabric is at least 20% lighter in weight than a cotton garment made to the same specifications. This is because the nylon / olefin specific gravity is 0.99 compared to 1.38 for cotton. The fabric has a soft hand feel of cotton but is nevertheless substantially light in weight. Those skilled in the art will appreciate that different weight fabrics using different yarn sizes can be produced by the same method.

  Woven, knitted and non-woven fabrics can be produced using the blends described above. Nylon is very easy to dye using an aqueous dyeing system. Fabrics made from nylon and olefin blends will be printed using any acidic system commonly used to dye nylon or silk.

  In addition, the fabric can be printed using any aqueous dyeing system commonly used for printing on nylon, silk or polyester.

  The advantages of fabrics and yarns made from blends of nylon and dyeable olefins are as follows:

1. ) Weaving, knitting and dyeing processes are fully developed in all parts of the world.
2. ) The fabric can be post-dyed using conventional equipment.
3. ) The fabric can be post-dyed using nylon dyeing methods.
4). ) A darker dyed nylon can be used as a cover.
5. ) Cation-dyed nylon can be used as a cover.
6). ) Printing using any aqueous system can be achieved.
7). ) The fabric is lighter in weight than 100% nylon, 100% cotton or polyester / cotton blends.
8). ) The fabric is washable and can be line or machine dried.
9. ) A flexible fabric can be made by using very small denier nylon.
10. ) The fabric is sewn on any conventional sewing machine.

Claims (15)

  Dispersible dyeable fibers or filaments comprising a melt blend of polyolefin and amorphous polyethylene terephthalate copolymer (PETG).   The disperse dyeable fiber or long fiber of claim 1, further comprising maleic anhydride in the melt blend.   A thread formed at least in part by the fibers or long fibers of claim 1.   4. The yarn of claim 3, wherein the melt blend comprises a mixture formed primarily by olefins blended with a polymerization modifier comprising PETG and maleic anhydride.   The yarn of claim 4, wherein the polymerization modifier comprises PETG and maleic anhydride in a ratio of about 48 parts PETG to about 12 parts maleic anhydride.   The yarn of claim 5, wherein the polymerization modifier comprises polypropylene in a ratio of about 50 parts polypropylene to 48 parts PETG to about 2 parts maleic anhydride.   The fiber or long fiber of claim 1, wherein the melt blend comprises polyester or nylon.   The fiber or long fiber according to claim 7, wherein the disperse-dyeable olefin is a mixture mainly formed of an olefin mixed with a polymerization regulator containing PETG and maleic anhydride.   9. The fiber or long fiber of claim 8, wherein the polymerization modifier comprises PETG and maleic anhydride in a ratio of about 48 parts PETG to about 2 parts maleic anhydride.   10. The fiber or long fiber of claim 9, wherein the polymerization modifier comprises polypropylene in a ratio of about 50 parts polypropylene to 48 parts PETG to about 2 parts maleic anhydride.   The fiber or long fiber according to claim 10, wherein the polymerization regulator is blended with an olefin in a ratio of about 95 parts olefin to about 5 parts of the polymerization regulator.   2. The fiber or long fiber of claim 1 combined with other fibers that can be dyed in more than one color in a single dyebath.   The fiber or long fiber according to claim 1, which has a core part and a sheath part, and one of the parts is dyeable, and the other part is non-dyeable.   14. A fiber or long fiber according to claim 13 having a dyeable olefin sheath and a dyeable olefin core.   14. The fiber or long fiber of claim 13, wherein the dyeable portion comprises a disperse dyeable olefin.