WO2022178397A1 - Differentially vat dyed yarns and method of making the same - Google Patents
Differentially vat dyed yarns and method of making the same Download PDFInfo
- Publication number
- WO2022178397A1 WO2022178397A1 PCT/US2022/017253 US2022017253W WO2022178397A1 WO 2022178397 A1 WO2022178397 A1 WO 2022178397A1 US 2022017253 W US2022017253 W US 2022017253W WO 2022178397 A1 WO2022178397 A1 WO 2022178397A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- single strand
- ply
- dyed
- yam
- vat
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title description 3
- 239000000975 dye Substances 0.000 claims abstract description 82
- 238000000034 method Methods 0.000 claims description 41
- 238000004043 dyeing Methods 0.000 claims description 36
- 239000000203 mixture Substances 0.000 claims description 33
- 239000004952 Polyamide Substances 0.000 claims description 20
- 229920002647 polyamide Polymers 0.000 claims description 20
- 238000010276 construction Methods 0.000 claims description 16
- 229920002302 Nylon 6,6 Polymers 0.000 claims description 8
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 8
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 8
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- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- WVDDGKGOMKODPV-UHFFFAOYSA-N Benzyl alcohol Chemical compound OCC1=CC=CC=C1 WVDDGKGOMKODPV-UHFFFAOYSA-N 0.000 description 3
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 239000002253 acid Substances 0.000 description 3
- 238000007605 air drying Methods 0.000 description 3
- 239000007844 bleaching agent Substances 0.000 description 3
- OXEFCDNMUKTKDV-UHFFFAOYSA-N calcoloid olive r Chemical compound C=1C=CC=CC=1C(=O)NC(C1=C(C(C2=CC=CC=C2C1=O)=O)C=1NC2=C3C=4C(C5=CC=CC=C5C3=O)=O)=CC=1C2=CC=4NC(=O)C1=CC=CC=C1 OXEFCDNMUKTKDV-UHFFFAOYSA-N 0.000 description 3
- 238000010014 continuous dyeing Methods 0.000 description 3
- 230000004069 differentiation Effects 0.000 description 3
- 239000002270 dispersing agent Substances 0.000 description 3
- 230000001788 irregular Effects 0.000 description 3
- 239000002932 luster Substances 0.000 description 3
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- JVBXVOWTABLYPX-UHFFFAOYSA-L sodium dithionite Chemical compound [Na+].[Na+].[O-]S(=O)S([O-])=O JVBXVOWTABLYPX-UHFFFAOYSA-L 0.000 description 3
- 238000011282 treatment Methods 0.000 description 3
- 239000000984 vat dye Substances 0.000 description 3
- 229920006309 Invista Polymers 0.000 description 2
- SJEYSFABYSGQBG-UHFFFAOYSA-M Patent blue Chemical compound [Na+].C1=CC(N(CC)CC)=CC=C1C(C=1C(=CC(=CC=1)S([O-])(=O)=O)S([O-])(=O)=O)=C1C=CC(=[N+](CC)CC)C=C1 SJEYSFABYSGQBG-UHFFFAOYSA-M 0.000 description 2
- 239000000980 acid dye Substances 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 2
- 239000008346 aqueous phase Substances 0.000 description 2
- 239000000969 carrier Substances 0.000 description 2
- 238000004040 coloring Methods 0.000 description 2
- 238000005562 fading Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
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- 230000002452 interceptive effect Effects 0.000 description 2
- 239000007800 oxidant agent Substances 0.000 description 2
- 239000003002 pH adjusting agent Substances 0.000 description 2
- 230000001846 repelling effect Effects 0.000 description 2
- 235000011121 sodium hydroxide Nutrition 0.000 description 2
- 238000009977 space dyeing Methods 0.000 description 2
- 238000004048 vat dyeing Methods 0.000 description 2
- TUSDEZXZIZRFGC-UHFFFAOYSA-N 1-O-galloyl-3,6-(R)-HHDP-beta-D-glucose Natural products OC1C(O2)COC(=O)C3=CC(O)=C(O)C(O)=C3C3=C(O)C(O)=C(O)C=C3C(=O)OC1C(O)C2OC(=O)C1=CC(O)=C(O)C(O)=C1 TUSDEZXZIZRFGC-UHFFFAOYSA-N 0.000 description 1
- 241000233031 Amblyomma tuberculatum Species 0.000 description 1
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000001263 FEMA 3042 Substances 0.000 description 1
- 235000000177 Indigofera tinctoria Nutrition 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- LRBQNJMCXXYXIU-PPKXGCFTSA-N Penta-digallate-beta-D-glucose Natural products OC1=C(O)C(O)=CC(C(=O)OC=2C(=C(O)C=C(C=2)C(=O)OC[C@@H]2[C@H]([C@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)[C@@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)[C@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)O2)OC(=O)C=2C=C(OC(=O)C=3C=C(O)C(O)=C(O)C=3)C(O)=C(O)C=2)O)=C1 LRBQNJMCXXYXIU-PPKXGCFTSA-N 0.000 description 1
- 239000005708 Sodium hypochlorite Substances 0.000 description 1
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- 239000004784 Superba Substances 0.000 description 1
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- 238000013459 approach Methods 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 235000019445 benzyl alcohol Nutrition 0.000 description 1
- QHIWVLPBUQWDMQ-UHFFFAOYSA-N butyl prop-2-enoate;methyl 2-methylprop-2-enoate;prop-2-enoic acid Chemical compound OC(=O)C=C.COC(=O)C(C)=C.CCCCOC(=O)C=C QHIWVLPBUQWDMQ-UHFFFAOYSA-N 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
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- 235000003891 ferrous sulphate Nutrition 0.000 description 1
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- 238000009472 formulation Methods 0.000 description 1
- 238000009998 heat setting Methods 0.000 description 1
- 230000002209 hydrophobic effect Effects 0.000 description 1
- 229940097275 indigo Drugs 0.000 description 1
- COHYTHOBJLSHDF-UHFFFAOYSA-N indigo powder Natural products N1C2=CC=CC=C2C(=O)C1=C1C(=O)C2=CC=CC=C2N1 COHYTHOBJLSHDF-UHFFFAOYSA-N 0.000 description 1
- BAUYGSIQEAFULO-UHFFFAOYSA-L iron(2+) sulfate (anhydrous) Chemical compound [Fe+2].[O-]S([O-])(=O)=O BAUYGSIQEAFULO-UHFFFAOYSA-L 0.000 description 1
- 229910000359 iron(II) sulfate Inorganic materials 0.000 description 1
- 125000000468 ketone group Chemical group 0.000 description 1
- QTWZICCBKBYHDM-UHFFFAOYSA-N leucomethylene blue Chemical compound C1=C(N(C)C)C=C2SC3=CC(N(C)C)=CC=C3NC2=C1 QTWZICCBKBYHDM-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229920003986 novolac Polymers 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 150000002978 peroxides Chemical class 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 239000001267 polyvinylpyrrolidone Substances 0.000 description 1
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 1
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 1
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- 230000000979 retarding effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- SUKJFIGYRHOWBL-UHFFFAOYSA-N sodium hypochlorite Chemical compound [Na+].Cl[O-] SUKJFIGYRHOWBL-UHFFFAOYSA-N 0.000 description 1
- 238000010186 staining Methods 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- LRBQNJMCXXYXIU-NRMVVENXSA-N tannic acid Chemical compound OC1=C(O)C(O)=CC(C(=O)OC=2C(=C(O)C=C(C=2)C(=O)OC[C@@H]2[C@H]([C@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)[C@@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)[C@@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)O2)OC(=O)C=2C=C(OC(=O)C=3C=C(O)C(O)=C(O)C=3)C(O)=C(O)C=2)O)=C1 LRBQNJMCXXYXIU-NRMVVENXSA-N 0.000 description 1
- 229940033123 tannic acid Drugs 0.000 description 1
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- 238000012360 testing method Methods 0.000 description 1
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Classifications
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/44—Yarns or threads characterised by the purpose for which they are designed
- D02G3/445—Yarns or threads for use in floor fabrics
-
- 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
- D06P3/24—Polyamides; Polyurethanes
- D06P3/243—Polyamides; Polyurethanes using vat or sulfur dyes, 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
- 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
- D06P3/8209—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of fibres containing 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
- D06P3/854—Textiles which contain different kinds of fibres containing modified or unmodified fibres, i.e. containing the same type of fibres having different characteristics, e.g. twisted and not-twisted fibres
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/26—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre with characteristics dependent on the amount or direction of twist
- D02G3/28—Doubled, plied, or cabled threads
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns
- D02G3/346—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns with coloured effects, i.e. by differential dyeing process
-
- 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
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
Definitions
- the present application relates to vat dyed yams and, in particular, to vat dyed yarns comprising plies yielding a tweed or heathered appearance.
- Acid dyes for example, are commonly employed for coloration of nylon fibers used in carpet yarns due to the ease with which cationic nylon polymer accepts the dye. This ease of dyeing, however, also facilitates staining if the nylon fibers are exposed to contaminants having dye-like properties during use.
- acid dyes are commonly applied to nylon fibers in batch or continuous processes. Under this approach, a risk exists of ozone fading if the material is installed in a tropical environment. Treatments have been developed to improve resistance of acid dyed nylon to ozone fading. These treatments include novolak resins, acrylic polymers, tannic acid or various combinations thereof. Such treatments, nevertheless, can alter shades of the dyed fiber and/or induce a reduction in lightfastness of the dyed fibers.
- a yarn comprises a first ply and a second ply each dyed with at least one vat dyestuff, wherein a denier ratio between the first ply and the second ply is greater than 1.
- a yarn comprises a first single strand and a second single strand each dyed with at least one vat dyestuff, wherein a difference in color depth (DL*) between the dyed first single strand and the dyed second single strand has an absolute value of at least 2 when the vat dyestuff is in an oxidized state.
- an absolute value of DL* ranges from 2-50 or from 3-30.
- An absolute value of DL* can also range from 5-20 or 10-30, in some embodiments.
- the terminology of “first ply and second ply” can be interchangeable with “first single strand and second single strand”.
- the first ply and the second ply can be dyed in the same dyebath in a single dyeing process.
- a yarn comprises a first ply and a second ply each dyed with at least one vat dyestuff, wherein a reflectance ratio between the second ply and the first ply ranges from 0.05 to 0.95.
- the reflectance ratio ranges from 0.4 to 0.6.
- the first ply and second ply of yarns described herein can be formed of any desired composition.
- the first ply and second ply are synthetic fibers.
- the first ply and second ply for example, can be formed of polyamides.
- yarns described herein can be used to fabricate various textile articles including floor coverings, such as carpet.
- a yam comprises a first ply and a second ply each dyed with at least one vat dyestuff, wherein the first ply and second ply are formed of differing polyamides.
- the polyamide of the first ply has lower crystallinity than the polyamide of the second ply.
- the first ply for example, can be formed of nylon 6, and the second ply is formed of nylon 6,6.
- the polyamide of the second ply can exhibit anionic character, in some embodiments.
- the polyamide of the second ply may comprise a sulfur content.
- the polyamide yam can exhibit any of the denier and/or reflectance ratios described herein.
- a method in some embodiments, comprises providing a yarn comprising a first ply and a second ply, and contacting the yarn with a dyeing composition comprising at least one vat dyestuff in reduced form.
- a dyeing composition comprising at least one vat dyestuff in reduced form.
- the vat dyestuff is oxidized, wherein the dyed first ply exhibits a darker or deeper color than the dyed second ply.
- the darker or deeper color of the first ply can originate from more of the vat dyestuff being received or exhausted onto the first ply relative to the second ply.
- a difference in color depth (DL*) between the dyed first ply or single strand and the dyed second ply or single strand has an absolute value of at least 2 when the vat dyestuff is in an oxidized state. In some embodiments, DL* ranges from 2- 50 or from 3-30. Moreover, in some embodiments, a denier difference between the first ply and second ply can yield a reflectance difference, wherein the lower denier ply reflects less light leading to a lighter coloring.
- a yam comprises a first ply and a second ply each dyed with at least one vat dyestuff, wherein a denier ratio between the first ply and the second ply is greater than 1. In some embodiments, the denier ratio is greater than 1.5 or greater than 2.
- the denier ratio between the first ply and the second ply for example can range from 1.2 to 10, in some embodiments.
- the denier ratio can be chosen according to several consideration including, but not limited to, the composition of the first and second plies, the chemical identify of the vat dyestuff, and exhaustion levels of the vat dyestuff on the first ply and the second ply.
- the first ply has a denier of 12 or higher
- the second ply has a denier less than 12.
- the denier ratio or disparity between the first ply and the second ply can be employed to modulate individual reflectance values of the first and second plies.
- the higher denier first ply for example, can exhibit higher reflectance while the lower denier second ply exhibits lower reflectance. This gradient in reflectance can render the second ply lighter in color to the observer, yielding the desired tweed or heathered effect.
- a yam comprises a first ply and a second ply each dyed with at least one vat dyestuff, wherein a reflectance ratio between the second ply and the first ply ranges from 0.05 to 0.95. In some embodiments, the reflectance ration ranges from 0.3 to 0.7 or from 0.4 to 0 6
- the first ply and second ply of yams described herein can be formed of any desired composition.
- the first ply and the second ply can be formed of the same composition or differing compositions.
- the first ply and the second ply can comprise synthetic compositions, natural compositions, or various combinations of synthetic and natural compositions. Specific compositions of the first ply and the second ply are chosen according to the technical objectives described herein of providing a yam with a tweed or heathered appearance.
- the first ply and second ply can be selected or chemically engineered to receive differing amounts of the vat dyestuff.
- the first and second plies for example, can exhibit differing levels of crystallinity.
- the first ply can exhibit lower crystallinity than the second ply, thereby providing an inter-chain structure for receiving higher amounts of the vat dyestuff relative to the higher crystallinity second ply. Moreover, in some embodiments, the first ply can exhibit a chemical structure more receptive to the vat dyestuff relative to the second ply.
- the first ply can comprise a higher number of cationic moieties or moieties having positive dipole moments for interaction with the anionic character of the vat dyestuff relative to the second ply.
- the second ply can comprise a higher number of anionic moieties or moieties having negative dipole moments for repelling or otherwise interfering with the anionic character of the vat dyestuffs during the dyeing process.
- Such chemical tailoring can result in more vat dyestuff being exhausted onto the first ply than the second ply, thereby yielding the desired color differential between the plies to provide a tweed or heathered appearance.
- the foregoing technical principles are illustrated by forming the first ply and the second ply of differing polyamides.
- the first ply for example, can be nylon 6, and the second ply is nylon 6,6.
- the nylon 6 exhibits lower crystallinity relative the nylon 6,6.
- the lower crystallinity can provide a more open structure for receiving greater amounts of the vat dyestuff.
- the nylon 6 may include greater number of cationic amine groups for interaction with the vat dyestuff.
- the nylon 6,6 fiber can comprise a sulfur content for generating anionic moieties or functionalities for repelling or otherwise interfering with anionic character of the vat dyestuff in the dyeing process.
- the nylon 6,6 can comprise a sulfur content of at least 2,000 ppm.
- the nylon 6,6, for example can have a sulfur content of 2,000 to 3,300 ppm.
- Yarns having construction and properties described herein can be used to provide a variety of textile products.
- the yams are employed in floor coverings, such as carpets.
- the yams for example, can be tufted and coated to produce a finished tweed or heathered carpet.
- the yarn comprising the first ply and the second ply can be tufted into a greige carpet construction, and subsequently dyed in batch mode or continuous mode using a vat dyeing system.
- the vat dyes greige is subsequently coated to provide a finished tweed or heathered carpet.
- the dyed yams can also display enhanced lightfastness, wet fastness, color fastness to ozone and/or resistance to household bleach. Dyed yam, for example, can be resistant to undiluted household bleach or diluted bleach of 0.3% sodium hypochlorite solution.
- the nylon fibers dyed with one or more vat dyestuffs can meet one or more criteria set forth in Table I.
- vat dyestuffs not inconsistent with the objectives of the present invention can be applied to nylon fibers having construction and/or properties described.
- Suitable vat dyestuffs can contain two or more ketone groups separated by a system of conjugated bonds.
- vat dyestuffs include indigo and derivatives thereof.
- Vat dyestuffs may also include various derivatives of anthroquinones. Table II provides a non-limiting list of vat dyes for use with nylon fibers according to some embodiments described herein.
- a method in some embodiments, comprises providing a yarn comprising a first ply and a second ply, and contacting the yarn with a dyeing composition comprising at least one vat dyestuff in reduced form.
- a dyeing composition comprising at least one vat dyestuff in reduced form.
- the vat dyestuff is oxidized, wherein the dyed first ply exhibits a darker or deeper color than the dyed second ply.
- the darker or deeper color of the first ply can originate from more of the vat dyestuff being received or exhausted onto the first ply relative to the second ply, as described herein.
- a denier difference between the first ply and second ply can yield a reflectance difference, wherein the lower denier ply reflects less light leading to a lighter coloring.
- the first ply and the second ply are combined to form the yarn prior to dyeing in the same or common vat dyebath. Therefore, the differential color effects between the dyed first ply and second ply are achieved in a single dyebath or single vat dyeing process.
- the ability to achieve the differential color effects in a single or common process realizes process efficiencies over individual dyeing of the first ply and second ply followed by combining the individually dyed plies into the yam construction.
- the dyeing composition can include one or more vat dyestuffs in any amount not inconsistent with the obj ectives of the present invention.
- vat dyestuff is present in the dyeing composition at an add-on level of at least 0.1% on weight fiber.
- Vat dyestuff can also be present in the dyeing composition at add-on levels according to Table III.
- the dyeing composition including one or more vat dyestuffs can be prepared according to several techniques.
- an aqueous dispersion of one or more vat dyestuffs is initially provided.
- Purified water free or substantially free of hardening species such as calcium and magnesium can be used as the dispersion continuous phase.
- one or more water softening agents can be added to the dispersion to sequester hardening species.
- Such purified or treated water is generally referred to as soft water herein.
- Vat dyestuff(s) are added to the continuous aqueous phase in amounts consistent with the add on levels provided in Table III.
- the continuous aqueous phase may be heated to a temperature of 30-35°C and mixing may be employed to assist in dispersion of the vat dyestuff(s).
- a reducing system is prepared for combination with the aqueous dispersion of the vat dyestuff(s).
- a reducing system comprises one or more chemical species for reducing the vat dyestuff(s), thereby placing the dyestuff(s) in the water soluble form.
- Reduction of the vat dyestuff(s) may convert the dyestuff(s) to leuco form, in some embodiments.
- Any suitable reductant species not inconsistent with the objectives of the present invention can be employed.
- Sodium dithionite and/or sodium hydrosulfite for example, can be a reductant for one or more vat dyestuffs.
- ferrous sulfate can be used in conjunction with sodium dithionite for dyestuff reduction.
- the reducing agent can be added to soft water to provide the reducing system.
- the water is heated to a temperature of 30-35°C, and the one or more reductants are added with mixing or other mechanical agitation. Amounts of reducing agent added to the soft water can be sufficient to reduce all or substantially all of the vat dyestuffs employed in the dyeing process.
- a reducing system is not necessary as the vat dyestuffs are provided in reduced form from the manufacturer.
- a solution of reduced vat dyestuff can be commercially available and used in accordance with methods described herein.
- One or more alkaline species for adjusting the pH of the dyeing composition is dispersed in soft water.
- Caustic soda (NaOH) or aqua ammonia can be employed as an alkaline pH adjusting agent.
- Other pH adjusting agents are well-known in the art and may also be used.
- the pH adjusting composition is added to the exhaust dye equipment.
- dispersing agent(s) and/or leveling agent(s) are added.
- Polyvinylpyrrolidone for example, can serve as a dispersing agent for the vat dyestuffs as well as a providing some retarding and leveling action.
- benzyl alcohol can be used.
- Table IV provides amounts of reducing and pH adjustment agents for dyeing compositions having various dyestuff concentrations (owf) for application by exhaust dyeing systems.
- Table V provides amounts of reducing and pH adjustment agents for dyeing compositions having various dyestuff concentrations (owf) for application by a continuous dyeing system at 450% wet pick up.
- Table VI provides amounts of reducing and pH adjustment agents for dyeing compositions having various dyestuff concentrations (owf) for application by continuous space dyeing at 100% wet pick up.
- Table VI - Reducing and pH Adjustment Agents Additionally, Table VII provides various liquor ratios (LR) for exhaust dyeing, continuous dyeing and continuous space dyeing processes according to some embodiments.
- initial mixing and wetting out of the nylon fiber, yam or greige by the dyeing composition can be allowed to occur over a time period of at least 15 minutes at a temperature of 30-35°C.
- a temperature ramp is subsequently administered. In some embodiments, temperature is ramped at 1.5°C/min to an 80°C hold for 45 minutes.
- the bath can be overflowed for initial cooling followed by draining off the spent dyebath from the exhaust dyeing apparatus.
- a rinse bath of ambient water is then provided, and the dyed nylon fibers are circulated through the bath for a minimum of 15 minutes to remove any unfixed material from the fiber surfaces.
- an organic acid component such as acetic acid
- 30-80 percent dyestuff exhaustion is achieved.
- the dyed nylon fibers are removed from the exhaust dyeing apparatus and extracted to mechanically remove as much water as possible, without fiber damage.
- Air drying can occur at ambient temperature or elevated temperatures. In some embodiments, for example, air drying occurs at temperatures of 200-300°F, such as 240-260°F. Drying is continued until a moisture content of 5% or less is achieved.
- the drying process also serves as an oxidation step for the vat dyestuffs on the nylon fibers. This drying and oxidation fixes the vat dyestuffs on the nylon fibers, greatly improving their fastness properties listed in Table I herein. Dyestuff oxidation and fixing during the heating process fundamentally differs from prior processes where one or more oxidizing agents are employed for vat dyestuff oxidation.
- prior processes can use peroxide and/or other oxidants for dyestuff oxidation.
- the present method surprisingly oxidizes and fixes the vat dyestuffs in the absence of such oxidizing species, thereby simplifying the dyeing process.
- the main difference with exhaustion processes is the separation of the vat dyestuff dispersion from the reducing system until just prior to application of the dyeing composition to the nylon fibers.
- a bath containing the pre-dispersed vat dyestuff(s) can be held in Tank A while Tank B contains the reducing system, pH adjustment agent(s) and other auxiliary materials such as wetting agents, leveling agents, carriers and the like.
- the contents of Tanks A and B are metered and mixed together in appropriate ratio to provide the dyeing composition.
- the dyeing composition is then applied to the nylon yam or carpet greige being processed continuously through either a space dye line (in the case of yam) or a continuous broad loom dye range (in the case of nylon carpet greige).
- the fiber can be exposed to heat to promote exhaustion of the vat dyestuff(s) on the fibers.
- saturated steam can be used as the heat source.
- the dyed fibers can be rinsed, extracted and dried as described above. The drying process oxidizes the vat dyestuff(s).
- a pretreatment process is applied to one or more of the plied, including the cationic ply and/or the anionic ply.
- the pretreatment process can be incorporated into example methods to increase the hydrophobic character of the cationic poly and/or the anionic ply.
- the pretreatment can include contacting a ply with a wax (e.g., in the form of a wax emulsion) to produce a wax-finished ply.
- Certain embodiments of the disclosure can include a yarn made from at least two plies (e.g., a first ply and a second ply), where one of the at least two plies is a wax-finished ply.
- the yam can have a construction defining the spatial relationship between the wax-finished ply and one or more other plies of the at least two plies, along the length of the yarn.
- one type of construction can include a “barberpole” construction, where the wax-finished ply and one of the other plies are twisted or otherwise wrapped around each other to create a diagonal stripping effect.
- barber pole constructions can include a regular or irregular striping effect.
- a regular stripping effect the positions of the wax-finished ply and the other ply wrapped around it are regularly spaced so that along a length of the yam, the position of the wax-finished ply repeats at least every 2 mm (e.g., between 0.2 cm and 2 cm, between 0.5 cm and 1.5 cm, between 0.5 and 1 cm, or between 0.6 and 0.8 cm).
- This effect can be adjusted in several manners. For instance, the thickness of the wax-finished ply and/or the other ply wrapped around it may be adjusted. Alternatively or additionally, the number and/or density of twists in the yarn may be adjusted.
- the position of the wax-finished ply is not regularly spaced and so does not have a specific repeating value.
- some constructions can be produced by arranging the first ply and the second ply to produce the construction.
- Aspects of arranging the first ply and the second ply can include introducing twists into the yarn at a density of 1 twists per inch to 10 twists per inch, such as 2 to 8, 1 to 5, or 8 to 10 twists per inch.
- the twists can be regularly spaced to produce a regular stripping effect or irregularly spaced to produce an irregular striping effect.
- the density of twists may vary along the length of the yarn or may be constant.
- Embodiments of the disclosure can also include methods for producing a dyed yarn.
- Example methods for producing a dyed yam can include obtaining a first ply and a second ply, optionally, applying a pretreatment process to at least one of the first ply, the second ply, or both arranging the first ply and the second ply to form a yarn having a construction, for example, a barberpole construction, exposing the yarn to a dyebath including at least one vat dyestuff in reduced form (i.e. reduced vat dyestuff), and oxidizing the vat dyestuff applied to the yarn.
- Some advantages of preparing dyed yarns according to methods of the present disclosure can include improved color differentiation between the first ply and the second play. For instance, it has been discovered that pretreatment of the ply or plies prior to dyeing the yarn can produce a greater difference in color values between the first play and the second ply in comparison to untreated ply or plies. Additionally, properties such as ionic character (e.g., anionic or cationic) can impact dyestuff uptake. Further, these differences in dye uptake can be realized in a more economic manner by exposing the yarn including the plies to the dyebath together, rather than separately dying each of the plies.
- ionic character e.g., anionic or cationic
- yams in accordance with the present disclosure may demonstrate improve color values for providing a heathered or tweed appearance, while also presenting economic advantages in manufacturing.
- various fiber properties can be achieved through differentiation between a first ply and a second ply, for example to achieve a barberpole and/or heathered effect with a vat dyestuff application.
- a first ply or filament can be darker after dyeing and a second ply or filament can be lighter after dyeing. Differences between the plies after dyeing can enable the tuning of various properties of a fiber.
- total ply denier can be varied where a first ply has a total denier greater than a second ply, and a second ply has a total ply less than the first ply.
- denier per filament can be varied where a first ply has a high denier per filament relative to a second ply (i.e. fewer filaments of larger cross section) and the second ply has a lower denier per filament relative to the first ply (i.e. higher number of total filaments of smaller cross section).
- luster level e.g. TiCk content
- filament cross section e.g. modification ratio
- MR modification ratio
- a nylon chemical property can be varied where a first ply is cationic or highly cationic and/or having a high amine group content (e.g.
- nylon physical characteristics can be varied where a first ply has a low crystallinity (e.g. nylon 6 type) and a second ply has a higher crystallinity (e.g. nylon 6.6 type).
- extrusion finish properties can be varied where a first ply has a high wetting speed finish (i.e. to promote high dyestuff exhaustion) and a second ply has a low wetting speed finish or a repellant finish, for example a wax finish (e.g. to promote low dyestuff exhaustion).
- Table 1 was developed by, first, producing 11 different twisted, heatset yarn packages, using dyeable commercial yarns for carpet use. Self-plied yarn packages were produced from each yarn type, using 5.25 twist per inch settings, and Superba heat setting.
- the dyestuff used was color index Vat Black 27, sold by Dystar as Indanthrene Olive R Liquid.
- An Ahiba lab dyeing apparatus was used and a Gretag Macbeth Color-eye 7000A was used for color measurements to determine the tristimulus values of the cut end of the dyed skeins.
- the L* information was used to determine DL* (delta L*) differences between the two yarns dyed competitively in each test case, as well as to determine an estimate of the amount of Vat Black 27 present on each yarn skein.
- Table 2 displays dying properties for two twisted yam packages. In one of the packages, a wax pretreatment (NF818 5%) applied prior to dying. The resulting dyed yarn has a larger DL* value compared to the yam without pretreatment. Table 2. Comparison of dying properties between wax pretreated yarn and control
Abstract
Description
Claims
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CN202280027865.XA CN117120678A (en) | 2021-02-22 | 2022-02-22 | Differential vat dyed yarn and method of making the same |
US18/278,287 US20240125013A1 (en) | 2021-02-22 | 2022-02-22 | Differentially vat dyed yarns and method of making the same |
CA3208994A CA3208994A1 (en) | 2021-02-22 | 2022-02-22 | Differentially vat dyed yarns and method of making the same |
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Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB789547A (en) * | 1955-07-05 | 1958-01-22 | British Celanese | Improvements in the colouring of textile materials with vat dyes |
US4118183A (en) * | 1976-04-09 | 1978-10-03 | Quikoton Ag | Process for the treatment of warp yarns |
US4613336A (en) * | 1983-06-03 | 1986-09-23 | Michael Quinnen | Knitted fabric produced from indigo-dyed yarn |
DE4103639A1 (en) * | 1991-02-07 | 1992-08-13 | Basf Ag | Dyeing cellulose textile with vat or sulphur dyestuff - using alpha=hydroxy carbonyl cpd. as sole reducing agent by heating side stream to dissolve ppte. |
US20050183218A1 (en) * | 2004-02-25 | 2005-08-25 | Rao Sundar M. | Overdyeable Pigmented Polymeric Fiber And Yarns And Articles Made Therefrom |
-
2022
- 2022-02-22 WO PCT/US2022/017253 patent/WO2022178397A1/en active Application Filing
- 2022-02-22 US US18/278,287 patent/US20240125013A1/en active Pending
- 2022-02-22 CA CA3208994A patent/CA3208994A1/en active Pending
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB789547A (en) * | 1955-07-05 | 1958-01-22 | British Celanese | Improvements in the colouring of textile materials with vat dyes |
US4118183A (en) * | 1976-04-09 | 1978-10-03 | Quikoton Ag | Process for the treatment of warp yarns |
US4613336A (en) * | 1983-06-03 | 1986-09-23 | Michael Quinnen | Knitted fabric produced from indigo-dyed yarn |
DE4103639A1 (en) * | 1991-02-07 | 1992-08-13 | Basf Ag | Dyeing cellulose textile with vat or sulphur dyestuff - using alpha=hydroxy carbonyl cpd. as sole reducing agent by heating side stream to dissolve ppte. |
US20050183218A1 (en) * | 2004-02-25 | 2005-08-25 | Rao Sundar M. | Overdyeable Pigmented Polymeric Fiber And Yarns And Articles Made Therefrom |
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