WO2019077633A1 - Process for dyeing fabrics having thermoplastic fibres using oxidative dyes - Google Patents

Process for dyeing fabrics having thermoplastic fibres using oxidative dyes Download PDF

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Publication number
WO2019077633A1
WO2019077633A1 PCT/IN2018/050674 IN2018050674W WO2019077633A1 WO 2019077633 A1 WO2019077633 A1 WO 2019077633A1 IN 2018050674 W IN2018050674 W IN 2018050674W WO 2019077633 A1 WO2019077633 A1 WO 2019077633A1
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WIPO (PCT)
Prior art keywords
fabric
fibres
thermoplastic
dyeing
dyed
Prior art date
Application number
PCT/IN2018/050674
Other languages
French (fr)
Inventor
Debasish Halder
Dharmendra Raj
Dharmesh Shah
Hemaxee BHATT
Supratim ACHARYA
Original Assignee
Arvind Limited
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Publication date
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Publication of WO2019077633A1 publication Critical patent/WO2019077633A1/en

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    • 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
    • D06P1/22—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 vat dyestuffs including indigo
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/56—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads elastic
    • 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
    • D06P1/22—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 vat dyestuffs including indigo
    • D06P1/228—Indigo
    • 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
    • D06P1/30—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 sulfur dyes
    • 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
    • D06P1/32—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 oxidation dyes
    • 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
    • D06P1/52—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 synthetic macromolecular substances
    • D06P1/5207—Macromolecular compounds obtained by reactions involving only carbon-to-carbon unsaturated bonds
    • D06P1/525—Polymers of unsaturated carboxylic acids or functional derivatives thereof
    • D06P1/5257—(Meth)acrylic acid
    • 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
    • D06P1/96—Dyeing characterised by a short bath ratio
    • D06P1/965—Foam dyeing
    • 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
    • D06P3/02—Material containing basic nitrogen
    • D06P3/04—Material containing basic nitrogen containing amide groups
    • D06P3/042—Material containing basic nitrogen containing amide groups using vat or sulfur dyes
    • 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
    • D06P3/02—Material containing basic nitrogen
    • D06P3/04—Material containing basic nitrogen containing amide groups
    • D06P3/08—Material containing basic nitrogen containing amide groups using oxidation dyes
    • 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
    • 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
    • D06P3/523—Polyesters using vat or sulfur dyes
    • 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
    • D06P3/58—Material containing hydroxyl groups
    • D06P3/60—Natural or regenerated cellulose
    • 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
    • D06P3/58—Material containing hydroxyl groups
    • D06P3/60—Natural or regenerated cellulose
    • D06P3/6025—Natural or regenerated cellulose using vat or sulfur dyes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/79—Polyolefins
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/79—Polyolefins
    • D06P3/793—Polyolefins using vat or sulfur dyes
    • 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
    • D06P3/82—Textiles which contain different kinds of fibres
    • D06P3/8204—Textiles which contain different kinds of fibres fibres of different chemical nature
    • 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
    • D06P3/82—Textiles which contain different kinds of fibres
    • D06P3/8204—Textiles which contain different kinds of fibres fibres of different chemical nature
    • D06P3/8219—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of fibres containing hydroxyl and amide 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
    • D06P3/82—Textiles which contain different kinds of fibres
    • D06P3/8204—Textiles which contain different kinds of fibres fibres of different chemical nature
    • D06P3/8285—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of cellulose and polyolefin fibres
    • 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
    • D06P5/20—Physical treatments affecting dyeing, e.g. ultrasonic or electric
    • D06P5/2066—Thermic treatments of textile materials
    • D06P5/2077—Thermic treatments of textile materials after dyeing
    • 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
    • D06P5/20—Physical treatments affecting dyeing, e.g. ultrasonic or electric
    • D06P5/2066—Thermic treatments of textile materials
    • D06P5/2083—Thermic treatments of textile materials heating with IR or microwaves
    • 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
    • D06P7/00—Dyeing or printing processes combined with mechanical treatment
    • 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
    • D06P3/82—Textiles which contain different kinds of fibres
    • D06P3/8204—Textiles which contain different kinds of fibres fibres of different chemical nature
    • D06P3/8223—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of fibres containing hydroxyl and ester groups
    • D06P3/8228—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of fibres containing hydroxyl and ester groups using one kind of dye
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features
    • D10B2403/011—Dissimilar front and back faces
    • D10B2403/0114—Dissimilar front and back faces with one or more yarns appearing predominantly on one face, e.g. plated or paralleled yarns

Definitions

  • the present invention relates to denim fabrics and preferably dyeing process of the denim fabrics. More particularly, the present invention relates to a dyeing process of denim fabrics comprising thermoplastic fibres using oxidative dye in continuous form.
  • Denim means a sturdy cotton warp-faced textile in which the weft passes under two or more warp threads.
  • the most common denim is indigo denim, in which the warp thread is dyed, while the weft thread is generally left undyed.
  • one side of the textile is dominated by the blue warp threads and the other side is dominated by the white/non-dyed weft threads. This causes blue jeans to be white on the inside.
  • the denim fabrics generally dyed with indigo and fading characteristic is a signature of denim.
  • the denim fabrics are strong, they are heavier in weight.
  • Various attempts have been made to manufacture light weight strong denim.
  • thermoplastic fibre with natural fibre has been used but it has certain drawbacks like pilling issue and uneven dyeing with oxidative dyes such as indigo, which is the main component of the denim fabric.
  • the fabric made from 100% thermoplastic fibre causes irritation and discomfort to the wearer's skin due to less moisture absorption property.
  • 100% thermoplastic denim fabric does not give denim-like look, that is, fading characteristic after every wash.
  • the thermoplastic materials such as Polyester, Polyamide, Polyethylene, Polyacrylonitrile and the like are hydrophobic in nature. Dyeing of such types of materials required a special set up.
  • the currently known process of dyeing thermoplastic material includes dope dyeing, HTHP (high temperature high pressure), batch dyeing and the like.
  • the high temperature high pressure dyeing is most recommended method.
  • the high temperature high pressure dyeing process involves three phenomenon namely, adsorption, diffusion and absorption.
  • the polyester is heated at high temperature i.e. above 100 °C and high pressure. At this temperature, the polyester molecules get opened-up and dye molecules get trapped in material due to high pressure. Further, oligomers are produced as by-product that damages machine parts.
  • the polyester is hydrophobic in nature and has very less affinity towards dye molecules.
  • proper dyeing conditions like temperature, pressure, auxiliaries are required to be maintained and if failed, the process introduces drawbacks such as uneven dyeing, dyeing spots that lead to degradation of material quality.
  • pigment dyeing is also used to dye thermoplastic materials, however, it is observed that pigment dyeing fails to give denim-like look, due to lack of wash down effect.
  • denim means fading characteristic of the fabric, which fails if the pigments dyeing method is used for dyeing the thermoplastic fabrics. Therefore, there is need of a method for denim-like dyeing fabric made from thermoplastic fibres that overcomes drawbacks of the current state of art and gives uniform dye distribution and denim look to a fabric with oxidative dye.
  • the present invention provides a process for dyeing fabrics having thermoplastic fibres using oxidative dyes, the process comprises the steps of providing a thermoplastic fabric comprising a plurality of warp thermoplastic filaments or yarns having thermoplastic fibres on a front side of the fabric and a plurality of weft yarn includes natural fibres or a blend of natural fibres and elastomeric fibres and/or man-made fibres on a rear side of the fabric, dyeing the thermoplastic fabric with a dye composition of oxidative dye on the front side of the fabric, curing the dyed fabric at atleast 170 °C for a predetermined time and subjecting the cured fabric to wash to obtain a dyed thermoplastic fabric having denim-like fading characteristic.
  • the predetermined time for curing is at least 20 seconds.
  • the dyeing includes surface dyeing.
  • the step providing a thermoplastic fabric includes weaving the fabric from the plurality of warp thermoplastic filaments or yarns having thermoplastic fibres and the plurality of weft yarn includes a natural fibres or blend of natural fibres and elastomeric fibres and/or man-made fibres in a predefined manner, performing sequential operations of singeing, thermal setting, desizing, scouring and bleaching the woven thermoplastic fabric.
  • the predefined weave pattern includes twill, satin/sateen, basket, dobby, woven knit, jacquard and all knit pattern in warp knit, weft knit, and the like.
  • the dyeing composition includes an oxidative dye from about 0.5%w/w to about 7%w/w, a foaming agent from about 3 %w/w to about 4%w/w, a sequestering agent from about 0.01 %w/w to about 0.02 %w/w, caustic from about 2%w/w to about 2.5%w/w, a reducing agent from about 2.5%w/w to about 3.5%w/w and a wetting agent from about 0.1 %w/w to about 0.2%w/w.
  • oxidative dye includes indigo, sulphur, vat dyes and the like.
  • the dyed thermoplastic fabric having denimlike fading characteristic is passed into the sanforizing machine for providing dimensional stability to the dyed thermoplastic fabric.
  • the present invention also provides a dyed thermoplastic fabric or garment thereof, the dyed thermoplastic fabric comprising a plurality of warp thermoplastic filaments or yarns having thermoplastic fibres and a plurality of weft yarn includes a natural fibres or blend of natural fibres and elastomeric fibres and/or man-made fibres wherein the dyed thermoplastic fabric manufactured from the process of the present invention.
  • FIG. 1 shows a front side and a rear side of weaving pattern of a fabric in accordance with an embodiment of the present invention.
  • the fabric (100) includes a plurality of warp yarns and a plurality of weft yarns.
  • the warp yarn includes thermoplastic fibres and the weft yarn includes a natural fibres or blend of natural fibres and elastomeric fibres and/or man-made fibres.
  • the elastomeric yarn includes Bi-component, dual core yarn, polyamide, polyolefin or polyurethane and the like.
  • the thermoplastic fibre includes as polyester whereas the natural fibre includes a cotton yarn.
  • the weft yarns may comprise of 100% man-made fibres. Further, it is understood here that the type of the warp yarn and the weft yarn may vary in alternative embodiment of the present invention.
  • the fabric (100) in an initial step, is woven in such a way that the weft yarn covers rear side of the fabric (100) and the warp yarn remains on a front side of the fabric (100).
  • This weaving pattern facilitates the natural fibres to come in contact with the wearer's skin thereby providing comfort.
  • the fabric (100) has advantages of thermoplastic fibre as quick drying property, light weight, high tenacity, functional property and advantages of the natural fibre such as better comfort.
  • the fabric (100) may be woven in a textile weaves including twill, satin/sateen, basket, dobby, woven knit, jacquard and all knit pattern in warp knit, weft knit, and the like.
  • the woven fabric is passed through various processing stages namely singeing, thermal setting, desizing, scouring, bleaching and dyeing.
  • the singeing step helps to remove loose fibre from the fabric (100) surface.
  • the fabric may be subjected to double side singeing in order to have appropriate cleaning of the woven fabric (100).
  • the desizing and scouring steps remove impurities from the fabric (100).
  • the processed fabric (100) is subjected to dyeing thereafter.
  • the dyeing preferably includes a surface dyeing technique wherein the woven fabric (100) is passed through a continuous foam dyeing machine where face side of the fabric (100) is subjected to dyeing.
  • the woven fabric (100) is subjected to dyeing with oxidative dyes such as indigo, sulphur, vat dyes and the like.
  • the fabric (100) is cured at atleast 170°C for a predetermined time.
  • the predetermined time for curing is atleast 20 seconds.
  • temperature helps to open up thermoplastic fibres through which oxidative dye molecules penetrates.
  • the curing temperature ranges from 170-200 °C for 20 sec to 70sec.
  • the curing is followed by a wash process wherein excess amount or unfixed dye is removed.
  • a wash process wherein excess amount or unfixed dye is removed.
  • hot water is used to wash the dyed fabric.
  • the washed dyed fabric is then passed into the sanforizing machine to give dimensional stability to the fabric.
  • the dyeing composition used in dyeing step comprises oxidative dye, foaming agent, sequestering agent, a predefined amount of wetting agent, caustic, and reducing agent.
  • the predefined amount of oxidative dye is from about 0.5% w/w to about 7% w/w.
  • oxidative dye is Indigo dye. However, it is understood here that any other dye may be used as an oxidative dye in alternative embodiments.
  • the predefined amount of foaming agent is from about 3 %w/w to about 4 % w/w.
  • the foaming agents include sodium lauryl sulphate.
  • the sequestering agent is from about 0.01 %w/w to about 0.02 %w/w.
  • Acrylic base polymer is used as the foaming agent.
  • the caustic is from about 2%w/w to about 2.5%w/w.
  • the reducing agent is from about 2.5%w/w to about 3.5 %w/w, wetting agent 0.1 %w/w to 0.2 %w/w.
  • Phosphoric acid ester base is used as the wetting agent.
  • wetting agent, foaming agent and sequestering agent may vary in alternative embodiments of the present invention.
  • the dyed thermoplastic fabric or garment stitched from the dyed thermoplastic fabric obtained by the process of the present invention has a denim-like fading characteristic.
  • the process is continuous dyeing process.
  • the weft yarns are the back side of the fabric and as the weft yarns are natural fibres or a blend of natural fibres and elastomeric fibres and/or man-made fibres, the fabric absorbs moisture thereby solve problem of irritation and discomfort to the wearer's skin.
  • the fabric or garments thereof are light in weight.
  • thermoplastic fabric having following features has been manufactured by a process as claimed in the present application and tested for wash down effect.
  • thermoplastic fabric having following features has been manufactured by a process as claimed in the present application and tested for wash down effect.
  • the fabric weight is tested with ASTM D 3776 method and stretch is tested with ASTM D 3107.
  • thermoplastic fibres mentioned herein includes thermoplastic filaments as well as thermoplastic fibers. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Coloring (AREA)

Abstract

The present invention provides a process for dyeing fabrics having thermoplastic fibres using oxidative dyes, wherein fabric has a plurality of warp thermoplastic filaments or yarns having thermoplastic fibres on a front side and a plurality of weft yarn includes natural fibres or a blend of natural fibres and elastomeric fibres and/or man-made fibres on a rear side and the fabric is dyed on the front side and cured the dyed fabric at atleast 170 °C for a predetermined time to obtain a dyed thermoplastic fabric having denim-like fading characteristic.

Description

ηυΓ1ι 1 Λ -_ _ __ . _ , ,
PROCESS FOR DYEING FABRICS HAVING THERMOPLASTIC FIBRES USING OXIDATIVE DYES
TECHNICAL FIELD OF INVENTION
The present invention relates to denim fabrics and preferably dyeing process of the denim fabrics. More particularly, the present invention relates to a dyeing process of denim fabrics comprising thermoplastic fibres using oxidative dye in continuous form.
BACKGROUND OF THE INVENTION
Traditionally, Denim means a sturdy cotton warp-faced textile in which the weft passes under two or more warp threads. The most common denim is indigo denim, in which the warp thread is dyed, while the weft thread is generally left undyed. As a result, one side of the textile is dominated by the blue warp threads and the other side is dominated by the white/non-dyed weft threads. This causes blue jeans to be white on the inside. The denim fabrics generally dyed with indigo and fading characteristic is a signature of denim. However, though the denim fabrics are strong, they are heavier in weight. Various attempts have been made to manufacture light weight strong denim. In one of the attempts, a blend of thermoplastic fibre with natural fibre has been used but it has certain drawbacks like pilling issue and uneven dyeing with oxidative dyes such as indigo, which is the main component of the denim fabric. Also, the fabric made from 100% thermoplastic fibre causes irritation and discomfort to the wearer's skin due to less moisture absorption property. Moreover, 100% thermoplastic denim fabric does not give denim-like look, that is, fading characteristic after every wash. Further, the thermoplastic materials such as Polyester, Polyamide, Polyethylene, Polyacrylonitrile and the like are hydrophobic in nature. Dyeing of such types of materials required a special set up. The currently known process of dyeing thermoplastic material includes dope dyeing, HTHP (high temperature high pressure), batch dyeing and the like. The high temperature high pressure dyeing is most recommended method. The high temperature high pressure dyeing process involves three phenomenon namely, adsorption, diffusion and absorption. For example, in case of polyester dyeing, the polyester is heated at high temperature i.e. above 100 °C and high pressure. At this temperature, the polyester molecules get opened-up and dye molecules get trapped in material due to high pressure. Further, oligomers are produced as by-product that damages machine parts. The polyester is hydrophobic in nature and has very less affinity towards dye molecules. Moreover, in HTHP dyeing, proper dyeing conditions like temperature, pressure, auxiliaries are required to be maintained and if failed, the process introduces drawbacks such as uneven dyeing, dyeing spots that lead to degradation of material quality.
In general practice, pigment dyeing is also used to dye thermoplastic materials, however, it is observed that pigment dyeing fails to give denim-like look, due to lack of wash down effect. In other words, denim means fading characteristic of the fabric, which fails if the pigments dyeing method is used for dyeing the thermoplastic fabrics. Therefore, there is need of a method for denim-like dyeing fabric made from thermoplastic fibres that overcomes drawbacks of the current state of art and gives uniform dye distribution and denim look to a fabric with oxidative dye.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a process for dyeing fabrics having thermoplastic fibres using oxidative dyes, the process comprises the steps of providing a thermoplastic fabric comprising a plurality of warp thermoplastic filaments or yarns having thermoplastic fibres on a front side of the fabric and a plurality of weft yarn includes natural fibres or a blend of natural fibres and elastomeric fibres and/or man-made fibres on a rear side of the fabric, dyeing the thermoplastic fabric with a dye composition of oxidative dye on the front side of the fabric, curing the dyed fabric at atleast 170 °C for a predetermined time and subjecting the cured fabric to wash to obtain a dyed thermoplastic fabric having denim-like fading characteristic. According to an embodiment, the predetermined time for curing is at least 20 seconds. According to further embodiment, the dyeing includes surface dyeing.
According to the present invention, the step providing a thermoplastic fabric includes weaving the fabric from the plurality of warp thermoplastic filaments or yarns having thermoplastic fibres and the plurality of weft yarn includes a natural fibres or blend of natural fibres and elastomeric fibres and/or man-made fibres in a predefined manner, performing sequential operations of singeing, thermal setting, desizing, scouring and bleaching the woven thermoplastic fabric. According to an embodiment, the predefined weave pattern includes twill, satin/sateen, basket, dobby, woven knit, jacquard and all knit pattern in warp knit, weft knit, and the like.
According to the present invention, the dyeing composition includes an oxidative dye from about 0.5%w/w to about 7%w/w, a foaming agent from about 3 %w/w to about 4%w/w, a sequestering agent from about 0.01 %w/w to about 0.02 %w/w, caustic from about 2%w/w to about 2.5%w/w, a reducing agent from about 2.5%w/w to about 3.5%w/w and a wetting agent from about 0.1 %w/w to about 0.2%w/w. According to embodiment, oxidative dye includes indigo, sulphur, vat dyes and the like.
According to the present invention, the dyed thermoplastic fabric having denimlike fading characteristic is passed into the sanforizing machine for providing dimensional stability to the dyed thermoplastic fabric.
The present invention also provides a dyed thermoplastic fabric or garment thereof, the dyed thermoplastic fabric comprising a plurality of warp thermoplastic filaments or yarns having thermoplastic fibres and a plurality of weft yarn includes a natural fibres or blend of natural fibres and elastomeric fibres and/or man-made fibres wherein the dyed thermoplastic fabric manufactured from the process of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front side and a rear side of weaving pattern of a fabric in accordance with an embodiment of the present invention. DETAILED DESCRIPTION OF INVENTION
Although specific terms are used in the following description for sake of clarity, these terms are intended to refer only to particular structure of the invention selected for illustration in the drawings and are not intended to define or limit the scope of the invention.
The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures.
Referring to FIG. 1 , a fabric (100) in accordance with a preferred embodiment of the present invention is shown. The fabric (100) includes a plurality of warp yarns and a plurality of weft yarns. In the context of the present invention, the warp yarn includes thermoplastic fibres and the weft yarn includes a natural fibres or blend of natural fibres and elastomeric fibres and/or man-made fibres. In an embodiment, the elastomeric yarn includes Bi-component, dual core yarn, polyamide, polyolefin or polyurethane and the like. In an embodiment, the thermoplastic fibre includes as polyester whereas the natural fibre includes a cotton yarn. Alternatively, the weft yarns may comprise of 100% man-made fibres. Further, it is understood here that the type of the warp yarn and the weft yarn may vary in alternative embodiment of the present invention.
In accordance with the preferred embodiment, in an initial step, the fabric (100) is woven in such a way that the weft yarn covers rear side of the fabric (100) and the warp yarn remains on a front side of the fabric (100). This weaving pattern facilitates the natural fibres to come in contact with the wearer's skin thereby providing comfort. The fabric (100) has advantages of thermoplastic fibre as quick drying property, light weight, high tenacity, functional property and advantages of the natural fibre such as better comfort. The fabric (100) may be woven in a textile weaves including twill, satin/sateen, basket, dobby, woven knit, jacquard and all knit pattern in warp knit, weft knit, and the like.
In next step, the woven fabric is passed through various processing stages namely singeing, thermal setting, desizing, scouring, bleaching and dyeing. In the context of the present invention, the singeing step helps to remove loose fibre from the fabric (100) surface. In an embodiment, the fabric may be subjected to double side singeing in order to have appropriate cleaning of the woven fabric (100). In the context of the present invention, the desizing and scouring steps remove impurities from the fabric (100).
In next step, the processed fabric (100) is subjected to dyeing thereafter. With reference to the present invention, the dyeing preferably includes a surface dyeing technique wherein the woven fabric (100) is passed through a continuous foam dyeing machine where face side of the fabric (100) is subjected to dyeing. In this step, the woven fabric (100) is subjected to dyeing with oxidative dyes such as indigo, sulphur, vat dyes and the like.
In final step, the fabric (100) is cured at atleast 170°C for a predetermined time. The predetermined time for curing is atleast 20 seconds. In curing process, temperature helps to open up thermoplastic fibres through which oxidative dye molecules penetrates. The curing temperature ranges from 170-200 °C for 20 sec to 70sec.
The curing is followed by a wash process wherein excess amount or unfixed dye is removed. Preferably, hot water is used to wash the dyed fabric. The washed dyed fabric is then passed into the sanforizing machine to give dimensional stability to the fabric.
In accordance with an embodiment of the present invention, the dyeing composition used in dyeing step comprises oxidative dye, foaming agent, sequestering agent, a predefined amount of wetting agent, caustic, and reducing agent.
In an embodiment, the predefined amount of oxidative dye is from about 0.5% w/w to about 7% w/w. In one preferred embodiment, oxidative dye is Indigo dye. However, it is understood here that any other dye may be used as an oxidative dye in alternative embodiments.
In an embodiment, the predefined amount of foaming agent is from about 3 %w/w to about 4 % w/w. In this one embodiment, the foaming agents include sodium lauryl sulphate. The sequestering agent is from about 0.01 %w/w to about 0.02 %w/w. In this one embodiment, Acrylic base polymer is used as the foaming agent. The caustic is from about 2%w/w to about 2.5%w/w. The reducing agent is from about 2.5%w/w to about 3.5 %w/w, wetting agent 0.1 %w/w to 0.2 %w/w. In this one embodiment, Phosphoric acid ester base is used as the wetting agent. However, it is understood here that wetting agent, foaming agent and sequestering agent may vary in alternative embodiments of the present invention. The dyed thermoplastic fabric or garment stitched from the dyed thermoplastic fabric obtained by the process of the present invention has a denim-like fading characteristic. The process is continuous dyeing process. Further, the weft yarns are the back side of the fabric and as the weft yarns are natural fibres or a blend of natural fibres and elastomeric fibres and/or man-made fibres, the fabric absorbs moisture thereby solve problem of irritation and discomfort to the wearer's skin. Moreover, the fabric or garments thereof are light in weight.
Example:
Product A:
A dyed thermoplastic fabric having following features has been manufactured by a process as claimed in the present application and tested for wash down effect.
Warp : 330 denier polyester
Weft : (10s Ne cotton yarn) + (150 + 40 denier poly elastane yarn)
Weave : Dobby knit weave
Weight : 9.5 Oz per square yard
Stretch : 20% The fabric weight is tested with ASTM D 3776 method and stretch is tested with
ASTM D 3107.
It is observed that the fabric provides a wash down effect like denim fabric even after 20 home washes. Product B
A dyed thermoplastic fabric having following features has been manufactured by a process as claimed in the present application and tested for wash down effect.
Warp : 450 denier polyester
Weft : 16 CSY + 70denier cotton elastane
Weave : 3 / 1 Twill
Weight : 8.5 Oz per square yard
Stretch : 20%
The fabric weight is tested with ASTM D 3776 method and stretch is tested with ASTM D 3107.
It is observed that the fabric provides a wash down effect like denim fabric even after 20 home washes.
The embodiments of the invention shown and discussed herein are merely illustrative of modes of application of the present invention. Reference to details in this discussion is not intended to limit the scope of the claims to these details, or to the figures used to illustrate the invention. The thermoplastic fibres mentioned herein includes thermoplastic filaments as well as thermoplastic fibers. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present invention.

Claims

Claims :
A process for dyeing fabrics having thermoplastic fibres using oxidative dyes, the process comprises the steps of:
providing a thermoplastic fabric comprising a plurality of warp thermoplastic filaments or yarns having thermoplastic fibres on a front side of the fabric and a plurality of weft yarn includes natural fibres or a blend of natural fibres and elastomeric fibres and/or man-made fibres on a rear side of the fabric;
dyeing the thermoplastic fabric with a dye composition of oxidative dye;
curing the dyed fabric at atleast 170 °C for a predetermined time; and subjecting the cured fabric to wash to obtain a dyed thermoplastic fabric having denim-like fading characteristic.
The process as claimed in claim 1 , wherein the step providing a thermoplastic fabric includes weaving the fabric from the plurality of warp thermoplastic filaments or yarns having thermoplastic fibres and the plurality of weft yarn includes a natural fibres or blend of natural fibres and elastomeric fibres and/or man-made fibres in a predefined manner, performing sequential operations of singeing, thermal setting, desizing, scouring and bleaching the woven thermoplastic fabric.
The process as claimed in claim 2, wherein the predefined weave pattern includes twill, satin/sateen, basket, dobby, woven knit, jacquard and all knit patterns in warp knit, weft knit, and the like.
4. The process as claimed in claim 1 , wherein the dyeing includes surface dyeing.
5. The process as claimed in claim 1 , wherein the predetermined time for curing is atleast 20 seconds.
6. The process as claimed in claim 1 or 5, wherein the predetermined time for curing ranges from 20 - 70 seconds.
7. The process as claimed in claim 1 wherein the temperature for curing ranges from 170°C -200°C.
8. The process as claimed in claim 1 , wherein the dyeing composition includes an oxidative dye from about 0.5 %w/w to about 7%w/w, a foaming agent from about 3 %w/w to about 4 %w/w, a sequestering agent from about 0.01 %w/w to about 0.02 %w/w, caustic from about 2 %w/w to about 2.5%w/w, a reducing agent from about 2.5%w/w to about 3.5 %w/w and a wetting agent from about 0.1 %w/w to about 0.2 %w/w.
9. The process as claimed in one of the preceding claims 1 to 8, wherein oxidative dye includes indigo, sulphur, vat dyes and the like.
10. A dyed thermoplastic fabric or garment stitched from the dyed thermoplastic fabric comprising a plurality of warp thermoplastic filaments or yarns having thermoplastic fibres and a plurality of weft yarn includes a natural fibres or blend of natural fibres and elastomeric fibres and/or man- made fibres wherein the dyed thermoplastic fabric manufactured from the process as claimed in one of the preceding claims 1-9 and has a denim-like fading characteristic.
PCT/IN2018/050674 2017-10-18 2018-10-17 Process for dyeing fabrics having thermoplastic fibres using oxidative dyes WO2019077633A1 (en)

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