Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
  • D06P5/13—Fugitive dyeing or stripping dyes
  • D06P5/137—Fugitive dyeing or stripping dyes with other compounds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
  • B29B17/02—Separating plastics from other materials
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J11/00—Recovery or working-up of waste materials
  • C08J11/04—Recovery or working-up of waste materials of polymers
  • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K23/00—Use of substances as emulsifying, wetting, dispersing, or foam-producing agents
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K23/00—Use of substances as emulsifying, wetting, dispersing, or foam-producing agents
  • C09K23/42—Ethers, e.g. polyglycol ethers of alcohols or phenols
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
  • B29B17/02—Separating plastics from other materials
  • B29B2017/0213—Specific separating techniques
  • B29B2017/0293—Dissolving the materials in gases or liquids
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/731—Filamentary material, i.e. comprised of a single element, e.g. filaments, strands, threads, fibres
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2367/00—Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
  • C08J2367/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
  • D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
  • D06P1/60—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing polyethers
  • D06P1/613—Polyethers without nitrogen
  • D06P1/6138—Polymerisation products of glycols, e.g. Carbowax, Pluronics
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
  • D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
  • D06P1/64—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing low-molecular-weight organic compounds without sulfate or sulfonate groups
  • D06P1/642—Compounds containing nitrogen
  • D06P1/649—Compounds containing carbonamide, thiocarbonamide or guanyl groups
  • D06P1/6495—Compounds containing carbonamide -RCON= (R=H or hydrocarbons)
  • D06P1/6498—Compounds containing -CONCO-, e.g. phthalimides, hydantoine; Compounds containing RCONHSO2R (R=H or hydrocarbon)
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
  • D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
  • D06P1/64—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing low-molecular-weight organic compounds without sulfate or sulfonate groups
  • D06P1/651—Compounds without nitrogen
  • D06P1/65106—Oxygen-containing compounds
  • D06P1/65118—Compounds containing hydroxyl groups
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
  • D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
  • D06P1/64—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing low-molecular-weight organic compounds without sulfate or sulfonate groups
  • D06P1/651—Compounds without nitrogen
  • D06P1/65106—Oxygen-containing compounds
  • D06P1/65131—Compounds containing ether or acetal groups
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
  • D06P3/34—Material containing ester groups
  • D06P3/52—Polyesters
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

• This invention relates to chemical compounds and methods for removing dye from polyester fibers, and more particularly to removing dye from panel fabric made from recycled poly(ethylene terephthalate) fibers.
• Panel fabric also known as vertical fabric, is used in furniture upholstery, wall systems and tackboards. Panel fabric is increasingly produced from synthetic materials such as polyester, most commonly PET (poly(ethylene terephthalate)). Panel fabric is replaced periodically and as a result, is often discarded in landfills. Many of the materials used in panel fabric are not biodegradable; thus disposal of it contributes to the environmental problems that arise from the over-use of landfills.
• the PET in the panel fabric would be recycled into fiber that can be reused, e.g., suitable for weaving into new panel fabric. In this way, the material is not only rendered recyclable, but recyclable in a sustainable fashion, decreasing the need for virgin PET or PET recycled from bottles, which can then be put to other uses.
• any PET that may be recovered when garnetted into loose fibers is unsuitable for significant reuse in panel fabric and carpet manufacturing.
• the staple fiber is generally too short to be reused in the yarn spinning process at more than about 3%. If the fibers could be melted, pelletized and extruded into full-length fiber, they could be recycled at about 100%.
• the presence of dyes in the fibers makes them difficult to melt and extrude. The dye molecules char and burn at extrusion temperatures, forming a residue that blocks the extrusion spinnerets. As a result, a process capable of removing dye before extrusion is needed.
• the invention solves some or all of the above mentioned problems by providing methods and compositions for removing dye molecules from polyester, PET in particular.
• the invention allows the PET to be reused by pelletizing and extruding it into fiber suitable for panel fabric or other applications calling for virgin PET, without disrupting the extrusion process by dye molecule charring.
• the invention addresses the problem of downcycling the PET in panel fabric by providing a way to use recycled PET that is economically and environmentally of the same value as the panel fabric itself.
• the PET can be melted, extruded and reused as panel fabric.
• the invention is an improvement over existing processes because it completely removes the dye molecules from the PET, instead of breaking only the chromophore of the dye.
• the PET may be melted and extruded, without remaining dye molecules burning or blocking the extrusion spimierets.
• the method of the present invention does not damage the PET by swelling.
• a method for removing dye from polyester fiber or fabric by contacting the polyester with a dye removal composition containing an aqueous solution of at least one leveling agent; heating the mixture of polyester and dye removal composition until it reaches an elevated temperature and pressure level higher than the equilibrium pressure of the dye removal composition at the elevated temperature; cooling the mixture; and removing the decolorized polyester from the mixture.
• a composition for removing dye from polyester includes an aqueous solution of about 0.5 wt% to about 8.0 wt% of at least one leveling agent.
• the invention in another embodiment, relates to a device for removing dye from polyester according to the present invention.
• the device includes a sealable vessel and a dye removal composition.
• the dye removal composition includes an aqueous solution of about 0.5 wt% to about 8.0 wt% of at least one leveling agent.
• the invention is also directed to a method for recycling panel fabric comprising polyester.
• the method involves removing from the fabric any structural elements, removing the dye from the fabric using a dye removal composition comprising an aqueous solution of at least one leveling agent, recovering the polyester fibers, melting the fibers, pelletizing the melted fiber and extruding the pellets into full-length fiber.
• the dye removal composition comprises at least one leveling agent selected from the group consisting of anionic leveling agents, nonionic leveling agents and mixtures thereof.
• the dye removal composition further comprises at least one chemical selected from the group consisting of scouring agents, wetting agents and leveling carriers.
• Leveling agents may perform one or more of these functions in addition to their function as leveling agents.
• the invention provides for a method of removing dye molecules from polyester fiber, and is particularly useful with PET fiber.
• the polyester may be used in the process as woven fabric or, alternatively, garnetted into loose fibers.
• the polyester is contacted with a dye removal composition comprising an aqueous solution of at least one leveling agent. This may be conveniently done in a standard dyeing vessel commonly used for disperse dyeing of polyester, which is sealable and temperature controlled.
• Effective leveling agents have good wetting, emulsifying and dispersing properties and will prevent redeposition. A leveling agent that promotes maximum coverage and color yield is also desirable. Leveling agents particularly suited for high temperature polyester dyeing will generally be suitable for the present invention. Effective leveling agents can also inhibit cationic dye from staining and settling on the walls of stainless steel equipments.
• the dye removal composition comprises an aqueous solution of at least one leveling agent. Suitable leveling agents include anionic leveling agents, nonionic leveling agents and mixtures thereof.
• the dye removal composition may further comprise leveling carriers, scouring agents and mixtures thereof. In a particular embodiment of the invention, the scouring agent or wetting agent is nonionic. In another embodiment of the invention, the leveling carrier comprises a nonionic leveling carrier.
• suitable leveling agents include those that comprise alkyl polyglycol ether, isopropyl alcohol, n-butyl phthalimide or nonyl phenol ethoxylate.
• suitable leveling carriers include those containing alkyl phthalimide.
• suitable scouring agents include scouring agents containing polyoxyethene ether or propylene glycol ether.
• the dye removal composition comprises isopropyl alcohol, n-butyl phthalimide, nonyl phenol ethoxylate, and propylene glycol ether.
• Particular leveling agents that may be used for the present invention include AVOLAN IW LIQUIDTM nonionic leveling agent and scouring agent (Bayer, Pittsburgh, PA), DIADAVIN UFNTM nonionic leveling wetting and scouring agent (Bayer, Pittsburgh, PA), LEVEGAL EAP-4TM leveling carrier (Bayer, Pittsburgh, PA), RAYCAPOL TDA-33 scouring agent (Clariant, Chicago, IL), RAYCALEV DTM (leveling agent), CAROLID NOL leveling agent (Bayer, Pittsburgh, PA) and RICHLEV D leveling agent (Richchem, High Point, NC), BURCO SOUR LFE-810TM scouring agent (Burlington Chemical Co., Burlington, NC).
• AVOLAN IW LIQUIDTM nonionic leveling agent and scouring agent Bayer, Pittsburgh, PA
• DIADAVIN UFNTM nonionic leveling wetting and scouring agent Bayer, Pittsburgh, PA
• the leveling agents When mixed with water or aqueous solution, the leveling agents can be used in weight ratios ranging from (under certain conditions) about 0.5% to as high as about 8.0% of leveling agent : water. However, particularly desirable results are achieved when the leveling agent(s) is present in an amount ranging from about 2.0 wt% to about 8.0 wt% of the total solution of leveling agents.
• An approximately 4.0 wt% aqueous solution of leveling agent(s) has been found to be particularly suitable for most applications. More particularly, an approximately 4.0 wt% solution comprising propylene glycol ether, isopropyl alcohol, n-butyl phthalimide and nonyl phenol ethoxylate and water has been found to be suitable for most applications.
• the polyester to be decolorized is separated from any structural elements and placed in a sealable vessel.
• the polyester may be woven fabric or loose fibers.
• Water and a dye removal composition comprising at least one leveling agent are added to a vessel at a temperature of about 20°C to about 25°C.
• any vessel made of a nonreactive material and sealable may be used in place of a standard dyeing vessel.
• the mixture of the polyester and dye removal composition are heated for a period of about 120 minutes. Because the vessel is sealed, as the temperature increases, there is a corresponding rise in the pressure. Thus, the pressure is higher than the equilibrium pressure of the dye removal composition at the elevated temperature.
• the pressure has reached about 28 psi to about 39 psi, more particularly about 33 psi, and the temperature has reached about 135°C to about 145°C, more particularly
• the vessel is maintained at that pressure and temperature for about 30 minutes to about 60 minutes, more particularly about 45 minutes.
• the vessel may be agitated during the period when the polyester is first contacted with the dye removal composition, when it is heated, during the holding period when the temperature and pressure are maintained, or any combination of these three. Agitation can be achieved, for example, by rolling the vessel or by continuously pumping the dye removal composition through the polyester.
• the holding stage is typically followed by a cooling down period of about 20 minutes to about 40 minutes wherein the temperature is decreased to about 20°C to about 50°C, more particularly 30°C.
• the mixture should be cooled rapidly to prevent or limit reabsorption of the dye by the polyester.
• the times and temperatures may vary somewhat depending upon the dyestuff and the leveling agent chosen, but will generally fall within the above ranges for most commonly encountered dyes.
• the decolorized polyester is then removed from the mixture. Any residual dye removal composition should be removed from the polyester, in order to further limit the chance of reabsorption. This can often be achieved by rinsing thoroughly with water.
• This cycle may be repeated as needed to remove additional dye from the polyester fiber or fabric.
• Those with skill in the art will recognize that more intense colors may require additional cycles to sufficiently decolorize the polyester.
• the method may be carried out as a batch, sequential batch semi-continuous or continuous process.
• the invention may be used to recycle panel fabric made from polyester.
• the invention is also useful for recycling panel fabric made from polyester that has already been recycled, such as recycled PET.
• To recycle panel fabric it should first be separated from any structural elements.
• the fabric can be, but is not required to be garnetted into loose fibers.
• any dye should be removed using a dye removal composition comprising an aqueous solution of at least one leveling agent. Once the dye has been removed, the polyester fibers can be recovered. The fibers can be melted and pelletized before being extruded into full-length fiber.
• Panel fabric may be created by weaving the recycled fiber.
• the process was carried out in an Ahiba Polymat dyeing machine in sealed vessels. Fifty (50) mL of water was added to an empty vessel. Four (4.0) mL of each of the following chemicals were also added to the vessel: CAROLID NOLTM leveling agent, BURCO SCOUR LFE-810TM scouring agent, and RICHLEV DTM leveling agent. Approximately 5.00 g of polyester was placed into the vessel. Fifty (50) mL of water was added to the vessel to cover the polyester. The vessel was sealed. The vessel was rolled to agitate the mixture. The temperature was raised from room temperature (about 22°C) to 50°C. The temperature was held at 50°C for
• the process was carried out in an Ahiba Polymat dyeing machine in sealed vessels. Fifty (50) mL of water was added to an empty vessel. Four (4.0) mL of each of the following chemicals were also added to the vessel: AVOLAN IW LIQUIDTM leveling agent, DIADAVIN UFNTM scouring agent, LEVEGAL EAP-4TM leveling carrier and RAYCALEV DTM leveling agent. Approximately 5.00 g of polyester was placed into the vessel. Fifty (50) mL of water was added to the vessel to cover the polyester. The vessel was sealed. The vessel was rolled to agitate the mixture. The temperature was raised from room temperature (about 22°C)

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Health & Medical Sciences (AREA)
• Sustainable Development (AREA)
• Life Sciences & Earth Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Environmental & Geological Engineering (AREA)
• Mechanical Engineering (AREA)
• Textile Engineering (AREA)
• Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
• Coloring (AREA)

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• 2003
  • 2003-01-31 US US10/505,248 patent/US20050198742A1/en not_active Abandoned
  • 2003-01-31 CA CA002476774A patent/CA2476774A1/en not_active Abandoned
  • 2003-01-31 WO PCT/US2003/003046 patent/WO2003064752A1/en not_active Application Discontinuation
  • 2003-01-31 BR BR0302963A patent/BR0302963A/pt not_active IP Right Cessation
  • 2003-01-31 EP EP03706030A patent/EP1476600A4/en not_active Withdrawn

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