Water-free fabric dyeing process and dye compositions

Abstract

A non-aqueous fabric dyeing method using a non-aqueous dyeing composition is described. The dyeing composition is a fluid at room temperature; contains no more than 5% water, no more than 5% VOCs and no more than 2.5% by weight vinyl monomers. The dye composition includes an organic dye that is solid at temperatures up to 130° C. and which sublimes or boils at 130 to 220° C., and further includes a carrier that is a liquid in the temperature range of 130 to 220° C.

Claims

1. A fabric dyeing process comprising the steps of: A. at a temperature of 10 to 100° C., applying a fluid dye composition using a non-immersive method to at least one surface of a fabric at an application weight of 2.5 to 250 grams of the dye composition per square meter of fabric, wherein the dye composition comprises a) a carrier phase that is liquid in the temperature range of 20° C. to 220° C.; said carrier phase having dissolved or suspended therein b) 2.5 to 300 grams, per liter of the dye composition, of at least one organic dye that is solid at temperatures below 130° C. and has a sublimation or boiling temperature of 130° C. to 220° C., and B. curing the dye composition by heating the fabric with the applied dye composition to a temperature at least equal to the boiling or sublimation temperature of the at least one organic dye for a period of at least 30 seconds, such that the dye boils or sublimes and at least a portion thereof penetrates into the fabric, wherein the dye composition contains no more than 5% by weight water, no more than 5% by weight of volatile organic compounds and no more than 2.5% by weight of vinyl monomers, and the dye composition has a viscosity of at least 50 centistokes to at most 5000 centistokes at 25° C., wherein in step A the fabric is moved continuously through a dye application station where the dye composition is applied to the fabric and the dye is applied with a gravure coater.

2. The fabric dyeing process of claim 1 wherein in step B the fabric is moved continuously through a heating station where the fabric with the applied dye composition is heated to a temperature of 140 to 220° C. for a period of at least 30 seconds.

3. The process of claim 1 wherein in step A the dye composition is applied at a coating weight of 5 to 50 grams/square meter.

4. The process of claim 1 wherein in step A a first dye composition is applied to a portion of a surface of the fabric and a second dye composition is applied to a different portion of the same surface of the fabric and in step B the first and second dye compositions are simultaneously cured.

5. The process of claim 4 wherein the first and second dye compositions have different colors after curing.

6. The process of claim 1 wherein in step A a first dye composition is applied to one surface of the fabric, a second dye composition is applied to an opposing surface of the fabric and in step B the first and second dye compositions are simultaneously cured.

7. The process of claim 6 wherein the first and second dye compositions have different colors after curing.

8. The process of claim 1 further comprising, after step B, applying a hydrophobic fabric treatment to the fabric.

9. The process of claim 1 wherein the carrier includes at least one poly(dimethylsiloxane) which at 25° C. is a liquid at having a viscosity of at least 50 centistokes and the poly(dimethylsiloxane) constitutes at least 10% by weight of the dye composition.

10. The process of claim 9 wherein the dye composition further comprises an organic thickener.

11. The process of claim 9 wherein the dye composition further comprising a carboxylic acid ester having a molecular weight of up to 1000 and a flash point of at least 120° C. as determined by the ASTM D92 open cup method, wherein the carboxylic acid ester is i) a C.sub.1-4 alkyl ester of a C.sub.12-24 linear or branched alkyl, alkenyl or polyalkenyl carboxylic acid, ii) a fatty acid mono-, di- or triglyceride, or a mixture of i) and ii).

12. A fabric dyeing process comprising the steps of: A. at a temperature of 10 to 100° C., applying a fluid dye composition using a non-immersive method to at least one surface of a fabric at an application weight of 2.5 to 250 grams of the dye composition per square meter of fabric, wherein the dye composition comprises a) a carrier phase that is liquid in the temperature range of 20° C. to 220° C.; said carrier phase having dissolved or suspended therein b) 2.5 to 300 grams, per liter of the dye composition, of at least one organic dye that is solid at temperatures below 130° C. and has a sublimation or boiling temperature of 130° C. to 220° C., and B. curing the dye composition by heating the fabric with the applied dye composition to a temperature at least equal to the boiling or sublimation temperature of the at least one organic dye for a period of at least 30 seconds, such that the dye boils or sublimes and at least a portion thereof penetrates into the fabric, wherein the dye composition contains no more than 5% by weight water, no more than 5% by weight of volatile organic compounds and no more than 2.5% by weight of vinyl monomers, and the dye composition has a viscosity of at least 50 centistokes to at most 5000 centistokes at 25° C., wherein in step A the fabric is moved continuously through a dye application station where the dye composition is applied to the fabric, the fabric with applied dye composition is formed into a roll, and step B is performed on the roll in a closed vessel.

13. The process of claim 12 wherein during at least a portion of step B the closed vessel is pressurized with a non-liquified gas to a gauge pressure of 350 to 7,000 kPa.

Description

EXAMPLE 1

(1) A fluid dye composition is prepared by mixing, in a laboratory mixer, 2 parts of an anthraquinone dye (Red 70027 from Continental Red), 30 parts of 1000 cst poly(dimethylsiloxane) (PDMS), 8 parts of guar gum, and 1.5 parts of isopropyl myristate. This fluid dye composition is then used to dye a high tenacity (HT) woven polyester fabric. HT fabric is one of the hardest fabrics to dye using conventional, water-based dyeing. Additionally, it is well known in the art that red dyes tend to be the most difficult dyes to use due to increased crocking and colorfast issues.

(2) The polyester fabric is mounted on a tenter frame, being secured on the selvage on each side by pins on the tenter frame. The so-mounted fabric is then pulled past a dye application station at which the fluid dye composition is poured onto the fabric just upstream of a knife-and-roller type knife blade apparatus. The knife blade apparatus is

(3) adjusted to gauge the coating weight to 30 to 60 grams per square meter. The coating is performed at 25±3° C. A uniform coating of the fluid dye composition is applied across the width of the fabric. Importantly, at the time of application, the fluid dye composition does not pass through the fabric at the coating station and contact the underlying roller.

(4) The tenter frame then transports continuously the fabric with applied fluid dye composition into a multi-zone, atmospheric oven under air, without any intervening processing steps (such as padding, drying, washing, etc). The zone temperatures are set at 195° C. with a final zone at 210° C. The line speed is selected such that the residence time in the 195° C. zones of the zone is 4 minutes, and the residence time in the 210° C. zone is one minute.

(5) The fluid dye composition cures in the 195° C. zones of the oven. In the 210° C. zone of the oven, residual dyestuff residing on the surface of the fabric is thermally removed. This eliminates any dry crocking issues and also removes the need for rinsing before a subsequent hydrophobic treatment is applied. The fabric is then cooled and rolled up with no further processing (in particular, without rinsing or washing) prior to applying a hydrophobic treatment.

(6) Even though the fluid dye composition does not penetrate through the fabric during the initial application step, the cured fabric is dyed on both sides with no detectable shade difference between front and back.

(7) A hydrophobic treatment is applied to the dyed fabric. The hydrophobic treatment includes a mixture of octadecyl acrylate, 1,6-hexanediol diacrylate, dipentaerythritol penta/hexa acrylate, lauroyl acrylate and a polydimethylsiloxane. The DWR treatment applied 15 gsm (grams per sq meter) of chemistry. The hydrophobic treatment is applied to each side of the fabric at a coating weight of 15 grams per square meter using a gravure roller. The coated fabric is rolled onto a beam and then cured under 500 psi (3.447 MPa) pressure of nitrogen at 100° C. for 30 min, following the procedure outlined in U.S. Pat. No. 9,902,874.

(8) The dyed fabric is evaluated for color fastness to crocking (wet and dry) according to AATCC 8; color fastness to water according to ISO 105-E01, color fastness to washing according to AATCC 6121), color fastness to perspiration (acid and alkaline) according to ISO 105-E04, and appearance after washing for 25 washes according to LTD-37. Results are as indicated in Table 1. Industry standards are indicated in the “Requirements” column for reference.

(9) The water repellency performance and the laundry durability of the DWR treatment applied after the water-free dye process is also tested using the AATCC 22 Spray Test (scale 0 to 100) and the Bundesmann ISO 9865 water repellency test (scale 1-5). Industry “best practices” call for an ISO 9865 rating of 2.5 after 3 washes. There is no standard for more than 3 washes because no previous DWR process can provide an ISO 9865 rating beyond 1 for more than 3 washes. The results show high performance (at least a 2.5 rating) through 10 washes and even beyond. All conventionally dyed fabrics with subsequent DWR treatment fail the ISO 9865 test at 5 or higher washes.

(10) TABLE-US-00001 TABLE 1 Test Standard Requirement Test Result CF to crocking Dry 4.0 4.5 (AATCC 8) Wet 3.0 4.5 CF to water Color change 4.0 4.5 (ISO 105-E01) Color Acetate 3.5 4.5 staining Cotton 4.5 Nylon 4.5 Polyester 4.5 Acrylic 4.5 Wool 4.5 CF to Color change 4.0 4.5 washing Color Acetate 3.5 4.5 (AATCC staining Cotton 4.5 61-2A) Nylon 4.5 Polyester 4.5 Acrylic 4.5 Wool 4.5 CF to Color change 4.0 4.5 perspiration Color Acetate 3.5 4.5 (ISO 105-E04) staining Cotton 4.5 Acid Nylon 4.5 Polyester 4.5 Acrylic 4.5 Wool 4.5 CF to Color 4.0 4.5 perspiration change (ISO 105-E04) Color Acetate 3.5 4.5 Alkaline staining Cotton 4.5 Nylon 4.5 Polyester 4.5 Acrylic 4.5 Wool 4.5 Appearance  5 washes 4.0 4.5 after repeated 10 washes 4.0 4.0 home 15 washes 4.0 4.0 laundering 20 washes 4.0 4.0 (LTD-37) 25 washes 4.0 4.0

(11) The water repellency performance and the laundry durability of the DWR treatment applied after the water-free dye process is also tested using the AATCC 22 Spray Test (scale 0 to 100) and the Bundesmann ISO 9865 water repellency test (scale 1-5). Industry “best practices” call for an ISO 9865 rating of 2.5 after 3 washes. There is no standard for more than 3 washes because no previous DWR process can provide an ISO 9865 rating beyond 1 for more than 3 washes. The results show high performance (at least a 4.2 rating) through 10 washes with a 100 spray rating on the AATCC 22 Spray Test, with 12-13 mL of water passing through the fabric. Conventionally dyed fabrics with subsequent DWR treatment fail the ISO 9865 test at 5 or higher washes.

(12) In specific embodiments, the invention is:

(13) 1. A fabric dyeing process comprising the steps of:

(14) A. at a temperature of 10 to 100° C., applying a fluid dye composition using a non-immersive method to at least one surface of a fabric at an application weight of 2.5 to 250 grams of the dye composition per square meter of fabric, wherein the dye composition comprises a) a carrier phase that is liquid in the temperature range of 20° C. to 220° C.; said carrier phase having dissolved or suspended therein b) 2.5 to 300 grams, per liter of the dye composition, of at least one organic dye that is solid at temperatures below 130° C. and has a sublimation or boiling temperature of 130° C. to 220° C., and

(15) B. curing the dye composition by heating the fabric with the applied dye composition to a temperature at least equal to the boiling or sublimation temperature of the at least one organic dye for a period of at least 30 seconds, such that the dye boils or sublimes and at least a portion thereof penetrates into the fabric, wherein the dye composition contains no more than 5% by weight water, no more than 5% by weight of volatile organic compounds and no more than 2.5% by weight of vinyl monomers, and the dye composition has a viscosity of at least 50 centistokes to at most 5000 centistokes at 25° C.

(16) 2. A fabric dyeing process as in embodiment 1 wherein the dye composition contains no more than 10% of chemicals that are water-miscible.

(17) 3. A fabric dyeing process as in embodiment 1 or 2 wherein in step A the fabric is moved continuously through a dye application station where the dye composition is applied to the fabric.

(18) 4. A fabric dyeing process as in any of embodiments 1-3 wherein in step B the fabric is moved continuously through a heating station where the fabric with the applied dye composition is heated to a temperature of 140 to 220° C. for a period of at least 30 seconds.

(19) 5. A fabric dyeing process as in embodiment 4 wherein in step B the fabric is affixed at opposing edges to a tenter frame, which tenter frame moves the fabric continuously through the heating station.

(20) 6. A fabric dyeing process as in any preceding embodiment wherein in step B the fabric is unsupported from beneath and no mechanical pressure is applied to a top surface of the fabric.

(21) 7. A fabric dyeing process as in any preceding embodiment wherein in step A the dye is applied with a gravure coater.

(22) 8. A fabric dyeing process as in any of embodiments 1-3 wherein the fabric with applied dye composition is formed into a roll, and step B is performed on the roll in a closed vessel.

(23) 9. A fabric dyeing process as in embodiment 8 wherein during at least a portion of step B the closed vessel is pressurized with a non-liquified gas to a gauge pressure of 350 to 7,000 kPa.

(24) 10. A fabric dyeing process as in any preceding embodiment wherein in step A the dye composition is applied at a coating weight of 5 to 50 grams/square meter.

(25) 11. A fabric dyeing process as in any preceding embodiment wherein the fabric prior to dyeing has an areal weight of 50 to 250 grams per square meter.

(26) 12. A fabric dyeing process as in any preceding embodiment wherein the fabric prior to dyeing has an air permeability of 0.472 to 23.6 L/s as measured according to ASTM D737, using a Textest FX 3300 instrument and a 38 cm.sup.2 test area.

(27) 13. A fabric dyeing process as in any preceding embodiment wherein in step A the dye composition is applied to only one surface of the fabric.

(28) 14. A fabric dyeing process as in any preceding embodiment wherein in step A a first dye composition is applied to a portion of a surface of the fabric and a second dye composition is applied to a different portion of the same surface of the fabric and in step B the first and second dye compositions are simultaneously cured.

(29) 15. A fabric dyeing process as in embodiment 14 wherein the first and second dye compositions have different colors after curing.

(30) 16. A fabric dyeing process as in any of embodiments 1-12 wherein in step A a first dye composition is applied to one surface of the fabric, a second dye composition is applied to an opposing surface of the fabric and in step B the first and second dye compositions are simultaneously cured.

(31) 17. A fabric dyeing process as in embodiment 16 wherein the first and second dye compositions have different colors after curing.

(32) 18. A fabric dyeing process as in any preceding embodiment wherein the fabric is a woven or knitted fabric.

(33) 19. A fabric dyeing process as in any preceding embodiment wherein the fabric is a polyester or polyamide fabric, or a blend of a polyester or polyamide with at least one other fiber.

(34) 20. A fabric dyeing process as in any preceding embodiment further comprising, after step B, applying a water-free hydrophobic fabric treatment to the fabric.

(35) 21. A fabric dyeing process as in any preceding embodiment wherein the organic dye is an anthroquinone or azo-type dye.

(36) 22. A fabric dyeing process as in any preceding embodiment wherein the dye composition contains 20 to 150 grams, per liter of the dye composition, of the at least one organic dye.

(37) 23. A fabric dyeing process as in any preceding embodiment wherein the carrier includes at least one poly(dimethylsiloxane) which at 25° C. is a liquid at having a viscosity of at least 50 centistokes and the poly(dimethylsiloxane) constitutes at least 10% by weight of the dye composition.

(38) 24. A fabric dyeing process as in embodiment 23 wherein the poly(dimethylsiloxane) constitutes at least 50% of the volume of the dye composition.

(39) 25. A fabric dyeing process as in embodiment 23 or 24 wherein the poly(dimethylsiloxane) has a viscosity of at least 100 cst at 25° C.

(40) 26. A fabric dyeing process as in embodiment 25 wherein the poly(dimethylsiloxane) has a viscosity of at least 300 cst at 25° C.

(41) 27. A fabric dyeing process as in any of embodiments 23-26 wherein the dye composition further comprises an organic thickener.

(42) 28. A fabric dyeing process as in embodiment 27 where in the thickener is selected from the group consisting of a polyacrylate polymer, guar gum, cellulose gum, xanthan gum, a cellulose ether, a cellulose ester, polyvinyl alcohol, a styrene-butadiene polymer and a polyurethane oligomer.

(43) 29. A fabric dyeing process as in any of embodiments 23-28 wherein the dye composition further comprising a carboxylic acid ester having a molecular weight of up to 1000 and a flash point of at least 120° C. as determined by the ASTM D92 open cup method.

(44) 30. A fabric dyeing process as in embodiment 29 wherein the carboxylic acid ester is i) a C.sub.1-4 alkyl ester of a C.sub.12-24 linear or branched alkyl, alkenyl or polyalkenyl carboxylic acid, ii) a fatty acid mono-, di- or triglyceride, or a mixture of i) and ii).

(45) 31. A fabric dyeing process as in embodiment 30 wherein the carboxylic acid ester is isopropyl myristate.

(46) 32. A fabric dyeing process as in embodiment 23 where the carrier includes at least 50 volume-% of the poly(dimethylsiloxane), 5 to 25 volume-% of a thickener and 1 to 25 volume-% of a carboxylic acid ester having a molecular weight of up to 1000 and a flash point of at least 120° C. as determined by the ASTM D92 open cup method.

(47) 33. A fabric dyeing process as in any of embodiments 23-32 wherein the carrier further comprises an ethoxylated nonionic surfactant.

(48) 34. A fluid dye composition comprising

(49) a) a carrier phase that is liquid in the temperature range of 20° C. to 220° C. and includes at least one poly(dimethylsiloxane) which at 25° C. is a liquid at having a viscosity of at least 50 centistokes; said carrier phase having dissolved or suspended therein

(50) b) 2.5 to 300 grams, per liter of the dye composition, of at least one organic dye that is solid at temperatures below 130° C. and sublimes and/or boils at a temperature of 130° C. to 210° C.,

(51) wherein the poly(dimethylsiloxane) constitutes at least 10% by weight of the dye composition and wherein the dye composition contains no more than 5% by weight water, no more than 5% by weight of volatile organic compounds and no more than 2.5% by weight of vinyl monomers, and the dye composition has a viscosity of at least 50 centistokes to at most 5000 centistokes at 25° C.

(52) 35. A fluid dye composition as in embodiment 34 wherein the organic dye is an anthroquinone or azo-based dye.

(53) 36. A fluid dye composition as in embodiment 34 or 35 wherein water constitutes no more than 1% of the volume of the dye composition.

(54) 37. A fluid dye composition as in any of embodiments 34-36 which contains 20 to 150 grams, per liter of the dye composition, of the at least one organic dye.

(55) 38. A fluid dye composition as in any of embodiments 34-37 wherein the poly(dimethylsiloxane) constitutes at least 50% of the volume of the dye composition.

(56) 39. A fluid dye composition as in any of embodiments 34-38 wherein the poly(dimethylsiloxane) has a viscosity of at least 100 cst at 25° C.

(57) 40. A fluid dye composition as in any of embodiments 34-39 wherein the poly(dimethylsiloxane) has a viscosity of at least 300 cst at 25° C.

(58) 41. A fluid dye composition as in any of embodiments 34-40, further comprising an organic thickener.

(59) 42. A fluid dye composition as in embodiment 41 where in the thickener is selected from the group consisting of a polyacrylate polymer, guar gum, cellulose gum, xanthan gum, a cellulose ether, a cellulose ester, polyvinyl alcohol, a styrene-butadiene polymer and a polyurethane oligomer.

(60) 43. A fluid dye composition as in any of embodiments 34-42, further comprising a carboxylic acid ester having a molecular weight of up to 1000 and a flash point of at least 120° C. as determined by the ASTM D92 open cup method.

(61) 44. A fluid dye composition as in embodiment 43 wherein the carboxylic acid ester is i) a C.sub.1-4 alkyl ester of a C.sub.12-24 linear or branched alkyl, alkenyl or polyalkenyl carboxylic acid, ii) a fatty acid mono-, di- or triglyceride, or a mixture of i) and ii).

(62) 45. A fluid dye composition as in embodiment 44 wherein the carboxylic acid ester is isopropyl myristate.

(63) 46. A fluid dye composition as in any of embodiments 34-45 where the carrier includes at least 50 weight-% of the poly(dimethylsiloxane), 5 to 25 weight-% of a thickener and 1 to 25 weight-% of a carboxylic acid ester having a molecular weight of up to 1000 and a flash point of at least 120° C. as determined by the ASTM D92 open cup method.

(64) 47. A fluid dye composition as in any of embodiments 34-46 wherein the carrier further comprises an ethoxylated nonionic surfactant.