KR101235118B1 - Dyed olefin yarn and textile fabrics using such yarns - 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

Dyed olefin yarn and textile fabrics using such yarns}

The present invention relates to fabrics made of olefin fibers or yarns modified to suit disperse dyes. Such fabrics are usually dyed through disperse dyes or printing methods. A solid color tone or a tone of various tones can be obtained by dyeing by a single dyeing tank or a printing method. The fabric of the present invention is made of greige, i.e., raw fabric, through a knitting, weaving or non-woven process. Solid tint is obtained by grafting a single level of dyeing additive to an olefin yarn or olefin fiber and dyeing in a disperse dye bath. Fabrics woven from a plurality of warp ends containing different proportions of dye additives are dyed in multiple tones in a single dye bath. As the amount of additives capable of disperse dyeing contained in olefin yarns or olefin fibers increases, the affinity for disperse dyes increases accordingly. The fabrics made according to the present invention can be stored in an unstained state in a dyeing plant. It is then colored using conventional dispersing dyes or printing methods. Surprisingly novel effects can be obtained using conventional economical disperse dyeing systems known to those skilled in the art. The invention is particularly useful in the apparel and household goods industry. The fabric produced by the present invention has the same appearance and feel as conventional fabrics but is 30 to 38% lighter in weight. This is because the specific gravity of olefin is 0.91 while that of cotton or polyester is 1.38. In addition, light fastness and wash fastness are similar to polyester.

Knits, fabrics and textiles are a huge industry in the world. The most commonly used textile material for making knitted fabrics is cotton. Cotton has been used for generations to make yarn and fabrics. Cotton is a natural fiber and is grown in many parts of the world. There are numerous cotton spinning systems around the world, and cotton yarns are made from clothing and household goods using cotton spinning systems. The cotton staples for making threads and fabrics are most widely used in Egypt and the United States.

The cotton spinning system starts with cotton bundles harvested from the field. The fiber bundles are called staples and are usually 3/4 to 1.5 inches in length. The longer the staple, the higher the value. You can make better yarns from longer staples. The machine cleans the staples and carding them to create various sizes of roving. The roving is twisted or spinned using well known machines to produce yarns of various sizes. This thread is made of knitwear or textiles to make clothing or household goods. Knitting or woven fabric manufacturers can make various types of clothing or household items using threads of various sizes. Cotton fabrics that are first woven and not dyed are called gray fabrics. This method is the most widely used and economical method of producing cotton fabrics. Typically, dyeing or printing of a fabric takes place after receipt of an order from an end user of the fabric. Dyed cotton fabrics are then cut to the appropriate form and all garments are made by sewing them. Cotton is used to make underwear, socks, sweaters, shirts, pants, casual sportswear and dresses. Usually no cotton is used to make sports jackets, gentlemen / ladies' suits or outerwear.

The most common way to color clothing fabrics is to dye knits, fabrics or non-woven fabrics. The cotton fabric is placed in a machine containing water, vat dyes or direct dyes and chemicals. The temperature of the dye solution and the dye bath is set to a desired value. A skilled worker puts the desired hue on the cotton fabric through this operation. The cotton fabric is dried and processed to meet the specific needs of the customer. The dyeing plant is a capital-intensive business that requires expensive dyes and processing equipment. In addition to dyeing, dyeing factories include dryer and compactor, chemical feeder, and processing devices such as a device for wrapping or folding cotton. Alternative fabrics of cotton can also be ideally machined using current face-to-face, dyeing and processing system systems used worldwide for dyeing and processing cotton fabrics.

Cotton is used in fabrics for the following reasons:

Cotton is easily grown all over the world.

Cotton is easily converted to yarn because it grows to standard staple length.

Cotton yarn works well on most knitting and looms.

Cotton fabrics are soft and pleasant to the touch.

Cotton absorbs sweat and moisture.

Cotton is easy to dye.

Cotton blends well with other synthetic fibers.

Cotton knitted or woven fabrics have a standard designation and can be purchased as unprocessed goods in most countries of the world. Producers can purchase standard cotton fabrics anywhere in the world. The producer then sends the fabric to the dyeing plant, where it is left undyed, waiting for the order of the fabric in a particular shade. Dyed fabrics are cut and sewn and made from household items such as clothing or curtains, bedspreads, or upholstery.

Synthetic Fiber Synthetics ):

Many attempts have been made to produce a satisfactory synthetic fiber or synthetic yarn to replace cotton and can be produced through conventional spinning devices.

Synthetic substitutes had to be created because there was not enough arable land to produce enough cotton to meet the global demand for textiles and clothing as the population grew. It is highly desirable to produce synthetic fibers to replace cotton.

Rayon( Rayon ):

In many attempts to produce synthetic fibers to replace cotton, rayon and rayon acetate are the first successful cotton substitutes. In the rayon process, cellulose extracted from wood is used. Rayon and rayon acetate are widely used in the apparel and household goods industry. However, the production of these fibers or yarns is not produced in the United States because they cause a lot of contamination. The rayon production process uses large amounts of caustic and anhydrides. Rayon has a very desirable quality. Easy to dye and made with rayon, the fabric is bright and soft and is a good substitute for cotton. Most rayon should be imported and produced by professional manufacturers, so it is expensive and not used except for expensive fashion apparels. Rayon can also be blended with cotton or other synthetic fibers to create a soft, draping fabric. The specific gravity of rayon or acetate is the same as the specific gravity of the cotton, so there is no weight benefit when used as a substitute fabric for cotton.

acryl( Acrylics ):

Synthetic fibers made using the acrylonitrile process are also used to make soft fibers. Examples include Solutia's Acrylan, American Cyanamid's Creslan, and Mann Industries' Mannacryl. This fiber is poorly dyed and is usually produced in large amounts of pigment dyes. In addition, acrylic is more expensive than cotton. Acrylic fibers have a specific gravity of 1.17, which makes them ideal for blending with wool for use in sweaters, socks, and Maryas. Acrylic fiber made from solution-dyed acrylic yarn is ideal for outdoor use, such as awnings, awnings, garden covers and coatings. Acrylic fiber is not a good alternative to cotton.

Polyester( Polyester ):

Most of the synthetic fibers are polyester, making up almost half of the fibers used to produce the fabric.

Nearly 60 years ago, DuPont introduced polyester staples to replace cotton. This is not a substitute for cotton, but is often used to blend with cotton. Early polyesters were grainy, did not absorb moisture, and were very difficult to dye. Efforts have long been made to blend cotton with cotton to soften the feel and to produce yarn using cotton spinning systems. The most famous polyester is a polyester called "micro denier". The micro denier is extruded through a spinneret and produces fibers of smaller diameter than cotton. A blend of 60% cotton and 40% polyester is a very common example. There is a wide variety of cotton / polyester blends, which are common in knits and textiles. There have been many expensive variations to make fabrics that can be spun and dyed from cotton / polyester blends. Undyed fabrics made from cotton / polyester blend yarns are dyed and processed in solid tones at current state-of-the-art dyeing and processing facilities and shipped to end users. Matching the color tone of cotton yarn dyed with one dyeing technique to the color tone of polyester yarn dyed with disperse dyes requires great skill. When dyeing this type of blend, a two-step process is used and is much more expensive than using a one-step process.

Polyesters have many drawbacks. It is not easy to dye and dyeing polyester and cotton in uniform shades requires great skill. Polyester fibers require high temperatures under certain pressures to absorb high energy dispersive dyes. Cotton is dyed with direct or vat dyes that do not require pressure or high temperatures. Dyeing plants that dye cotton / polyester blends require very skilled techniques. Fabrics made from cotton / polyester blends should be dyed using a two-step process. First draw one, then dye the other. Most skilled dyeing plants have a number of disperse shades for dyeing polyester and cotton / polyester blends.

The production of polyester is a very large industry. Approximately 33 billion pounds of polyester are produced worldwide for use in apparel and home furnishings. Polyester is widely used all over the world but has many disadvantages.

Polyester has the following disadvantages:

Blending polyester with cotton requires great technology.

Polyester is difficult to dye.

Polyester warms up.

Fabrics made from 100% polyester are heavy.

High temperature and pressure are required to dye or print the polyester.

Polyester does not absorb moisture in the body.

In the garment and home appliances industry it is highly desirable to have synthetic fibers or yarns that exhibit satisfactory properties. Ideally, the fabric should be made of synthetic fiber yarns to produce a fabric similar to that made from 100% cotton. Polyesters do not meet these criteria.

Olefins ( Olefin ):

Olefins (polypropylene, polyethylene) are artificial fibers and consist of at least 85% of ethylene, propylene or other olefin series. Olefin fibers can be an ideal alternative to cotton except that they are not easily dyed in conventional dyeing and printing systems. Olefin is easy and economical to produce into fibers and has a texture very similar to cotton. We have found that olefins with 1.8 dpf (denier per filament, denier per filament), staple length of 1.5 to 2 inches are a good alternative to cotton. In addition to being pleasant to touch, olefin fibers have the following characteristics:

Olefin fibers can be easily spun using current spinning systems.

Olefin yarns work well in knitting machines.

The olefin yarn is soft to the touch.

Olefin staples are well treated in nonwovens.

Olefin fabrics are similar in texture to cotton.

Olefin fabric dries quickly.

Olefin fabrics release moisture well but retain body heat.

Olefin fabrics do not soil well.

Olefin fiber and Olefin yarn  Disadvantages:

The main disadvantage of olefin fibers is that they are not dyed well by conventional dyeing methods. Almost all olefin fibers and olefin yarns are dyed by pigment or solution dyeing. Pigment dyed yarn fabrics can not be dyed with the latest trendy colors ordered by end users. This greatly increases the cost of manufacturing fabrics and makes them too hard to handle in the apparel and home appliances industry. Polypropylene is currently used mainly to make carpets and rugs.

The present invention relates to a process for producing knitted fabrics, woven fabrics or nonwovens using olefin yarns and olefin fibers reinforced to allow dyeing with disperse dyes. The olefin composition of the present invention can accept a disperse dye. The olefins are not dyed, but grafting the additives to the olefins according to the invention accepts any disperse dyes used in dyeing equipment used to dye polyester or blends of polyester and cotton. You do not need to buy any special dyes to express the required hue. The olefins according to the invention are applied to dyeing with disperse dyes. The present invention produces yarns that are grafted with additives to olefins to make gray knitted, woven or nonwoven fabrics. The fabrics of the invention can be stored as undyed products. The grained fabrics are usually dyed using disperse dyes which are used to dye the polyester. Dyeing olefin fabrics does not require the same high temperatures as dyeing polyester and is ideal for 220-250 ° F. When the olefin fabric is dyed through the present invention, any color can be expressed in bright and dark tones.

Multitone ( Multitones ):

Only one solid color is of course dyed in multitones. Fabrics made using olefin yarn grafted with 1 to 15% dye promoter are dyed in multitones of the same color in a single dye bath containing disperse dyes. This is achieved by grafting on olefin fibers or olefin yarns by varying the concentration of the dyeing promoters to be detailed in the present invention. As an example, we will refer to a thread with a 5% staining promoter as A, a thread with a 3% staining promoter as B, and a thread with a 1.5% dyeing promoter as C. When yarns A, B and C are placed together in a weaving machine, such as a weaving machine, the composite is dyed with three new color tones in a single dye bath. One is dark, one is medium and one is light. The preferred concentration range of the grafted dye promoter is 1-7%.

If a fabric is made from yarns with two dyeing levels and no dye-promoting agent, the fabric is two tones and white. This is a new and surprising effect. Those skilled in the art will find many satisfactory ways to make new fabrics using the present invention.

Solid  hue( Solid Shades ):

Fabrics made of olefin yarn grafted with only one level of dye promoter will be dyed in solid shades. Preferred concentrations to be grafted are 5% on the weight of goods. Other concentrations may be used to change the coloration of the dye, but the inventors have found that the preferred mixing ratio for making a solid hue is 5% owg.

Surprisingly novel effects can be obtained using the 100% olefin yarn of the invention. The advantages of using olefins prepared according to the invention are as follows:

1.Olefin fabric does not fade even when sucked in warm water.

2. The olefin fabric can be dried on a clothesline and quickly dried in a low temperature dryer.

3. Disperse dyed olefin fabrics do not stretch or shrink during the washing process.

4. The olefin fabric does not wrinkle when dried.

5. Olefin fabric is not contaminated well.

6. The olefin fabric is soft to the touch.

7. The olefin fabric is 38% lighter than cotton.

8. Olefin fabric absorbs moisture from the body and is breathable.

9. Olefin fabric is not moldy or green algae.

10. Olefin fabrics are bulkier than most fibers.

11. Olefin yarns can be produced by spinning or continuous filaments.

12. Olefin fabrics are easy to clean and suitable for travel garments.

Olefin dyeing promoter Olefin Dye Enhancers ):

There are a variety of ways to allow olefins to accept or promote dyes.

Related Patent

U.S. Patent No. 6,420,482 to Domingguez et al. 4,320,046 to Havens

Henkee et al. 6,146,574 Fuest 3,926,553

Calogero 6,126,701 to Farber et al. 3,652,198

Sheth 5,576,366 Brown et al. 3,622,264

No. 5,550,192 to Sheth et al. 3,315,014 to Coover et al.

5,169,405 to Hoyt et al. 3,256,362 to Craubuer et al.

All the above patents teach those skilled in the art how to make grafts that can be grafted onto polyolefins to dye polyolefins. All the above patents refer to chemistry very different from the chemistry of the present invention. Craubuer 3,256,362 mentions unsaturated polyesters, which is different from the rest of the invention above. This Craubuer's patent requires a polyester that is difficult to mix and an unrelated form. Craubuer's patented unsaturated polyesters are not amorphous and do not mix well at the low temperatures needed to produce olefins.

Each of the methods mentioned in the above patents causes problems in spinning or extruding to the small size required for garments. These patents require the selection of a special device or dye to dye yarns or fabrics. As far as the inventors know, none of the above patents has been applied to make apparel or home textile products on a large scale. The carpet industry uses olefin yarn in a limited way. It is desirable to have dyeable olefins that can be used not only for carpet making but also for apparel and household goods. In addition, dyeable olefins are only really useful until the lab can match the color tone transferable to a production dyeing machine with little additional change using an available disperse dye material that is not modified by the dyeing agent. The present invention allows dyeers to easily match colors in the laboratory that can be transferred to a mass production machine.

A preferred method for enabling the polyolefin to be dispersed and dyed is as follows:

Amorphous glycol modified polyethylene terephthalate (PETG) mixtures are the preferred components used for grafting on polyolefins. Amorphous PETG was chosen because it melts at temperatures similar to polypropylene. This allows those skilled in the art to make dyeable polyolefins using conventional olefin fiber extruders. No special equipment is required to do this. The advantage of this additive is that no drying and dehumidification is required when adding the graft. In addition to amorphous PETG, the present invention used maleic anhydride to improve graft adhesion to dispersion and olefin fibers. Preferred products are amorphous PETG No. 1428 and Maleic Anhydride No. of Uniroyal 3200. A mixture of 96% PETG 1428 and 4% Maleic Anhydride is ideal (% means% by weight unless otherwise noted). The inventors lowered the mixing ratio of polypropylene to prepare 50% active compound, so that 50% polypropylene, 48% amorphous PETG, and 2% maleic anhydride. Those skilled in the art will be able to select a suitable method for making the mixture. Of course, while the above example is the best suggestion by experiment, those skilled in the art will be able to change the ratio to suit their needs. If the mixture is in pellet form, it may be packaged in Gaylord's or drum without a special gas sealant.

Maleic anhydride helps to fix the graft completely to the polyolefin. Maleic anhydride is not necessary for the olefin to be dyeable with disperse dyes. However, the inventors have found that amorphous PETG is not evenly dispersed in the absence of maleic anhydride. This results in non-uniform dispersion and non-uniform staining.

Dyeable olefin fibers and Olefin Yarn :

Pellets containing 48% amorphous PETG (polyester), 2% Maleic Anhydride and 50% polypropylene are fed to the olefin fiber extruder using 10% owg. The result is a fiber in which the 5% disperse dye mixture is grafted to 95% olefins. Those skilled in the art will be able to vary the mixing ratio grafted to the olefins in order to obtain the desired color tone in the dye bath containing the disperse dye. We dyed the fibers with varying mixing ratios and found that 5% owg for dark solid shades and 2.5% owg for pale shades are suitable for improving dyeing performance. 5% owg fibers and 2.5% owg fibers were dyed in a single dye bath to obtain a satisfactory two-tone color tone. We will use "dye enhanced olefin" as a term referring to the grafted output.

Pellets containing a mixture of 50% olefin, 48% amorphous PETG and 2% Maleic Anhydride are preferred for the following reasons:

The only dye graft absorbs is disperse dyes.

The mixture melts at the process temperature of the olefins.

The mixture is combined and easily extruded into pellets.

The mixed pellets do not need to be dried to feed the olefin fiber extruder.

The mixture is mixed evenly and well dispersed in the olefins during the extrusion of the fibers.

Grafts that allow dyeing are stable under any dyeing conditions.

The grafted yarn or fabric can be dyed or printed using standard disperse dyes.

Printing is easy and requires only 2 to 4 minutes of exposure to steam at a temperature of 212 ° F.

Colors do not fade when rinsed in warm water at 175 ° F.

The graft improves the feel of the olefin.

The present invention will be described in more detail below.

Example 1-Single Color Fabrics

a.) The olefin pellets having a Melt Flow Index of 8 to 22 are extruded and mixed well with the PETG / Maleic Anhydride mixture of the above mentioned mixing ratios. A mixture of 95% olefins and 5% PETG / Maleic Anhydride is extruded into a staple mass using a conventional staple extrusion apparatus. The fiber is 1.8 dpf and cut to 1.5 inches. Approximately 1000 pounds of staples are produced and bundled into bales. The denier dpf per filament is similar to the dpf value of the face and so is the length of the staple.

b.) Staple fiber bales of dye-promoted olefins are blended together in a cotton carding process and are made well by blended roving. Rovings made using conventional cotton devices are ring spun with a 10/1 cotton count and wound into a three pound package. Approximately 1000 pounds of yarn are produced.

c.) The 10 / 1-olefin yarn is knitted with a 10 cut circular knitting machine. This manufacturing process produces an un-dyed gray fabric and is ideal for making sweaters by cutting and sewing.

d.) The sweater gray fabric is dyed in a conventional jet-dyeing machine used to dye the polyester. Maintain a temperature of 250 ° F. to avoid damaging the olefins. A 0.005% owg of disperse dye Terasil Blue BRL is used with standard dye disperse chemicals and water. The sweater fabrics made from this show a new and satisfying dark blue hue. The fabric is dried in a relatively low temperature oven. The temperature is kept below the melting point of the olefin or at 200 ° F. Once the moisture has evaporated, the dried bright fabric remains and is wrapped in rolls for subsequent shipment. Olefins contain a very limited amount of moisture, resulting in very short drying times compared to cotton or cotton-polyester blends.

f.) Once the sweater fabric is cut and sewn, it is very wonderful. It is at least 30% lighter than a cotton sweater made from the same spec. This is because the specific gravity of olefins is 0.91 while the specific gravity of cotton or cotton-polyester blends is 1.38.

This innovative material sweater actually floats in water. It has a cotton-like appearance and feel, but weighs a lot less. Those skilled in the art will appreciate that it is possible to produce fabrics of different weights using different sizes of yarn in the same manner.

Example 2 Ton on Tone Olefin Fabric

a.) The olefin pellets with a melt flow index of 8 to 22 are well mixed and grafted with the aforementioned olefin dyeing promoter mixture. As described in the present invention, the above mixture is a mixture of 5% of a dispersion dye promoter composed of PETG and Maleic Anhydride and 95% of an olefin. The mixture is extruded into staple masses through a conventional staple extrusion apparatus. The dpf value is 1.8 and the staples are cut to 1.5 inches. Approximately 1000 pounds of staples are produced and bundled into bales. Denier dpf per filament is similar to dpf of face and so is staple length. Such a batch will be referred to as "staple A ".

b.) The olefin pellets having a melt flow index of 8 to 22 are well mixed and grafted with the aforementioned olefin and dye promoter mixtures. As described in the present invention, the above mixture is a mixture of 3% of a dispersion dye promoter consisting of PETG and Maleic Anhydride and 97% of an olefin. The mixture is extruded into staple masses through a conventional staple extrusion apparatus. The dpf value is 1.8 and the staples are cut to 1.5 inches. Approximately 1000 pounds of staples are produced and bundled into bales. Denier dpf per filament is similar to dpf of face and so is staple length. Such a batch will be referred to as "staple B. "

c.) The olefin staple fibers are blended in the carding process for each bale and made into rovings. Rovings made using a conventional cotton device are spun in 10/1 face number and wound into a 3 pound package. Approximately 1000 pounds of yarn are produced for each yarn, with 1000 pounds of olefin yarn A grafted with 5% dyeing promoter and 1000 pounds of olefin yarn B grafted with 3% dyeing promoter. Both will accept disperse dyes.

d.) Olefin yarn A containing 5% dye promoter and olefin yarn B containing 3% dye promoter are placed side by side in a 10-cut knitting machine. Both rooms are 10/1. The yarns are knitted in a 10-cut circular knitting machine. This manufacturing process produces undyed gray fabric and is ideal for making sweaters by cutting and sewing.

e.) The sweater gray fabric is usually dyed in a conventional jet dyeing machine used for dyeing polyester. The temperature is kept at 250 ° F. to prevent olefin damage. A 0.005% owg of disperse dye Terasil Blue BRL is used with standard dye disperse chemicals and water. The sweater fabric thus produced has a new and satisfying two-tone blue tint. In order to express more than one color tone on a fabric, only one color tone may be used. The fabric is dried in a relatively low temperature oven. The temperature is kept below the melting point of olefins or 200 ° F. The drying time is very short compared to cotton or cotton-polyester blends. Moisture evaporates rapidly from the olefins, resulting in a dry, bright two-ton blue fabric that is wrapped in rolls for shipment.

f.) The two ton sweater fabric is wonderful once it has been cut and sewn. The effect of this two tone is new and gives a natural feel like wool or linen. Weighs less than 30% less than a cotton sweater made from the same spec. This is because the specific gravity of olefins is 0.91 while the specific gravity of cotton or cotton-polyester blends is 1.38. This fresh sweater actually floats in the water.

Those skilled in the art can vary the amount of dyeing accelerators and the number of cotton yarns of olefin yarns supplied to the knitting machine to produce a variety of fashionable yet amazing gray fabric products made from blends of olefins or other yarns and olefins. You will understand. Those skilled in the art will also appreciate that different weight fabrics can be made from yarns of different sizes in the same manner.

Example 3 Solid Shade of Continuous Filament Fabric

a.) The olefin pellets with a melt flow index of 8 to 22 are extruded and mixed well with the mixture using PETG and Maleic Anhydride mentioned above. 95% of the olefins and 5% of the PETG / Maleic mixture are extruded into continuous filament yarns using conventional extrusion equipment. This filament fiber is 5.4 dpf and approximately 1000 pounds of yarn are produced and wound in a pirn.

b.) Unstretched yarns are stretched one to three times and are false twisted in conventional texturing machines. The textured yarns each have 277 filaments of 1.8 denier. This thread is soft and has a cotton-like feel. This thread is bright, uncolored, and wound into 3 pound cones. Appropriate spin finish is performed during the process.

c.) The textured yarn is knitted in a 10-cut knitting machine. As a result, it becomes a bright, soft-looking sweater gray fabric that is not dyed.

d.) Bright textured continuous filament sweater Gray fabric is usually dyed in a conventional jet dyeing machine used for dyeing polyester. The temperature is kept at 250 ° F. to prevent olefin damage. 0.005% owg disperse dye Terasil Blue BRL is used with standard dye dispersion chemicals. The resulting sweater fabric has a solid, dark blue color with a fresh and satisfying bright hue. The fabric is dried in a relatively low temperature oven. The temperature is kept below the melting point of the olefin or 200 ° F. The drying time is very short compared to cotton or cotton-polyester blends. Moisture evaporates from the olefins, resulting in a dry, light fabric that is soft and soft to the touch. It is then wrapped in rolls for shipment.

e.) The continuous filament sweater fabric is very wonderful after being cut and sewn. It is bright and bright in the sky. The skilled person in the art to which the present invention pertains shows a solid color tone, and the same technique as described in Example 2 may be used to vary the olefin yarn in various ways and obtain 2 or 3 tons in a single dye bath. . It's 30% lighter than a sweater made of polyester. This is because the specific gravity of the polyester is 1.38, whereas the specific gravity of the olefin is only 0.91. This new sweater actually floats in the water. Suckable, no ironing, ideal for travel clothes.

Those skilled in the art will appreciate that the same technique can be used to produce thinner filaments, for example 20, 70, 120 or 150 denier yarns. This example shows that the same filament yarns can be dyed using the same PETG / Maleic Anhydride mixture used to make staple fibers dyeable. You can also use these threads to make fabrics.

Example 4 Printing Olefin Fabrics

Screen Printing-The knitted fabric of Example 1 was fed to a six color aqueous continuous screen printing machine. A standard dye paste using disperse dyes was fed to each screen along with a thicker. The screen was constructed to create a floral pattern of six colors. The printing paste was pressed onto the fabric. The knitted fabric was put into a steam box to fix the dye. To fix the dye, it is necessary to apply 2-4 minutes of steam at a temperature of 212 ° F. The knitted fabric is placed in a steam box and wound up continuously to remove excess dye and dry. The result is a sweater fabric with six floral prints.

Amazing results were obtained, with some of them not being printed or overly printed. The drying time was very short and the temperature of the oven was set at 200 ° F. to make contact with the knitted fabric. It will be appreciated that a woven fabric can also be made using the same technique.

<Example 5-Space Dye Printing Color on Yarn using the Knit de Knit Process>

a.) The olefin pellets with a melt flow index of 8 to 22 are extruded and mixed well with the mixture of PETG and Maleic Anhydride mentioned above as preferred. 95% of the olefins and 5% of the PETG / Maleic Anhydride mixture are extruded into staple masses using conventional staple extrusion equipment. This fiber is 1.8 dpf and cut to 1.5 inches. Approximately 1000 pounds of staples are produced and baled. Denier dpf per filament is similar to that of cotton and so is staple length.

b.) The olefin staple fiber bales are blended together in a carding process and made into rovings. The roving is made using a conventional cotton machine, radiating in a 10/1 facet, and wrapped in a 3 pound package. Approximately 1000 pounds of yarn are produced. This grafted 10/1 olefin is twisted into a dyeable 10/2 olefin.

c.) Knitted sleeve-The 10/2 olefin yarn is woven into one endless sleeve.

d.) Space Die Printing—Printing three colors on the sleeve using a knit de knit process well known in the art. This process is a continuous process where the undyed sleeve is passed through a squeegee roller submerged in a disperse dye tank for the first tint. The sleeve continues to pass through the second pattern roller, printing the second hue, and passing through the third roller for the third hue. Each color tone contains a disperse dye. The colored knitted sleeves are exposed to steam for at least 2 minutes, preferably 4 minutes. This allows the disperse dye to settle the desired concentration of hue. Knitted sleeves have a solid beige background color, with dark brown and charcoal prints on them. The sleeve is subsequently washed and dried in succession. The dryer is set at a low temperature of 200 ° F. and the moisture will evaporate. The dried sleeve is collected in a can container and transferred to a winding room.

e.) The sleeve is de-knit or wound onto a yarn package through a winding operation well known in the art. The thread is a pleasing beige with dark brown and dark charcoal spots and is wound in a 3 pound cone.

f.) The 10/2 space dyed yarn is knitted in a 10 cut knitting machine. The result is a space dyed fabric with 3 tons. Space-dyed olefin fabrics usually do not appear surprisingly in patterns that are associated with skein or dip dyeing of sweater yarns. The fabrics are washed with hot water in a jet dyeing machine or a winch dyeing machine to give bulkability and clarity of hue. This also prevents the end user from contracting when washing the sweater. The fabric is dried in a low temperature oven at 200 ° F. There is no need to clean the fabric, but additional processing is required to prevent shrinkage of the fabric.

g.) Space Dyed sweater After the fabric is cut and sewn it is very wonderful. It is 30% lighter than a cotton sweater made from the same spec. This is because the specific gravity of olefins is only 0.91 compared to 1.38 for cotton or cotton-polyester blends. This amazing sweater actually floats in water.

Although this example uses 10/2 yarns, it will be appreciated that any size would be suitable as long as the dyeable olefin was actually subjected to a knit knit system. Many satisfactory color tones can be obtained and are not limited to the embodiments described above. Those skilled in the art can obtain satisfactory results with spun yarn or filament yarn through experiments.

Other space dyeing or printing methods may be used. Those skilled in the art will appreciate that a variety of machines can be adapted and used to meet the specifications outlined above. Warp printing or package impregnation is a common method of space dyeing threads.

There are various sizes of yarns used to make fabrics. Radiation is usually in the form of a sum or a single yarn with numbers of 18's, 20's, 24's, 28's, 30's, 36's, 40's. Continuous filament yarn is usually made of 20/1, 70/1, 100/1, 150/1, 200/1, 300/1, 500/1 or 1000/1. The above mention the size of a common thread used to make a knitted or woven fabric. It should be understood that any size yarn or staple fiber can be dyed using the preferred blend of the present invention. From these threads all forms of dyeable fabrics, nonwovens or knits can be made.

There are continuous filament machines that extrude more than one color using a plurality of extruders that feed the extrudate to the spinneret. If one dye promoter mixture instead of pigment is fed to each extruder in different proportions, a continuous filament yarn with different tones of color will be produced from a single dye bath.

<Example 6-Tri-Tone Filament Fabric>

a.) The olefin pellets with a melt flow index of 8 to 22 are well mixed and grafted with the olefin dyeing promoter mixture described above. The machine has three extruders that supply extrudates to one spinnerette. Barmag, Plantex, and Rieter are manufacturing such machines. One extruder is fed with a mixture of 95% olefins and 5% dyeing accelerator, another is fed with a mixture of 97% olefins and 3% dyeing promoter and a third extruder with a mixture of 99% olefins and 1% dyeing promoter. A single white yarn of 5.4 dpf with these three levels of dye affinity is wound into a three pound package.

b.) Thread is stretched and textured at this stage. The yarn is stretched three times and is subjected to a false texture by a conventional stretching combustor known to those skilled in the art. The result is a continuous filament yarn having 300 ends of 1.8 dpf. 1/3 of the yarn has 5% additive, 1/3 has 3% additive, 1/3 has 1% additive.

c.) The yarn is knitted on a 30 "rib knitting machine. The tubular fabric produced is a white, gray tube which is sent to a dyeing factory.

d.) The tube is dyed with 0.005% owg of disperse dye. The result is a tweed fabric with surprisingly dark, medium and pale blue tones. 1/3 of the yarn accepts one level of disperse dye, 1/3 of the yarn accepts two levels of disperse dye, and 1/3 of the yarn accepts three levels of disperse dye.

e.) The fabric is opened and dried at a low temperature of 220 ° F. and wound on rolls for shipment.

f.) Cut and sew the fabric to create a spring coat that fits snugly to the body and has ribs and a dress button. Those skilled in the art will be able to vary the extrusion size and the ratio of the disperse dye mixture to be grafted to achieve the desired effect.

Those skilled in the art will be able to make various changes in order to knit one ton yarn dyeable and three ton yarn dyeable. When the fabric is dyed, the fabric has solid tone stripes with three tone stripes. This is merely an example and it shows that many changes are possible using the present invention. It is advisable to add the additives to the two extruders and the third extruder to produce the non-dyed part. When treated in the Terasil Blue disperse dye bath, the two single yarns will be dyed in blue and the third single yarn will remain white.

Since the printed yarn will be dyed in a distinct tone during each color decay, the three-tone yarn fabric is ideal for space dyeing or printing. Of course, those skilled in the art are not limited to the above examples, but the examples should be indicative.

According to the present invention, spinners, weavers and dryers can make new and light color fabrics. The present invention allows the fabric to be stored undyed until just prior to shipment for dyeing and fabricating it in trendy shades.

Example 7-Woven Fabric of Olefin

The olefin yarn is made in accordance with the present invention and then enhanced to accept the dark solid hue of the disperse dye. It is spun into a 24/1 size in a cotton spinning system, wound to 3 pound cones, and contains 5% owg of dyed graft.

An appropriate number of slopes are slashed and wound on the woven beam. The beam feeds the yarn into a simple box loom.

Olefin yarns containing 2.5% dyed grafts made in accordance with the present invention are fed to the weft yarn in a box room. It is spun in a 24/1 size in cotton spinning systems. Approximately 60 inches wide simple fabrics are produced. Looking at the ingredients, half of the yarns contained 5% dyeing promoter made according to the invention and the other half contained 2.5% dyeing promoter made according to the present invention.

The woven gray cloth is dyed in a jet dyeing machine using Terasil Blue disperse dye at 250 ° F., 0.005% owg.

The yarn wound on the warp or beam is dyed blue in dark tones and the wefts are dyed in blue mid tones. The fabric is two tone tweed color.

The fabric is dried in a relatively low temperature oven at 200 ° F. to maintain temperatures below the melting point of the olefins.

The fabric remains fixed in the tenter or pulled position during passage through the dryer, thereby preventing the fabric from shrinking during further processing.

The fabric is cut and sewn to make ladies' jackets and skirts. These are combined into a pair of women's clothing made from 100% olefin fabrics. The garment is easy to wash, timeless and light. 38% lighter than polyester or wool blends.

The above is an example, and the present invention can be used by those skilled in the art to make various dyeable fabrics for use in clothing or household goods. You can create various patterns such as bird's eye, jacquard, twill or prints. All of them are lightweight, dull and dyed, and can dye any shade required by the market.

Example 8 Sheath-Core Filaments or Yarn

U. S. Patent No. 6,136, 436 to Kennedy et al. Discloses a method of making sheath-core continuous filament fibers or yarns. The inventor will apply the process described in US Pat. No. 6,136,436 to the present invention, and the process described below will be added.

U. S. Patent No. 6,136, 436 discloses a process for making a sheath of nylon or polyester around an olefin core. In this embodiment, an olefin core and a sheath are used. The outer sheath contains 10% to 70% olefins grafted with amorphous PETG dye promoter and the core is 100% olefin.

The fabric is knitted or woven from one or more yarns having different dye levels. The fabric is dyed according to the embodiment mentioned above. Since sheath constitutes 10% to 70% of the total, it has a great cost saving effect. Those skilled in the art will be able to vary the ratio of the sheath to the dyeing promoter to achieve the desired effect.

One variation of the above is the use of olefin sheaths which cannot be dyed and dyeable olefin cores. The result is a thread that is transparent on the outside and colored on the inside. Those skilled in the art will be able to vary these yarns or fibers to achieve the desired effect.

Example 9 Fabric Knitted or Woven Using Dyeable Olefin Blended with Polyester

Blending polyester and dyeable olefin fibers to form yarns yields new and surprising effects. The yarn thus made is composed mostly of polyester and the core is composed mostly of dyeable olefins. Crossing the sheath and core is minimal.

After making the olefin fibers according to the invention, the fibers are treated with an additive of the invention so as to accept the solid color tone of the disperse dye.

a.) The olefin pellets with a melt flow index of 8 to 22 are extruded and mixed well with the PETG and Maleic Anhydride mixtures mentioned as preferred in the present invention. A mixture of 95% olefins and 5% PETG / Maleic is extruded into a staple mass using conventional staple extrusion equipment. The fiber is 1.8 dpf and cut to 1.5 inches. Approximately 650 pounds of staples are produced and baled. The denier dpf value per filament is similar to the dpf of the face and so is the staple length.

b.) The dye-promoted olefin staple fibers in the carding process are blended with 1.35 dpf, 1.5 inch long polyester staple fibers to produce rovings blended with 65% dyeable olefins and 35% polyester. The rovings are made using a conventional cotton device and ring squared with 28/1 face number and then wound into a 3 pound package.

c.) Approximately 1000 pounds of unique yarn is produced. Heavy polyesters with a specific gravity of 1.38 move out of the yarn by centrifugal force to become sheaths around the core, with most of the light olefin remaining in the core.

d.) Twist the thread to form a twisted yarn of 28/2. Both single yarns are 65% dyeable olefins and 35% polyester.

e.) The yarn is then woven with a greige cloth in a conventional box room using 40 single yarns per inch for warp yarns and 40 single yarns per inch for weft yarns. The width of the woven fabric is 67 inches.

f.) The gray fabric is dyed in a conventional jet dyeing machine used for dyeing the polyester. The temperature is kept at 250 ° F. to prevent olefin damage. A 0.005% owg of disperse dye Terasil Blue BRL is used with standard dye disperse chemicals and water. The result is a fabulous and satisfactory fabric with a bright blue tint. The fabric is dried in a relatively low temperature oven. The temperature is kept below the melting point of the olefin, but is raised to 255 ° F. since the olefin core is protected by a polyester sheath. Once the moisture has evaporated, it becomes a dried bright fabric and wrapped on rolls for shipment. Olefins contain a very limited amount of moisture and 35% of the fabric is polyester, which drastically shortens the drying time compared to cotton or cotton-polyester blends.

g.) After finishing, the fabric shrinks to 61.5 inches. The fabric is now stable and does not shrink by more than 1% even after washing. This makes it easy to wash, wear, iron, and easy to clean.

h.) Dyed fabrics are very novel after cutting and sewing. It is at least 20% lighter than polyester garments made from the same spec. This is because the specific gravity of the polyester / olefin is only 1.07, while the specific gravity of the polyester is 1.38. It has a soft touch like cotton but it weighs a lot less. It will be appreciated by those skilled in the art that the fabrics of different sizes and weights can be made in different sizes in the same manner. In addition, the yarn can be knitted using a conventional knitting machine.

These blends can be used to make fabrics, knits or nonwovens.

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

1.) Weaving, knitting and dyeing processes are well developed all over the world.

2.) You can use polyester that is dyed more darkly as sheath.

3.) It is possible to dye or print fabrics using conventional apparatus.

4.) Thermal transfer sublimation printing process can be used.

5.) It is lighter than 100% polyester or 100% cotton or blend of both.

6.) Permanent press processing is easily performed.

7.) It is washable and clothesline drying or machine drying.

8.) Micro denier polyester produces a soft fabric.

9.) All normal sewing machines can be used to sew fabrics.

10.) Dyed fabric does not shrink more than 1 ~ 5%.

<Example 10-Fabric Woven or knitted using Dyeable Olefin Blended with Nylon>

New and surprising effects are obtained when nylon is blended with dyeable olefin fibers. The outer cover of the yarn thus made is mostly nylon and the core is mostly made of dyeable olefins. Crossing the sheath and core is minimal. Thus, it is a yarn having a sheath composed mostly of nylon and a core composed mostly of dyed olefins.

After making the olefin fibers according to the invention, the fibers are treated with an accelerator to accept the solid color tone of the disperse dye.

a.) The olefin pellets with a melt flow index of 8 to 22 are extruded and mixed well with the PETG / Maleic Anhydride mixture mentioned above. A mixture of 95% olefins and 5% PETG / Maleic is extruded into a staple mass using conventional staple extrusion equipment. The fiber is 1.8 dpf and cut to 1.5 inches. Approximately 650 pounds of staples are produced and baled. The denier per filament (dpf) value is similar to the dpf value of the face and so is the staple length.

 b.) Dye-promoted olefin staple fibers are blended with 1.35 dpf, 1.5 inch nylon staple fibers in a carding process to a blend roving containing 65% dyeable olefins and 35% nylon. Using a conventional cotton device, the roving is square with a yarn having a face count of 28/1 and wound into a 3 pound package.

c.) Approximately 1000 pounds of unique yarn is produced. The heavier nylon, with a specific gravity of 1.14, moves out of the yarn by centrifugal force, forming a sheath and enclosing the core, with most of the lighter olefins remaining in the core.

d.) The yarn is twisted to make a twist yarn of 28/2.

e.) The yarn is then woven with a greige cloth in a conventional box room using 40 single yarns per inch for warp yarns and 40 single yarns per inch for weft yarns. The width of the woven fabric is 67 inches.

f.) This gray fabric is dyed with a conventional jet dyeing machine usually used for dyeing fabrics. The temperature is kept at 250 ° F. to prevent olefin damage. A 0.005% owg of disperse dye Terasil Blue BRL is used with standard dye disperse chemicals and water. The result is a fabulous and satisfactory fabric with a bright blue tint. The fabric is dried in a relatively low temperature oven. The temperature is kept below the melting point of the olefin, but is raised to 255 ° F. since the olefin core is protected by nylon sheath. Once the moisture has evaporated, it becomes a dried bright fabric and wrapped on rolls for shipment. Olefin contains a very limited amount of moisture and 35% of the fabric is nylon, resulting in significantly shorter drying times compared to cotton or cotton-polyester blends.

g.) If the fabric is dyed using only acid dyes, only nylon will be dyed. If disperse and acid dyes are used together, nylon will be dyed in one shade while olefins will be dyed in different shades for a heather effect. After processing, the fabric shrinks to 61.5 inches, resulting in surprising results. The fabric is now stable and does not shrink by 1-5% even after washing. This makes it easy to wash, wear, ironing, and grooming.

h.) Dyed fabrics are very novel when cut and sewn. It is at least 20% lighter than cotton garments made from the same spec. This is because the specific gravity of nylon / olefin is only 0.99 compared to 1.38 of cotton. This fabric has a soft touch like cotton, but it weighs a lot less. It will be appreciated by those skilled in the art that the fabrics of different sizes and weights can be made in different sizes in the same manner.

These blends can be used to make fabrics, knits or nonwovens. Nylon can be dyed very easily using a water-based dye system. Fabrics made from nylon and olefin blend yarns can be printed using any acid system, usually used to dye nylon or silk.

In addition, it is possible to print textiles using any water dyeing system usually used for printing nylon, silk or polyester.

The advantages of fabrics and yarns made from nylon and dyeable olefin blends are:

1.) Weaving, knitting and dyeing processes are well developed around the world.

2.) Piece dyeing of the fabric is possible using conventional apparatus.

3.) It is possible to dye fabric by using nylon dyeing method.

4.) More thickly dyed nylon can be used as sheath.

5.) Cation dyeing nylon can be used as a sheath.

6.) Printing is possible with any water system.

7.) Fabric is lighter than 100% nylon or 100% cotton or polyester / cotton blend.

8.) It is washable and clothesline dry or machine dry.

9.) Using microdenier nylon produces a soft fabric.

10.) You can sew fabrics with all commonly used sewing machines.

Claims (27)

Disperse dyeable fibers comprising a melt blend of polyolefin and amorphous PETG. The method of claim 1, And wherein said melt mixture further comprises maleic anhydride. A yarn formed with at least a portion of the fibers of claim 1. The method of claim 3, The molten mixture is olefin and Seal comprising a mixture of modifiers comprising PETG and maleic anhydride. 5. The method of claim 4, The modifier of PETG and maleic anhydride in a weight ratio of 48: 12. 6. The method of claim 5, Wherein said modifier is polypropylene, PETG and maleic anhydride having a weight ratio of 50: 48: 2. Consisting of a mixture of polyester or nylon, and dispersible dyeable olefins, Wherein said disperse dyeable olefin is a mixture of olefin and a modifier comprising PETG and maleic anhydride. delete 8. The method of claim 7, Wherein said modifier comprises PETG and maleic anhydride in a weight ratio of 48: 2. 10. The method of claim 9, Wherein said modifier comprises polypropylene and comprises polypropylene, PETG and maleic anhydride in a weight ratio of 50: 48: 2. The method of claim 10, The modifier is a fiber in which the olefin and the modifier are mixed in a weight ratio of 95: 5. The method of claim 1, Said fibers combined with other fibers capable of dyeing more than one color in a single dye bath. In the fiber having a sheath and a core, One of the core or sheath consists of the disperse dyeable fibers of claim 1, and the other one consists of the fibers that are not disperse dye. 14. The method of claim 13, The fiber is composed of an olefin sheath that is dispersed and dyed and an olefin core that is not dispersed. 14. The method of claim 13, Wherein said core or sheath to be disperse dyed comprises a disperse dyeable olefin. delete delete delete delete delete delete delete delete delete delete delete delete