Note: Descriptions are shown in the official language in which they were submitted.
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TEXTILE MATERIALS CONTAINING DYED POLYPHENYLENE SULFIDE FIBERS
AND METHODS FOR PRODUCING THE SAME
TECHNICAL FIELD OF THE INVENTION
[0001] This application relates to textile materials containing dyed
polyphenylene sulfide fibers and methods for producing the same.
BACKGROUND
[0002] Polyphenylene sulfide is a thermoplastic polymer that exhibits a
number of desirable properties. For example, polyphenyelne sulfide exhibits
resistance to heat, various chemicals (e.g., acids, alkalis, and bleaches),
mildew,
aging, UV exposure (e.g., sunlight), and abrasion. Due to its thermoplastic
nature
and the desirable properties, polyphenylene sulfide polymer has been extruded
into
fibers suitable for use in making textile materials. These polyphenylene
sulfide fibers
have been used in industrial textile materials, such as high temperature
filtration
media and automotive hose reinforcement, for many years. However, despite the
many advantages offered by the polyphenylene sulfide polymer, the textile
fibers
made from the polymer have not found practical use in apparel or decorative
textile
applications. The main reason for this lack of use is that no practical means
for
dyeing polyphenylene sulfide polymers has been developed.
[0003] A need therefore remains for a method of dyeing polyphenylene
sulfide
fibers that produces fibers with the full range of colors and shades desired
for
apparel and decorative textile applications and exhibiting the colorfastness
needed
for such applications. The invention described in this applications seeks to
provide
such a method and the dyed polyphenylene sulfide fibers produced by such a
method.
BRIEF SUMMARY OF THE INVENTION
[0004] In a first embodiment, the invention provides a textile material
comprising a plurality of dyed polyphenylene sulfide fibers, wherein the
polyphenylene sulfide fibers have a cross-sectional area, the polyphenylene
sulfide
fibers comprise a disperse dye that is distributed substantially evenly across
the
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cross-sectional area of the fibers, and the disperse dye is selected from the
group
consisting of disperse dyes having a molar mass of about 350 g/mol or more,
disperse dyes comprising a nitro group, and mixtures thereof.
[0005] In a second embodiment, the invention provides a method for dyeing
polyphenylene sulfide fibers, the method comprising the steps of:
(a) providing a textile material comprising polyphenylene sulfide fibers;
(b) providing a dye liquor comprising a liquid medium and a disperse dye
selected from the group consisting of disperse dyes having a molar mass of
about
350 g/mol or more, disperse dyes comprising a nitro group, and mixtures
thereof;
(c) applying the dye liquor to the textile material;
(d) heating the textile material under ambient atmosphere to a temperature
sufficient to evaporate substantially all of the liquid medium from the
textile material;
and
(e) heating the textile material under ambient atmosphere to a temperature
of about 180 C or more to fix the disperse dye to the polyphenylene sulfide
fibers.
DETAILED DESCRIPTION OF THE INVENTION
[0006] In a first embodiment, the invention provides a textile material
comprising a plurality of dyed polyphenylene sulfide fibers. The textile
material of
this first embodiment can take any suitable form. For example, the plurality
of dyed
polyphenylene sulfide fibers can be consolidated to provide a yarn. In such an
embodiment, the yarn can contain other fibers in addition to the dyed
polyphenylene
sulfide fibers, as is described in further detail below. In another
embodiment, the
plurality of dyed polyphenylene sulfide fibers can be consolidated into a
nonwoven
textile material. The textile material can also be a woven textile material
comprising
a plurality of interlaced yarns, at least one of which contains the dyed
polyphenylene
sulfide fibers. The textile material can also be a knit textile material
comprising one
or more interlooped yarns, at least one of which contains the dyed
polyphenylene
sulfide fibers.
[0007] The dyed polyphenylene sulfide fibers can comprise any suitable
polyphenylene sulfide polymer. The polyphenylene sulfide polymer can have any
suitable molar mass. Preferably, the polyphenylene sulfide polymer has a mass
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average molar mass of about 20,000 g/mol or more. More preferably, the
polyphenylene sulfide polymer has a mass average molar mass of about 30,000
g/mol or more, about 40,000 g/mol or more, or about 50,000 g/mol or more.
Preferably, the polyphenylene sulfide polymer has a mass average molar mass of
about 100,000 g/mol or less. More preferably, the polyphenylene sulfide
polymer
has a mass average molar mass of about 80,000 g/mol or less, about 70,000
g/mol
or less, or about 60,000 g/mol or less. In a particularly preferred
embodiment, the
polyphenylene sulfide polymer has a mass average molar mass of about 40,000
g/mol to about 60,000 g/mol. The polyphenylene sulfide polymer can have any
suitable melt viscosity. Preferably, the polyphenylene sulfide polymer has a
melt
viscosity of about 1,000 poise or more when measured at 300 C and an apparent
shear rate of 400 s-1 in accordance with ASTM Test Method 3835. More
preferably,
the polyphenylene sulfide polymer has a melt viscosity of about 1,000 poise to
about
3,000 poise or about 1,000 poise to about 2,200 poise when measured as
described
above.
[0008] The
polyphenylene sulfide polymer can exhibit any suitable degree of
crystallinity. Preferably, the percent crystallinity of the polyphenylene
sulfide polymer
is 10% or more. More preferably, the percent crystallinity of the
polyphenylene
sulfide polymer is about 20% or more, about 25% or more, or about 30% or more.
The percent crystallinity of the polyphenylene sulfide polymer preferably is
about
80% or less. More preferably, the percent crystallinity of the polyphenylene
sulfide
polymer is about 75% or less. Thus, in a series of preferred embodiments, the
percent crystallinity of the polyphenylene sulfide polymer is from 10% to
about 80%,
about 20% to about 80%, or about 30% to about 75%.
[0009] The dyed
polyphenylene sulfide fibers of the textile material comprise
at least one dye. The dye can be any suitable dye, but disperse dyes are
particularly
preferred. Preferably, the dye is a disperse dye selected from the group
consisting
of disperse dyes having a molar mass of about 350 g/mol or more, disperse dyes
comprising a nitro group, and mixtures thereof. In another preferred
embodiment,
the dye is a disperse dye selected from the group consisting of disperse dyes
having
a molar mass of about 400 g/mol or more, disperse dyes comprising a nitro
group,
and mixtures thereof. While not wishing to be bound to any particular
mechanism or
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theory, it has been observed that disperse dyes having a higher molar mass
(e.g.,
about 350 g/mol or more or about 400 g/mol or more) and/or a polar nature
(such as
disperse dyes containing a nitro group) are capable of satisfactorily dyeing
the
polyphenylene sulfide fibers, whereas disperse dyes that do not possess either
of
these characteristics are not. For example, it has been observed that dyes
that do
not possess either of these characteristics do not become sufficiently fixed
in the
polyphenylene sulfide fiber. With the exception of nitrodiphenylamine disperse
dyes,
the disperse dye preferably has a boiling point of 590 C or more, more
preferably
about 600 C or more. With the exception of nitrodiphenylamine disperse dyes,
the
disperse dye preferably has a flash point of 300 C or more, more preferably
about
310 C or more. In a particular embodiment, the disperse dye has a boiling
point of
590 C or more (e.g., about 600 C or more) and a flash point of 300 C or
more
(e.g., about 310 C or more).
[0010] The disperse dye can be any suitable disperse dye that possesses one
or more of the characteristics described above. In a more specific preferred
embodiment, the disperse dye is selected from the group consisting of azo dyes
(e.g., azothiophene dyes, azobenzothiazole dyes), diazo dyes, anthraquinone
dyes,
nitro dyes (e.g., nitrodiphenylamine dyes), quinoline dyes, dibenzofuran dyes,
naphthalimide dyes (e.g., aminoketone dyes), and mixtures thereof. Specific
disperse dyes that have been found useful in dyeing the polyphenylene sulfide
fibers
include, but are not limited to, C.I. Disperse Red 356, C.I. Disperse Red 167,
C.I.
Disperse Blue 77, C.I. Disperse Orange 30, C.I. Disperse Orange 44, C.I.
Disperse
Red 91, C.I. Disperse Blue 77, C.I. Disperse Blue 27, C.I. Disperse Blue 60,
C.I.
Disperse Yellow 86, C.I. Disperse Yellow 42, C.I. Disperse Yellow 58, C.I.
Disperse
Yellow 163, C.I. Disperse Red 86, C.I. Disperse Violet 57, C.I. Disperse Red
159,
C.I. Disperse Red 279, C.I. Disperse Yellow 114, C.I. Disperse Blue 56, C.I.
Disperse Blue 165, C.I. Disperse Red 153, C.I. Disperse Brown 1,0.1. Disperse
Violet 33, C.I. Disperse Red 92, and C.I. Disperse Blue 87. Any of the above-
mentioned dyes can be used in combination to produce polyphenylene sulfide
fibers
and textile materials exhibiting the desired color and shade.
[0011] The disperse dye preferably is distributed substantially evenly
throughout the thickness of the polyphenylene sulfide fibers. In other words,
the
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disperse dye preferably is distributed substantially evenly across the cross-
sectional
area of the polyphenylene sulfide fibers. This distribution of the disperse
dye within
the polyphenylene sulfide fibers is believed to be unique. For example, prior
attempts to dye polyphenylene sulfide fibers have relied upon surrounding the
polyphenylene sulfide polymer with a sheath of an easily-dyed polymer (e.g., a
polyamide). In such products, the dye only penetrates and fixes in the sheath,
and
the polyphenylene sulfide polymer remains undyed (or contains very little dye
at the
interface between the polyphenylene polymer and the sheath). The distribution
of
the disperse dye through the thickness or across the cross-sectional area can
be
determined by any suitable technique. For example, individual polyphenylene
sulfide
fibers can be sectioned and the coloration of the fibers can be examined, for
instance, using an optical microscope. When the coloration of the fibers is
observed
to be substantially even through the thickness or across the cross-sectional
area of
the fibers, one has confirmed that the dye is substantially evenly distributed
through
the thickness or across the cross-sectional area of the fiber.
[0012] The textile material described above can contain other fibers in
addition
to the polyphenylene sulfide fibers. In such embodiments, the textile material
can
further comprise any suitable natural fiber or synthetic fiber or combination
of natural
fibers and/or synthetic fibers. These additional fibers can be intimately
blended with
the polyphenylene sulfide fibers within the textile material. For example, the
textile
material can be a yarn in which the polyphenylene sulfide fibers are
intimately
blended with, for example, cellulosic fibers. Alternatively, the additional
fibers and
the polyphenylene fibers can be present in separate elements within the
textile
material. For example, the textile material can comprise a first yarn
containing the
polyphenylene sulfide fibers and a second yarn containing, for example,
cellulosic
fibers.
[0013] As noted above, the textile material can comprise any suitable
natural
or synthetic fiber(s) in addition to the polyphenylene sulfide fibers. In a
preferred
embodiment, the textile material further comprises cellulose fibers. The
cellulose
fibers used in such an embodiment can be natural cellulose fibers (e.g.,
cotton
fibers), regenerated cellulose fibers, or any combination thereof. Suitable
regenerated cellulose fibers include, but are not limited to, rayon fibers
(e.g., viscose
6
rayon fibers, high wet modulus rayon fibers, modal fibers, and polynosic
fibers),
lyocell fibers, and mixtures thereof.
[0014] When the textile material comprises cellulose fibers, the textile
material
can further comprise a flame retardant that is added to improve the flame
resistance
of the cellulose fibers and the textile material containing the same. In such
embodiments, any suitable flame retardant can be used. Preferably, the flame
retardant is a phosphorus-based flame retardant, such as the flame retardants
based
on tetrahydroxymethlphosphonium salts and condensates thereof. Suitable
examples of such flame retardants include, but are not limited to, those flame
retardants described in U.S. Patent No. 7,713,891; U.S. Patent No. 8,012,890;
U.S.
Patent No. 8,012,891; U.S. Patent No. 8,722,551; U.S. Patent No. 9,091,020;
U.S.
Patent No. 9,453,112; and U.S. Patent Application Publication No. US
2015/0118931
Al.
[0015] The textile material can also comprise synthetic fibers in addition
to the
polyphenylene sulfide fibers, such as thermoplastic synthetic fibers and/or
inherent
flame resistant fibers. Suitable thermoplastic synthetic fibers include, but
are not
necessarily limited to, polyester fibers (e.g., poly(ethylene terephthalate)
fibers,
poly(propylene terephthalate) fibers, poly(trimethylene terephthalate)
fibers),
poly(butylene terephthalate) fibers, and blends thereof), polyamide fibers
(e.g., nylon
6 fibers, nylon 6,6 fibers, nylon 4,6 fibers, and nylon 12 fibers), polyvinyl
alcohol
fibers, and combinations, mixtures, or blends thereof. Preferably, the
thermoplastic
synthetic fibers are selected from the group consisting of polyester fibers,
polyamide
fibers, and mixtures thereof.
[0016] When the textile material comprises thermoplastic synthetic fibers,
the
textile material can further comprise a flame retardant that is added to
improve the
flame resistance of the thermoplastic synthetic fibers and the textile
material
containing the same. Any flame retardant suitable for use with thermoplastic
synthetic fibers can be used in such embodiments.
[0017] As utilized herein, the term "inherent flame resistant fibers"
refers to
synthetic fibers which, due to the chemical composition of the material from
which
they are made, exhibit flame resistance without the need for an additional
flame
retardant treatment. In such embodiments, the inherent flame resistant fibers
can be
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any suitable inherent flame resistant fibers, such as polyoxadiazole fibers,
polysulfonamide fibers, poly(benzimidazole) fibers, aramid fibers (e.g., meta-
aramid
fibers and para-aramid fibers), polypyridobisimidazole fibers,
polybenzylthiazole
fibers, polybenzyloxazole fibers, melamine-formaldehyde polymer fibers, phenol-
formaldehyde polymer fibers, oxidized polyacrylonitrile fibers, polyamide-
imide fibers
and combinations, mixtures, or blends thereof. In a preferred embodiment, the
textile material comprises aramid fibers in addition to the polyphenylene
sulfide
fibers.
[0018] The textile materials described above are believed to be well-suited
for
use in applications where the textile material must meet certain requirements
for
flame resistance. For example, the textile material can be a fabric used in
the
manufacture of curtains or window treatments, which fabric should meet the
most
stringent requirements of NFPA 701. The textile material can also be used in
the
manufacture of upholstery and furniture fabrics, automotive fabrics (e.g.,
woven, knit,
or nonwoven textiles used in automotive applications), aircraft interiors,
etc.
[0019] In a second embodiment, the invention provides a method for dyeing
polyphenylene sulfide fibers. The method generally comprises the steps of: (a)
providing a textile material comprising polyphenylene sulfide fibers; (b)
providing a
dye liquor comprising a liquid medium and a disperse dye; (c) applying the dye
liquor
to the textile material; (d) heating the textile material under ambient
atmosphere to a
temperature sufficient to evaporate substantially all of the liquid medium
from the
textile material; and (e) heating the textile material under ambient
atmosphere to a
temperature sufficient to fix the disperse dye to the polyphenylene sulfide
fibers.
[0020] The textile material utilized in the method can be any suitable
textile
material comprising polyphenylene sulfide fibers, such as any of the textile
materials
described above.
[0021] As noted above, the dye liquor comprises a liquid medium and a
disperse dye. The liquid medium can be any liquid medium suitable for use with
disperse dyes. Typically, the liquid medium is an aqueous medium, such as
water.
The liquid medium can comprise a surfactant or wetting agent in order to
improve
wetting of the polyphenylene sulfide fibers with the dye liquor. In a
preferred
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embodiment, the dye liquor has a pH of about 4 to about 7.5, more preferably
about
to about 7.
[0022] The disperse dye present in the dye liquor can be any of the
disperse
dyes discussed above in connection with the textile material of the invention.
In a
preferred embodiment, the dye liquor further comprises a volatile organic acid
having
a boiling point of about 100 C to about 170 C. Suitable examples of such
volatile
organic acids include, but are not limited to, acetic acid, formic acid,
propionic acid,
butyric acid, and mixtures thereof. While not wishing to be bound to any
particular
theory, it is believed that such volatile organic acids improve the color
yield of the
dyeing process, especially when the dye is fixed at temperatures of 180 C or
more.
Further, with a boiling point of 100 C to 170 C, it is believed that the
organic acid
vaporizes during the dye fixation step and does not leave any harmful residue
on the
fibers.
[0023] In a preferred embodiment, the dye liquor further comprises a dye
carrier. Suitable dye carriers include, but are not limited to, propylene
glycol,
ethylene glycol, dipropylene glycol, tripropylene glycol, diethylene glycol,
triethylene
glycol, benzoic acid, triethanolamine, polyethylene oxide, polyethylene
glycol,
copolymers of ethylene oxide and propylene oxide, and mixtures thereof. While
not
wishing to be bound to any particular theory, it is believed that such dye
carriers can
assist in dye solubilization and/or dye penetration and diffusion into the
polyphenylene sulfide fibers.
[0024] The dye liquor can be applied to the textile material in any
suitable
fashion and using any suitable apparatus. Typically, the textile material is
passed
through a bath of the dye liquor so that it is saturated with the dye liquor.
Upon
exiting the bath, the textile material can be passed through one or more nip
rollers,
which apply pressure to the textile material and remove excess dye liquor
before the
drying step. Alternatively, the dye liquor can be sprayed directly onto the
surface of
the textile material.
[0025] Following application of the dye liquor, the textile material is
heated
under ambient atmosphere to a temperature sufficient to evaporate
substantially all
of the liquid medium (and any volatile organic acid and/or dye carrier in the
dye
liquor) from the textile material. The textile material can be heated to any
suitable
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temperature in this step. Preferably, the textile material is heated to a
temperature
greater than 40 C, more preferably 100 C, 130 C, or 140 C.
[0026] Following the drying step, the textile material is heated to a
temperature sufficient to fix the dye in the polyphenylene sulfide fibers.
This dye
fixation step preferably is performed under ambient atmosphere, meaning that
the
step is not performed in a closed system under elevated pressure. The textile
material can be heated to any suitable temperature in order to fix the dye.
Preferably, the textile material is heated to a temperature of 160 C or more.
More
preferably, the textile material is heated to a temperature of about 180 C or
more or
about 190 C or more. The textile material preferably is not heated to a
temperature
greater than 260 C because such temperatures have been observed to cause
adverse dye degradation. In a preferred embodiment, the textile material is
heated
to a temperature of about 180 C to about 260 C, more preferably about 190 C
to
about 240 C.
[0027] Following the dye fixation step, the textile material can be
further
treated in order to remove and/or neutralize any unfixed disperse dye that
remains
on the textile material. Thus, in a preferred embodiment, the method described
above further comprises the step of treating the textile material from step
(e) with a
caustic solution to remove or neutralize unfixed disperse dye on the textile
material.
The textile material can be treated with the caustic solution in any suitable
manner.
For example, the textile material can be immersed in a bath of the caustic
solution
(maintained at a temperature of 40 C to about 80 C) for a sufficient amount
of time
to remove and/or neutralize the unfixed dye. Alternatively, the textile
material can be
impregnated with the caustic solution and then steamed. The caustic solution
preferably comprises a reducing agent that is capable of reducing any unfixed
disperse dye to an uncolored form. Suitable reducing agents include, but are
not
limited to, sodium bisulfite. Following treatment with the caustic solution as
described above, the textile material is then washed in water to remove the
dye
residues and dried.
[0028] When the textile material comprises other fibers in addition to the
polyphenylene sulfide fibers, the method described above can be modified in
order
to dye the additional fibers. For example, when the textile material comprises
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cellulose fibers in addition to the polyphenylene sulfide fibers, the dye
liquor can
further comprise one or more vat dyes, which will dye the cellulose fibers.
The
method can also be preceded or succeeded by a series of steps that dye the
additional fibers. For example, when the textile material comprises polyester
fibers,
the textile material can be jet dyed using disperse dyes in order to impart
the desired
color and shade to the polyester fibers. In such an embodiment, the textile
material
can be jet dyed before or after dyeing in accordance with the method described
above. Alternatively, the polyester fibers and the polyphenylene sulfide
fibers can be
dyed simultaneously using the method described above using one or more
suitable
disperse dyes. In such an embodiment, one can select a single disperse dye
having
the appropriate properties to dye both the polyphenylene sulfide fibers and
the
polyester fibers, or one can use a mixture of disperse dyes, at least one of
which
possesses the appropriate properties (as described above) to dye the
polyphenylene
sulfide fibers.
[0029] The following examples further illustrate the subject matter
described
above but, of course, should not be construed as in any way limiting the scope
thereof.
EXAMPLE 1
[0030] This example demonstrates the production of textile materials
according to the invention.
[0031] Dye liquors were produced using the components listed in Table 1
below.
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Table 1. Composition of dye liquors.
Dye Liquor 1 Dye Liquor 2 Dye Liquor 3 Dye Liquor 4
% propylene 10 % propylene 10 % propylene 10 % propylene
glycol glycol glycol glycol
1% Triton X-705 1% Triton X-705 1% Triton X-705 1% Triton X-705
87.5% di water 87.5% di water 87.5% di water 87.5% di water
1% Navy C2G 1% Qualsperse 1% Qualsperse 1% Yellow GWL
Rubine 3BSK Blue BNS
0.5% acetic acid 0% acetic acid 0.5% acetic acid 0.5% acetic acid
pH = 3.2 pH = 5.5 pH = 3.3 pH = 3.3
Navy C2G is a mixture containing C.I. Disperse Blue 291 and a minor amount of
an
orange disperse dye. Disperse Blue 291 is an azo dye containing two nitro
groups.
The molar mass of Disperse Blue 291 is 509 g/mol. Qualsperse Rubine 3BSK is a
commercially available version of al. Disperse Red 167. Disperse Red 167 is an
azo dye containing a nitro group. Disperse Red 167 has a molar mass of 505.9
g/mol, a boiling point of 713 C, and a flash point of 385 C. Qualsperse Blue
BNS is
a water dispersion of CA. Disperse Blue 60. Disperse Blue 60 is an
anthraquinone
dye having a molar mass of 379 g/mol, a boiling point of 681 C, and a flash
point of
363 C. Terasil Yellow GWL is a water dispersion of C.I. Disperse Yellow 42.
Disperse Yellow 42 is a diphenylamine dye containing a nitro group. Disperse
Yellow 42 has a molar mass of 369 g/mol, a boiling point of 548 C, and a
flash point
of 285 C.
[0032] Several pieces of a polyphenylene sulfide nonwoven textile material
were impregnated with a dye liquor containing approximately 1% by weight of
the
disperse dye described in Table 1. The wet pick-up of the dye liquor was
approximately 50% owf. After impregnation with the dye liquor, the nonwoven
textile
materials were dried at a temperature of approximately 120 C (250 F) to
remove
water and then placed in a lab convection oven set at (215 C) 420 F. The
nonwoven textile materials were left in the oven for approximately 6 minutes.
[0033] After heating, the nonwoven textile materials were then immersed in
an
aqueous solution containing 3% sodium hydroxide and 6% sodium bisulfite. The
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aqueous solution was maintained at a temperature of approximately 60 C, and
the
nonwoven textile materials were left in the solution for approximately 20
minutes.
The nonwoven textile materials were then rinsed with water several times and
immersed in a 5% hydrogen peroxide solution. The hydrogen peroxide solution
was
maintained at a temperature of approximately 50 C, and the nonwoven textile
materials were left in the solution for approximately 10 minutes. After
treatment with
the hydrogen peroxide solution, the nonwoven textile materials were then
rinsed with
water several times and finally dried at a temperature of approximately 120 C
(250
F).
[0034] The dyeing procedure described above was repeated on similar
nonwoven textile materials using similar dye liquors containing other disperse
dyes.
These disperse dyes are listed and described in Table 2 below. Table 2 also
includes the properties for some of the dyes used in making Dye Liquors 1-4.
Table 2. Disperse dyes used in treating nonwoven materials and their molar
masses
(in g/mol), boiling points (in C), and flash points (in C).
Disperse Molar F.P.B.P.
Light
Chemical structure
dyes mass fastness
i=-='WH2)`2C R3
\
Disperse 412 0 4
Red 356 ==0
111,114 0
õ
Disperse
505.9 713.2 385.1 ¨ 4
ki
Red 167 w-tt
C
Oa 0 --tr '
Disperse
376 625 332 r X'sj 3
Blue 77
OH 0 OH
Disperse
Orange 450 645 344 v*-0-44 f,NP'SPOODI: 4
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Disperse Molar
B.P.F.P. Light
Chemical structure
dyes mass fastness
Disperse * . C.WAVIW,
Orange 382.8 663 355 0.ft ¨ 4
44
.9
Disperse Aky,,oPiaWi
355 638 340 1 3.5
Red 91 = .
8 CAi
i70.2 Ktre' H
= 1
Disperse A.:1
376 625 332 1.31 3
Blue 77
H 0 OH
H
N
Disperse ,J1
420 681 366 --- 3
Blue 27 11:., k
OH 0 OH
N H ,
Disperse
379 677 363 yio..1-12),(3cH3
3
Blue 60
NH, 0
e =
Disperse
365 510 262 4
Yellow 86 (f:µ
ocA,
N
Disperse
369 548 285 Hsc02"1"4H 3
Yellow 42
[0035] The
nonwoven textile materials dyed using the procedure described
above exhibit excellent coloration. The polyphenylene sulfide fibers in the
nonwoven
showed a uniform coloration throughout the cross-section of the fibers, which
is
indicative of high color yield and excellent dye fixation. The dyed nonwoven
textile
materials also showed virtually no color loss after 5 washes. Further, the
lightfastness of the dyed nonwoven textile materials was measured in
accordance
with AATCC Test Method 16.3, which is entitled "Colorfastness to Light: Xenon-
Arc."
In particular, the lightfastness of dyed nonwoven textile materials was
measured
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after 20 hours of exposure to the xenon lamp. The results of these
measurements
for several disperse dyes are set forth in Table 2 above.
[0036] Knit fabrics made using a filament polyphenylene sulfide fiber were
dyed in accordance with the procedure described above using some of the dye
liquors described above. These dyed knit fabrics exhibited similar properties
to the
dyed nonwoven textile materials.
EXAMPLE 2
[0037] This example demonstrates the production of a textile material
according to the invention.
[0038] Polyphenylene sulfide fibers and cotton fibers were blended and
spun
together to yield a 20 count single ply yarn. The yarn contained 65%
polyphenylene
sulfide fibers and 35% cotton fibers. Several of these yarns were then woven
together to produce a 3x1 twill fabric having fabric weight of approximately
203 g/m2
(6 oz/yd2). The fabric was then impregnated with an aqueous dye liquor
containing a
mixture of vat dyes (to dye the cotton) and a mixture of disperse dyes (to dye
the
polyphenylene sulfide fibers). The composition of the dye liquor is set forth
in Table
3 below.
Table 3. Dye liquor composition.
Component Amount (g/L)
Lumachrom Orange SCZ (C.I. Disperse Orange 30) 5.0
Qualsperse Rubine 3BSK (Cl. Disperse Red 167) 2.1
Qualsperse Blue BNS (C.I. Disperse Blue 60) 4.5
Antimigrant HC-M1 21
Acetic acid 1.5
Yellow PG (Vat dye) 6.6
Roycevat Brown BR (vat dye) 4.6
Olive TM (Vat dye) 5.3
Water Balance of each liter
15
Following immersion in the dye liquor, the fabric was dried at approximately
120 C (250 F)
for approximately 3 minutes to remove the water. The fabric was then placed in
a lab
convection oven set at (215 C) 420 F. The fabric was left in the oven for
approximately 5
minutes. The fabric was then cooled.
[0039] The fabric was next immersed in an aqueous solution containing 3%
sodium
hydroxide and 6% sodium bisulfite. The fabric was then placed in a saturated
steamer for
approximately 3 minutes, followed by rinsing in hot water and immersion in a
6% hydrogen
peroxide solution. The fabric was lastly rinsed in hot water.
[0040] The resulting fabric had a bright orange color with uniform color
appearance.
The dyed fabric also exhibited good crocking fastness (dry crocking rating of
4-5),
lightfastness, and washfastness.
[0041] All references, including publications, patent applications, and
patents, cited
herein to the same extent as if each reference were individually and
specifically indicated to
be set forth in its entirety herein.
[0042] The use of the terms "a" and "an" and "the" and similar referents
in the
context of describing the subject matter of this application (especially in
the context of the
following claims) are to be construed to cover both the singular and the
plural, unless
otherwise indicated herein or clearly contradicted by context. The terms
"comprising,"
"having," "including," and "containing" are to be construed as open-ended
terms (i.e.,
meaning "including, but not limited to,") unless otherwise noted. Recitation
of ranges of
values herein are merely intended to serve as a shorthand method of referring
individually
to each separate value falling within the range, unless otherwise indicated
herein, and each
separate value is incorporated into the specification as if it were
individually recited herein.
All methods described herein can be performed in any suitable order unless
otherwise
indicated herein or otherwise clearly contradicted by context. The use of any
and all
examples, or exemplary language (e.g., "such as") provided herein, is intended
merely to
better illuminate the subject matter of the application and does not pose a
limitation on the
scope of the subject matter unless otherwise claimed. No language in the
Date Recue/Date Received 2020-12-11
CA 03042500 2019-05-01
WO 2018/085037
PCT/US2017/056894
16
specification should be construed as indicating any non-claimed element as
essential to the practice of the subject matter described herein.
[0043] Preferred embodiments of the subject matter of this application are
described herein, including the best mode known to the inventors for carrying
out the
claimed subject matter. Variations of those preferred embodiments may become
apparent to those of ordinary skill in the art upon reading the foregoing
description.
The inventors expect skilled artisans to employ such variations as
appropriate, and
the inventors intend for the subject matter described herein to be practiced
otherwise
than as specifically described herein. Accordingly, this disclosure includes
all
modifications and equivalents of the subject matter recited in the claims
appended
hereto as permitted by applicable law. Moreover, any combination of the above-
described elements in all possible variations thereof is encompassed by the
present
disclosure unless otherwise indicated herein or otherwise clearly contradicted
by
context.
