U.S. patent application number 16/283248 was filed with the patent office on 2019-12-26 for process for dyeing a textile substrate containing residual oligomers.
This patent application is currently assigned to FAR EASTERN NEW CENTURY CORPORATION. The applicant listed for this patent is FAR EASTERN NEW CENTURY CORPORATION. Invention is credited to I-Han Chen, Hsin-Yun Huang, Jau-Tzeng Wang.
Application Number | 20190390400 16/283248 |
Document ID | / |
Family ID | 68968192 |
Filed Date | 2019-12-26 |
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United States Patent
Application |
20190390400 |
Kind Code |
A1 |
Wang; Jau-Tzeng ; et
al. |
December 26, 2019 |
PROCESS FOR DYEING A TEXTILE SUBSTRATE CONTAINING RESIDUAL
OLIGOMERS
Abstract
A process for dyeing a textile substrate containing residual
oligomers includes the steps of: a) attaching the textile substrate
on a mounting carrier to constitute a substrate-loaded carrier
which is to be subjected to supercritical dyeing in a dyeing
autoclave; and b) overlying the textile substrate with a
micro-porous film which includes pores having a pore size such that
when the textile substrate is dyed in the dyeing autoclave, a
dye-containing supercritical fluid is allowed to pass through the
micro-porous film to permit the textile substrate to be dyed while
the residual oligomers entrained in the supercritical fluid are
retained by the micro-porous film.
Inventors: |
Wang; Jau-Tzeng; (Taipei
City, TW) ; Huang; Hsin-Yun; (Taipei City, TW)
; Chen; I-Han; (Taipei City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FAR EASTERN NEW CENTURY CORPORATION |
Taipei City |
|
TW |
|
|
Assignee: |
FAR EASTERN NEW CENTURY
CORPORATION
Taipei City
TW
|
Family ID: |
68968192 |
Appl. No.: |
16/283248 |
Filed: |
February 22, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06P 1/94 20130101; D06P
3/54 20130101; D06P 5/001 20130101; D06P 3/52 20130101 |
International
Class: |
D06P 1/94 20060101
D06P001/94 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 21, 2018 |
TW |
107121281 |
Claims
1. A process for dyeing a textile substrate containing residual
oligomers, comprising the steps of: a) attaching the textile
substrate on a mounting carrier to constitute a substrate-loaded
carrier which is to be subjected to supercritical dyeing in a
dyeing autoclave; and b) overlying the textile substrate of the
substrate-loaded carrier with a micro-porous film which includes
pores having a pore size such that when the textile substrate is
dyed in the dyeing autoclave, a dye-containing supercritical fluid
is allowed to pass through the micro-porous film to permit the
textile substrate to be dyed while the residual oligomers entrained
in the supercritical fluid are retained by the micro-porous
film.
2. The process according to claim 1, wherein the pore size of the
pores of the micro-porous film is smaller than a particle size of
the residual oligomers.
3. The process according to claim 2, wherein the pore size of the
pores of the micro-porous film is in a range from 0.1 .mu.m to 1.0
.mu.m.
4. The process according to claim 3, wherein the pore size of the
pores of the micro-porous film is in a range from 0.2 .mu.m to 0.8
.mu.m.
5. The process according to claim 1, wherein the micro-porous film
has a thickness in a range from 10 mm to 90 mm.
6. The process according to claim 1, wherein the micro-porous film
is made from a polymeric material.
7. The process according to claim 6, wherein the polymeric material
is polytetrafluoroethylene.
8. The process according to claim 6, wherein the polymeric material
is polyurethane.
9. The process according to claim 6, wherein the polymeric material
is polypropylene.
10. The process according to claim 1, wherein the textile substrate
is made from a polyester material.
11. The process according to claim 1, wherein the dye-containing
supercritical fluid includes a disperse dye.
12. The process according to claim 1, wherein in step a), the
mounting carrier is tubular-shaped, and the textile substrate is
wound on the tubular-shaped mounting carrier around an axis.
13. The process according to claim 1, wherein the dye-containing
supercritical fluid includes supercritical carbon dioxide.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of Taiwanese Application
No. 107121281, filed on Jun. 21, 2018.
FIELD
[0002] The disclosure relates to a process for dyeing a textile
substrate, and more particularly to a process for dyeing a textile
substrate containing residual oligomers.
BACKGROUND
[0003] A traditional water-based dyeing process is usually followed
by a water washing process, resulting in undesirable production of
a large amount of waste water. Therefore, the water-based dyeing
process is being replaced with a supercritical fluid dyeing process
to alleviate the problem of discharging the waste water. However,
the processes of synthesizing polymer such as polyester and
spinning yarns from polymeric fibers may produce a small amount of
residual oligomers, which may leach from a textile made from the
yarns due to flowing of the supercritical fluid through the textile
in a high temperature dye bath, resulting in formation of color
stain on the textile after the supercritical fluid dyeing process.
In addition, the residual oligomers may aggregate with the dye that
is contained in the supercritical fluid to form sediments that may
be deposited on an inner wall of a dyeing autoclave, resulting in
pollution thereof.
[0004] Currently, there is still a need to conduct a water washing
process after the supercritical fluid dyeing process to remove the
residual oligomers from the dyed textile. Therefore, the problem of
discharging waste water cannot be effectively alleviated. In
addition, only about 15% to 25% of the residual oligomers may be
removed by the water washing process.
SUMMARY
[0005] Therefore, an object of the disclosure is to provide a
process for dyeing a textile substrate containing residual
oligomers which can overcome the aforesaid shortcomings of the
prior art.
[0006] According to the disclosure, there is provided a process for
dyeing a textile substrate containing residual oligomers,
comprising the steps of:
[0007] a) attaching the textile substrate on a mounting carrier to
constitute a substrate-loaded carrier which is to be subjected to
supercritical dyeing in a dyeing autoclave; and
[0008] b) overlying the textile substrate of the substrate-loaded
carrier with a micro-porous film which includes pores having a pore
size such that when the textile substrate is dyed in the dyeing
autoclave, a dye-containing supercritical fluid is allowed to pass
through the micro-porous film to permit the textile substrate to be
dyed while the residual oligomers entrained in the supercritical
fluid are retained by the micro-porous film.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other features and advantages of the disclosure will become
apparent in the following detailed description of the embodiment(s)
with reference to the accompanying drawings, of which:
[0010] FIG. 1 is a scanning electron microscopy image of a treated
polyester textile of Example 1;
[0011] FIG. 2 is a scanning electron microscopy image of a treated
polyester textile of Comparative Example 1; and
[0012] FIG. 3 is a scanning electron microscopy image of a treated
polyester textile of Comparative Example 2.
DETAILED DESCRIPTION
[0013] A process for dyeing a textile substrate containing residual
oligomers according to the disclosure comprises the steps of:
[0014] a) attaching the textile substrate on a mounting carrier to
constitute a substrate-loaded carrier which is to be subjected to
supercritical dyeing in a dyeing autoclave; and
[0015] b) overlying the textile substrate of the substrate-loaded
carrier with a micro-porous film which includes pores having a pore
size such that when the textile substrate is dyed in the dyeing
autoclave, a dye-containing supercritical fluid is allowed to pass
through the micro-porous film to permit the textile substrate to be
dyed while the residual oligomers entrained in the supercritical
fluid are retained by the micro-porous film.
[0016] In certain embodiments, the pore size of the pores of the
micro-porous film is smaller than a particle size of the residual
oligomers. In certain embodiments, the pore size of the pores of
the micro-porous film is in a range from 0.1 .mu.m to 1.0 .mu.m. In
certain embodiments, the pore size of the pores of the micro-porous
film is in a range from 0.2 .mu.m to 0.8 .mu.m.
[0017] In certain embodiments, the micro-porous film has a
thickness in a range from 10 mm to 90 mm.
[0018] In certain embodiments, the micro-porous film is made from a
polymeric material. In certain embodiments, the polymeric material
for making the micro-porous film is polytetrafluoroethylene. In
certain embodiments, the polymeric material for making the
micro-porous film is polyurethane. In certain embodiments, the
polymeric material for making the micro-porous film is
polypropylene.
[0019] In certain embodiments, the textile substrate is made from a
polyester material.
[0020] In certain embodiments, the dye-containing supercritical
fluid includes a disperse dye. The disperse dye used in the
following examples includes Disperse Red 92 and Disperse Blue
60.
[0021] In certain embodiments, in step a), the mounting carrier is
tubular-shaped, and the textile substrate is wound on the
tubular-shaped mounting carrier around an axis.
[0022] In certain embodiments, the dye-containing supercritical
fluid includes supercritical carbon dioxide.
[0023] Examples of the disclosure will be described hereinafter. It
is to be understood that these examples are exemplary and
explanatory and should not be construed as a limitation to the
disclosure.
Example 1
[0024] A polyester textile (10 g; commercially available from Far
Eastern New Century Corporation, Taiwan; Catalogue Number: 75/72
SDR) was wound on a stainless steel, tubular-shaped mounting
carrier around an axis.
[0025] A micro-porous film of polytetrafluoroethylene (ePTFE;
commercially available from Yeu Ming Tai Chemical Industrial Co.,
Ltd., Taiwan; Catalogue Number: STF-5126; size: 15 cm.times.15 cm;
thickness: 35 mm; pore size: 0.2-0.8 .mu.m) was tightly and fully
overlaid on the polyester textile that was wound on the stainless
steel, tubular-shaped mounting carrier in a manner that the
polyester textile was not exposed from the micro-porous film. The
micro-porous film was then fixed by cotton or nylon thread.
[0026] The stainless steel, tubular-shaped mounting carrier
together with the polyester textile and the micro-porous film was
placed in an autoclave (1 L). Liquefied carbon dioxide (150.+-.3 g)
was introduced into the autoclave and was heated under turbulence
to a temperature ranging from 120.degree. C. to 130.degree. C. The
autoclave was pressurized with carbon dioxide gas to a pressure
ranging from 250 bar to 300 bar to form supercritical carbon
dioxide in the autoclave for a period of 120 min.
[0027] Afterwards, the temperature and the pressure of the
autoclave were reduced to 60.degree. C. and a normal pressure,
respectively. Following treatment of the supercritical carbon
dioxide, the polyester textile (referred below as a supercritical
carbon dioxide-treated polyester textile) was detached from the
stainless steel, tubular-shaped mounting carrier.
Example 2
[0028] The procedures of Example 2 were similar to those of Example
1 except that the micro-porous film of ePTFE was replaced with a
micro-porous film of polypropylene (PP; commercially available from
Finetech Research and Innovation Corporation, Taiwan; Catalogue
Number: M-PP047N0451; size: 15 cm.times.15 cm; thickness: 47 mm;
pore size: 0.45 .mu.m).
Example 3
[0029] The procedures of Example 3 were similar to those of Example
1 except that the micro-porous film of ePTFE was replaced with a
micro-porous film of polyurethane (PU; commercially available from
Taiwan GUL Co. Ltd.; Catalogue Number: ITPUC035137; size: 15
cm.times.15 cm; thickness: 35 mm; pore size: 0.2-0.6 .mu.m).
Example 4
[0030] The procedures of Example 4 were similar to those of Example
1 except that Disperse Red 92 (0.05 g) was placed into the
autoclave prior to the introduction of liquefied carbon dioxide
into the autoclave.
Example 5
[0031] The procedures of Example 5 were similar to those of Example
1 except that Disperse Blue 60 (0.05 g) was placed into the
autoclave prior to the introduction of liquefied carbon dioxide
into the autoclave.
Comparative Example 1
[0032] The procedures of Comparative Example 1 were similar to
those of Example 1 except that the polyester textile wound on the
stainless steel, tubular-shaped mounting carrier was not overlaid
with the micro-porous film of ePTFE.
Comparative Example 2
[0033] The procedures of Comparative Example 2 were similar to
those of Example 4 except that the polyester textile wound on the
stainless steel, tubular-shaped mounting carrier was not overlaid
with the micro-porous film of ePTFE.
Comparative Example 3
[0034] The procedures of Comparative Example 3 were similar to
those of Example 5 except that the polyester textile wound on the
stainless steel tubular-shaped mounting carrier was not overlaid
with the micro-porous film of ePTFE.
Scanning Electron Microscopic Observation:
[0035] Each of the supercritical carbon dioxide-treated polyester
textiles of Example 1, and Comparative Examples 1 and 2 was
observed at a surface thereof which was distal from the stainless
steel, tubular-shaped mounting carrier during the treatment of
supercritical carbon dioxide using a scanning electron microscope.
The results for the supercritical carbon dioxide-treated polyester
textiles of Example 1, and Comparative Examples 1 and 2 are shown
in FIGS. 1 to 3, respectively.
[0036] As shown in FIG. 1, the observed surface of the
supercritical carbon dioxide-treated polyester textile of Example 1
is smooth and even. In contrast thereto, as shown respectively in
FIGS. 2 and 3, the observed surfaces of the supercritical carbon
dioxide-treated polyester textiles of Comparative Examples 1 and 2
have a significant amount of residual oligomer particles, which are
indicated by arrows. It is thus demonstrated that as compared to
the treatments of the polyester textile of Comparative Examples 1
and 2, the treatment of the polyester textile of Example 1
significantly decreased the amount of residual oligomer particles
that remained thereon.
Quantitative Analysis of Residual Oligomers:
[0037] 50 mg of each of the supercritical carbon dioxide-treated
polyester textiles of Examples 1 to 5 and Comparative Examples 1 to
3, and 50 mg of each of the treated micro-porous films of Examples
1 to 4 were placed respectively in a container, following by
addition of 1.5 ml of a solvent mixture of hexafluoroisopropanol
and chloroform in a volume ratio of 3:2 and left to stand
overnight. Then, chloroform (10 ml) and methanol (5 ml) were added
into the container, followed by centrifugation and filtration to
obtain a filtrate. A determined amount of the filtrate was taken
for a quantitative analysis of residual oligomers using high
performance liquid chromatography (HPLC) (mobile phase: a solvent
mixture of methanol and acetonitrile; column: a C18 HPLC column
commercially available from ES Industries; fillers: particle size
of 3.5 .mu.m, pore size of 100 .ANG., specific surface area of 350
m.sup.2/g; elution temperature: 35.degree. C.). Retention rate of
each of the micro-porous films of Examples 1 to 5 was calculated
according to Formula (1). The results are shown in Table 1.
Retention rate=[A1/(A1+A2)].times.100% (1)
wherein
[0038] A1 is an amount of residual oligomers remaining on a
micro-porous film, and
[0039] A2 is an amount of residual oligomers remaining on a
polyester textile.
TABLE-US-00001 TABLE 1 A2 ((Amount of A1 (Amount of residual
oligomers residual oligomers remaining on a remaining on a
Retention polyester textile) micro-porous film) rate Ex. 1 5250 ppm
4550 ppm 46.4% Ex. 2 7090 ppm 2870 ppm 28.8% Ex. 3 7950 ppm 1980
ppm 19.9% Ex. 4 5760 ppm 4180 ppm 42.1% Ex. 5 5230 ppm 4570 ppm
46.6% Comp. Ex. 1 10060 ppm -- -- Comp. Ex. 2 12090 ppm -- -- Comp.
Ex. 3 11758 ppm -- --
[0040] As shown in Table 1, the total amounts of the residual
oligomers (i.e., A1+A2) of Examples 1 to 5 and Comparative Examples
1 to 3 are all about 10000 ppm. The retention rates achieved by the
micro-porous films of Examples 1 to 5 are in a range from 19.9% to
46.6%. Specifically, the retention rates achieved by the ePTFE
micro-porous films of Examples 1, 4, and 5 are all above 40%. It is
thus demonstrated that in Examples 1 to 5, a significant amount of
the residual oligomers remaining on the polyester textile can be
transferred to and retained by the micro-porous film, so as to
significantly reduce the amount of the residual oligomers remaining
on the polyester textile. Therefore, the currently required water
washing process that is conducted after the supercritical fluid
dyeing process can be omitted in the process for dyeing a textile
substrate containing residual oligomers according to the
disclosure.
Color Measurement:
[0041] CIE L*,a*,b* color values of each of the supercritical
carbon dioxide-treated polyester textiles of Examples 4 and 5 and
Comparative Examples 2 and 3 were measured using a color difference
meter (Manufacturer: Nippon Denshoku Co., Ltd; Model: NE 4000). The
results are shown in Table 2.
TABLE-US-00002 TABLE 2 CIE L* value CIE a* value CIE b* value Ex. 4
9.88 10.58 3.84 Comp. Ex. 2 28.58 2.71 1.28 Ex. 5 10.12 3.32 -9.89
Comp. Ex. 3 27.32 1.48 -2.33
[0042] As shown in Table 2, the CIE L* value of each of the
supercritical carbon dioxide-treated polyester textiles of Examples
4 and 5 is much smaller than that of each of the supercritical
carbon dioxide-treated polyester textiles of Comparative Examples 2
and 3. It is thus demonstrated that a dyeing degree (i.e., a
coloring power) of each of the supercritical carbon dioxide-treated
polyester textiles of Examples 4 and 5 is much higher than that of
each of the supercritical carbon dioxide-treated polyester textiles
of Comparative Examples 2 and 3.
[0043] The CIE a* value of the supercritical carbon dioxide-treated
polyester textile of Example 4 is much larger than that of the
supercritical carbon dioxide-treated polyester textile of
Comparative Example 2. It is thus demonstrated that a dyeing degree
of a red dye (i.e., Disperse Red 92) of the supercritical carbon
dioxide-treated polyester textile of Example 4 is much higher than
that of the supercritical carbon dioxide-treated polyester textile
of Comparative Example 2, so that the supercritical carbon
dioxide-treated polyester textile of Example 4 is relatively red
compared to the supercritical carbon dioxide-treated polyester
textile of Comparative Example 2.
[0044] The CIE b.sup.+ value of the supercritical carbon
dioxide-treated polyester textile of Example 5 is much smaller than
that of the supercritical carbon dioxide-treated polyester textile
of Comparative Example 3. It is thus demonstrated that a dyeing
degree of a blue dye (i.e., Disperse Blue 60) of the supercritical
carbon dioxide-treated polyester textile of Example 5 is much
higher than that of the supercritical carbon dioxide-treated
polyester textile of Comparative Example 3, so that the
supercritical carbon dioxide-treated polyester textile of Example 5
is relatively blue compared to the supercritical carbon
dioxide-treated polyester textile of Comparative Example 3.
[0045] In view of the aforesaid, the process for dyeing a textile
substrate containing residual oligomers according to the disclosure
can effectively reduce the amount of the residual oligomers
remaining on the polyester textile after supercritical dyeing
treatment, so that the currently required water washing process
that is conducted after the supercritical fluid dyeing process can
be omitted. In addition, the process for dyeing a textile substrate
containing residual oligomers according to the disclosure enhances
the dying degree of the supercritical carbon dioxide-treated
polyester textile.
[0046] In the description above, for the purposes of explanation,
numerous specific details have been set forth in order to provide a
thorough understanding of the embodiment(s). It will be apparent,
however, to one skilled in the art, that one or more other
embodiments may be practiced without some of these specific
details. It should also be appreciated that reference throughout
this specification to "one embodiment," "an embodiment," an
embodiment with an indication of an ordinal number and so forth
means that a particular feature, structure, or characteristic may
be included in the practice of the disclosure. It should be further
appreciated that in the description, various features are sometimes
grouped together in a single embodiment, figure, or description
thereof for the purpose of streamlining the disclosure and aiding
in the understanding of various inventive aspects, and that one or
more features or specific details from one embodiment may be
practiced together with one or more features or specific details
from another embodiment, where appropriate, in the practice of the
disclosure.
[0047] While the disclosure has been described in connection with
what is (are) considered the exemplary embodiment(s), it is
understood that this disclosure is not limited to the disclosed
embodiment(s) but is intended to cover various arrangements
included within the spirit and scope of the broadest interpretation
so as to encompass all such modifications and equivalent
arrangements.
* * * * *