PROCESS FOR THE TREATMENT OF LYOCELL FIBERS

Abstract

The present invention relates to a process for the treatment of lyocell fibers, comprising the step of contacting the fiber with at least one treatment medium, at least one treatment medium containing an amount of a crosslinking agent, wherein the cross-linking agent is capable of crosslinking cellulose under alkaline conditions and has a solubility in water at 20° C. of 20 g/l or less, and further comprising the step of treating the fiber with the cross-linking agent under alkaline conditions, characterized in that the cross-linking agent is added to the fiber in the form of a suspension or in solid form. The present invention also relates to lyocell fibers obtainable by the process of the present invention.

Claims

1. Process for the treatment of lyocell fibers, comprising the step of contacting the fiber with at least one treatment medium, at least one treatment medium containing an amount of a crosslinking agent, wherein the cross-linking agent is capable of crosslinking cellulose under alkaline conditions and has a solubility in water at 20° C. of 20 g/l or less, and further comprising the step of treating the fiber with the cross-linking agent under alkaline conditions, characterized in that in the step of contacting the fiber the cross-linking agent is present in the form of a suspension or in solid form.

2. Process according to claim 1, characterized in that contacting the fiber with the treatment medium comprises at least a first and a second contacting step.

3. Process according to claim 2, characterized in that in the first contacting step a first treatment medium and in the second contacting step a second treatment medium are employed, wherein the compositions of the first treatment medium and the second treatment medium are different.

4. Process according to claim 3, characterized in that the first treatment medium contains a majority of the total amount of the crosslinking agent employed.

5. Process according to claim 3, characterized in that the first treatment medium is an aqueous suspension of the crosslinking agent.

6. Process according to claim 3, characterized in that at least one of the first and the second treatment media is alkaline.

7. Process according to claim 6, characterized in that only the second treatment medium is alkaline.

8. Process according to claim 1, characterized in that the temperature of the contacting step is from 10° C. to 50° C.

9. Process according to claim 1, characterized in that the temperature of the step of treating the fiber with the crosslinking agent is higher than that of the contacting step, preferably 60° C. to 120° C., more preferably 80° C. to 110° C.

10. Process according to claim 1, characterized in that the step of treating the fiber with the cross-linking agent is performed in the presence of steam.

11. Process according to claim 10, characterized in that the step of treating the fiber with the cross-linking agent is performed in a steam chamber.

12. Process according to claim 1, characterized in that the fiber is present in the form of a tow.

13. Process according to claim 1, characterized in that the process is carried out in a continuous way.

14. Process to claim 1, characterized in that the steps of contacting and treating the fiber are performed with the fiber being in never-dried form.

15. Process according to claim 1, characterized in that the crosslinking agent is essentially soluble at a pH-value of 13 or more.

16. Process according to claim 1, characterized in that the crosslinking agent is p-[(4,6-dichloro-1,3,5-triazin-2-yl)amino]benzenesulfonic acid and/or a salt thereof.

17. Lyocell fiber obtainable by a process according to claim 1, characterized in that it exhibits a wet abrasion value of 200 revolutions or more and, after having been blended for a time period of 9 minutes, exhibiting a Canadian Standard Freeness value in ml CSF of at least 80% of the Canadian Standard Freeness value in ml CSF of the fiber before having been blended.

18. Lyocell fiber according to claim 17, characterized in that it exhibits a wet abrasion value of 400 revolutions or more.

19. Lyocell fiber according to claim 17, characterized in that it exhibits a Canadian Standard Freeness value in ml CSF of at least 85% of the Canadian Standard Freeness value in ml CSF of the fiber before having been blended.

20. Lyocell fiber according to claim 17, characterized in that it is crosslinked with p-[(4,6-dichloro-1,3,5-triazin-2-yl)amino]benzenesulfonic acid and/or a salt thereof.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 is a UV-photomicrograph of lyocell fibers after having been contacted with a crosslinking agent according to the present invention.

[0033] FIG. 2 is a UV-photomicrograph of lyocell fibers after having been contacted with a crosslinking agent according to the state of the art of EP 0 538 977.

DETAILED DESCRIPTION OF THE INVENTION

[0034] The present invention employs crosslinking agents which crosslink cellulose under alkaline conditions but are not or only poorly water-soluble at room temperature.

[0035] The chemical reaction of a crosslinking agent with cellulose can take place in two steps: In a first step, the crosslinking agents forms a first bond with the fiber with one of its functional groups.

[0036] In a second step, the crosslinking agent forms a second bond with the fiber with a further of its functional groups. By way of forming this second bond, the fibers or, respectively, the cellulose molecules within the fibers get bonded to each other, i.e. they are crosslinked.

[0037] Depending on the nature of the crosslinking agent, said first bond with the fiber can be formed under mild conditions (such as neutral pH-value), while for forming said second bond more harsh conditions (such as an alkaline pH-value) are necessary.

[0038] The present invention employs crosslinking agents which need alkaline conditions at least for forming said second bond with the fiber.

[0039] Furthermore, the present invention employs crosslinking agents which are not or only very poorly soluble in water at 20° C., i.e. having a solubility in water at 20° C. of 20 g/l or less.

[0040] Preferably, on the other hand, the crosslinking agent employed may have a certain small solubility in water at room temperature, such as 5 g/l or more.

[0041] A crosslinking agent fulfilling these conditions is p-[(4,6-dichloro-1,3,5-triazin-2-yl)amino]benzenesulfonic acid and/or the sodium salt thereof (SDTB). As mentioned above, according to EP 0 538 977, agents of this kind are applied to lyocell fiber in the form of an alkaline solution at elevated temperature. As also mentioned above, it was found that this way of treatment does not lead to satisfactory results.

[0042] In contrast thereto, it has been surprisingly shown that by applying a crosslinking agent as defined above to the lyocell fiber in the form of a suspension or in solid form, instead of being in solution, the object of the present invention can be achieved.

[0043] For the purposes of the present invention, a suspension means a mixture of the crosslinking agent with a liquid (such as, especially, water), wherein the crosslinking agent is dissolved to an extent of 50% at most.

[0044] Those who are skilled in the art know that impregnation of the fiber with a suspension of particles results in a non-uniform, punctual distribution of the chemical reagent on the surface of the fiber and would expect that this results in inhomogenous fiber properties.

[0045] Surprisingly it was found that in the case of the crosslinking agent as defined above, if the crosslinking agent is applied to the fiber in an aqueous suspension, i.e. if the treatment medium containing the crosslinking agent is an aqueous suspension of the same, the fibrillation protection of the Lyocell fiber is permanent and stable.

[0046] A preferred embodiment of the present invention is characterized in that contacting the fiber with the treatment medium comprises at least a first and a second contacting step.

[0047] Preferably, in the first contacting step a first treatment medium and in the second contacting step a second treatment medium are employed, wherein the compositions of the first treatment medium and the second treatment medium are different.

[0048] One of the two treatment media may contain a majority of the total amount of the crosslinking agent employed. Preferably, the first treatment medium contains the majority of the total amound of the crosslinking agent employed.

[0049] The concentration of the crosslinking agent in the treatment medium or said first and/or second treatment medium may range of from 5 to 200 g/l, especially in the case of SDTB.

[0050] The respective concentrations of the crosslinking agent in the first treatment medium and the second treatment medium may differ from each other. Especially, the concentration of the crosslinking agent in the first treatment medium may be higher than the concentration of the crosslinking agent in the second treatment medium.

[0051] The second treatment medium may contain no or no significant amount of crosslinking agent.

[0052] Preferably, the first treatment medium is an aqueous suspension of the crosslinking agent.

[0053] At least one of the first and the second treatment media may be alkaline.

[0054] Preferably, only the second treatment medium is alkaline.

[0055] The temperature of the contacting step may be from 10° C. to 50° C.

[0056] The conditions of the step of contacting the fiber with the crosslinking agent, especially the pH-value of the medium and/or the temperature, may be adjusted by the skilled artisan and should be selected such that the crosslinking agent is not dissolved or dissolved only to a small extent in the treatment solution. Thus, the fiber is impregnated with the crosslinking agent predominantly at its surface.

[0057] The step of treating the fiber with the crosslinking agent after having contacted the fiber means that the fiber and the crosslinking agent stay in contact for a certain time for the crosslinking reaction to take place. Depending on the conditions of the contacting step, part of the crosslinking reaction such as forming the said first bond with the cellulose fiber may already take place during the contacting step.

[0058] In the step of treating the fiber after having contacted the fiber with the crosslinking agent, the conditions may be such that the crosslinking agent is or becomes soluble. The conditions need to be chosen such that the crosslinking agent is capable of forming said second bond with the cellulose fiber.

[0059] Especially, the temperature of the step of treating the fiber with the crosslinking agent may be higher than that of the contacting step, preferably 60° C. to 120° C., more preferably 80° C. to 110° C.

[0060] In a preferred embodiment, the step of treating the fiber with the cross-linking agent is performed in the presence of steam.

[0061] Especially the step of treating the fiber with the cross-linking agent may be performed in a steam chamber, such as a J-box.

[0062] Exposing the fibers to hot conditions, especially to steam during the crosslinking reaction, is known per se.

[0063] It needs to be mentioned that the steps of contacting the fiber and treating the fiber need not to take place in different reagent vessel but might also take place in just one vessel, by stepwise changing of the conditions.

[0064] The present process can be applied to fibers both in cut form, i.e. staple fiber form and in form of endless filaments, i.e. in the form of a tow.

[0065] Preferably, the fiber is present in the form of a tow.

[0066] Furthermore, preferably the process is carried out in continuous way.

[0067] In a further preferred embodiment, the steps of contacting and treating the fiber are performed with the fiber being in never-dried form. The term “never-dried”, as known to the skilled artisan, means that the fiber has not yet undergone a drying step since its formation by being extruded from a spinneret.

[0068] The crosslinking agent employed according to the present invention is essentially soluble at a pH-value of 13 or more.

[0069] Accordingly, the step of treating the fiber with the crosslinking agent may preferably be carried out at a pH-value of 13 or more.

[0070] Preferably, the crosslinking agent is p-[(4,6-dichloro-1,3,5-triazin-2-yl)amino]benzenesulfonic acid and/or a salt thereof, especially the sodium salt thereof (SDTB).

[0071] It was found that by using a suspension of SDTB for contacting the fiber, the SDTB particles are located at the surface of the fiber, and do not penetrate into the fiber (see FIG. 1). During the step of crosslinking, by heating the impregnated fiber e.g. in a steamer, it is believed that the SDTB becomes soluble, thus forming a uniform crosslinked cellulosic fiber surface film which protects the fibrils from being split off. It was found that the uniform cross-linked surface results in homogenous fiber properties, such as dye uptake.

[0072] As mentioned above, it was found that lyocell fibers treated according to the process of the present invention exhibit stable fibrillation properties, i.e. both with regard to wet abrasion value (NSF) and CSF value.

[0073] Thus, the object of the present invention is also achieved by a lyocell fiber obtainable by a process according to the present invention, i.e. which is crosslinked with a crosslinking agent as defined above, and which is characterized in that it exhibits a wet abrasion value of 200 revolutions or more and, after having been blended for a time period of 9 minutes, exhibiting a Canadian Standard Freeness value in ml CSF of at least 80% of the Canadian Standard Freeness value in ml CSF of the fiber before having been blended.

[0074] Preferably, the lyocell fiber of the present invention exhibits a wet abrasion value of 400 revolutions or more.

[0075] The wet abrasion value of the lyocell fiber of the present invention may reach amounts of up to 1000, up to 2000, up to 3000, or even more revolutions.

[0076] Furthermore, the lyocell fiber according to the present invention preferably exhibits a Canadian Standard Freeness value in ml CSF of at least 80% of the Canadian Standard Freeness value in ml CSF of the fiber before having been blended.

[0077] Furthermore, it was found that the fibrillation protection achieved for the lyocell fiber according to the invention resists the conditions of many commonly applied steps of processing textile articles, such as dyeing processses, over a wide range of pH-values.

[0078] The lyocell fiber according to the present invention may be present in a titre range of from 0.9 to 3.0 dtex, preferably 1.3 to 1.7 dtex.

[0079] The present invention also encompasses the use of the lyocell fiber according to the present invention for the manufacture of textile articles, such as yarns and fabrics.

[0080] Furthermore, the present invention also encompasses textile articles, such as yarns and fabrics, containing the lyocell fiber according to the present invention.

EXAMPLES

[0081] Test Methods:

[0082] Wet Abrasion Value (NSF)

[0083] The method described in the publication by Helfried Stover: “Zur Fasernassscheuerung von Viskosefasern” Faserforschung and Textiltechnik 19 (1968) Issue 10, p. 447-452, was employed.

[0084] The device employed is an Abrasion Machine Delta 100 of Lenzing Technik Instruments departing from the above-cited publication. The steel shaft is continuously shifted in the longitudinal direction during the measurement in order to prevent the formation of grooves in the filament hose.

[0085] Source of supply of the filament hose: Vom Baur GmbH & KG. Marktstraße 34, D-42369 Wuppertal

[0086] Twenty fibers with a length of 38 mm are placed on a metal roll with a thickness of 1 cm and weighed down with a pre-tensing weight. The roll is covered with a viscose filament yarn stocking and is continuously moistened. The roll is turned at a speed of 500 rotations per minute during measuring, and at the same time it is turned diagonal to the fiber axis backwards and forwards whereby a pendulum movement of approximately 1 cm takes place.

[0087] The number of revolutions until the fibers are worn through and the pre-load weight triggers a contact is determined.

[0088] Test Conditions:

[0089] Water flow rate: 8.2 ml/min

[0090] Speed of rotation: 500 U/min

[0091] Abrasion angle: 40°

[0092] Pre-load weight: 50 mg

[0093] The mean value of the abrasion cycles of 20 fibers is taken as the measured value. The higher the number of revolutions until the fibers are worn through, the less fibrillation of the fibers takes place.

[0094] Canadian Standard Freeness Test (CSF)

[0095] To test the fibrillation of lyocell fibers the fiber is cut to 5 mm lengths and 3.3 g air-dry fiber are put into 1000 ml tap water in a graduated cylinder, the top of the cylinder is closed and the cylinder is gently inverted 180° three times.

[0096] This fiber suspension is transferred to the Canadian Standard of freeness testing equipment according to TAPPI T227 om-99 (manufactured by Lorentzen & Wetters, Sweden). The temperature and the CSF value are measured. The weight of the sample is determined after 4 hours drying in an oven at 105° C. Corrections of the measured CSF results are performed to take account of the concentration and temperature of the fiber slurry. The corrections are based on the following equations:

Concentration correction=(X−0.3)×590×(1+(((0.4−X)/0.2)×(C/1000)))×(1-4C−390).sup.2/((C.sup.0.2)×87000)))

Temperature correction=(20−T)×4.6×(1−(((400−C).sup.2)/((C.sup.0.25)×61000)))

[0097] Where

[0098] X=concentration of the fiber slurry

[0099] T=temperature of the fiber slurry

[0100] C=measured CSF

[0101] The two resulting correction values are then added to or subtracted, respectively, from the measured CSF in any order.

[0102] This gives a CSF value for an unfibrillated fiber sample in the wet state, not yet having been mechanically stressed. As mentioned above, unfibrillated Lyocell fiber without fibrillation protection gives a starting CSF of about 700 (Lenzinger Berichte, 84 (2005)110-115).

[0103] For disintegrating the fiber, a blender with a one liter stainless steel container with two-piece lid (Waring blender 8011EB model 38BL41) filled with fiber suspension of 3.3 g lutro fiber in 500 ml tap water is run with a speed of 18000 RPM for a certain period of time during which fibrillation may occur. The longer the blender is run the more likely it is that the fiber will fibrillate. After blending the fiber slurry is transferred to a graduated cylinder, diluted with tap water to give 1000 ml suspension and the cylinder is gently inverted 180° three times and the CSF measured and the value corrected as described above.

[0104] The blender unit/equipment has to be calibrated in regard to its severity of blending.

[0105] To this end, a reference sample of standard lyocell fiber (1.3 dtex/38 mm cutting length, tenacity conditioned 36 cN/tex, elongation conditioned 13%, bright, showing a starting CSF of 700 ml), such as LENZING™ Lyocell, is employed.

[0106] The fibers are blended for 4 minutes and 6 minutes, respectively, and the CSF value is determined The CSF value after blending for 4 minutes should be below 200 ml, and the CSF value after blending for 6 minutes should be below 100 ml.

[0107] If these thresholds are not met, the blending intensity of the device employed is adapted until these values are reached.

[0108] Fiber Preparation Method 1:

[0109] An aqueous solution of cellulose and NMMO was extruded into an aqueous coagulation bath to form 1.3 dtex filaments of Lyocell. After washing with water to remove all excess NMMO, the Lyocell filaments were pressed to a moisture content of 125% and cut into 20 cm long hanks of fibers.

[0110] Fiber Preparation Method 2:

[0111] An aqueous solution of cellulose and NMMO was extruded into an aqueous coagulation bath to form 1.3 dtex filaments of Lyocell. The filaments were washed with water to remove all excess NMMO, pressed to a moisture content of 150-200% and then treated further.

Example 1

[0112] A filament of lyocell was produced according to fiber preparation method 2 and then passed into the first impregnation bath into which 8.3 w-% of SDTB on cellulose was dosed into an aqueous circulation system at a temperature of 50° C. to give a concentration of 40 g/l of an aqueous, paste-like suspension. The filaments were pressed to a moisture content of 110-140% and then passed through a second impregnation bath at 10° C. into which 1.34 w-% of NaOH and 1.1 w-% of Na.sub.2CO.sub.3 on cellulose was dosed into an aqueous circulation system. The filaments were then pressed to a moisture content of 160-190%, heated to 100° C. in a steaming chamber for 9 minutes and then washed thoroughly by adding acidic water (pH 3.5) and then by water until they were free of excess chemicals and dried.

Example 2

[0113] A filament of lyocell was produced according to fiber preparation method 2 and then passed into the first impregnation bath into which 8.3 w-% of SDTB on cellulose was dosed into an aqueous circulation system at a temperature of 35° C. to give a concentration of 40 g/l of an aqueous paste-like suspension. The filaments were pressed to a moisture content of 180-210% and then passed through a second impregnation bath at 10° C. into which 1.34 w-% of NaOH and 1.1 w-% of Na.sub.2CO.sub.3 on cellulose was dosed into an aqueous circulation system. The filaments were then pressed to a moisture content of 170-200%, heated to 100° C. in a steaming chamber for 8.5 minutes and then washed thoroughly by adding acidic water (pH 3.5) and then by water until they were free of excess chemicals and dried.

Example 3: Reference Example According to EP 0 538 977, Example 4f

[0114] A filament of lyocell was produced according to fiber preparation method 1. A hank of 30 g never-dried lyocell fibers was impregnated for 30 seconds at 70° C. in 600 g of an aqueous bath made up by combining a 70° C. warm solution of Thiotan R, a 70° C. solution of Na.sub.2CO.sub.3 and a 70° C. solution of Na.sub.2SO.sub.4 (final concentrations: 50 g/l Thiotan R (=13 g/l SDTB), 20 g/l Na.sub.2CO.sub.3, 100 g/l Na.sub.2SO.sub.4). The fibers were pressed at 3 bar on a Foulard and heated to 102° C. in a steam chamber for 20 minutes. The filaments were washed neutral with 600 g of an aqueous acetic acid solution with a concentration of 1 g/l. The fibers were dried at 60° C. overnight.

Reference Example 4

[0115] A filament of lyocell was produced according to fiber preparation method 2 and then directly passed into an impregnation bath into which 9.5 w-% of SDTB, 2.7 w-% of NaOH and 1.1 w-% of Na.sub.2CO.sub.3 on cellulose were dosed into an aqueous circulation system at a temperature of 10° C. to give a concentration of 92 g/l of SDTB. The SDTB was dissolved to an extent of more than 50% in the bath. The filaments were then pressed to a moisture content of 150-170%, heated to 100° C. for 8.5 minutes using a steam chamber and then the filaments were washed by adding acidic water (pH 3.5) and then by water until they were free of excess chemicals and dried.

Example 5

[0116] A filament of lyocell was produced according to fiber preparation method 2 and then passed into the first impregnation bath into which 8.1 w-% of SDTB and 0.35 w-% of NaOH on cellulose was dosed into an aqueous circulation system at a temperature of 50° C. to give a concentration of 58 g/l of an aqueous paste-like suspension. The filaments were pressed to a moisture content of 160-190% and then passed through a second impregnation bath at 10° C. into which 1.2 w-% of NaOH and 1.1 w-% of Na.sub.2CO.sub.3 on cellulose was dosed into an aqueous circulation system. The filament was then pressed to a moisture content of 160-190%, heated to 100° C. in a steaming chamber for 8.5 minutes and then washed thoroughly by adding acidic water (pH 3.5) and then by water until they were free of excess chemicals and dried.

[0117] The fibers were analyzed in terms of their wet abrasion value (NSF) and CSF-value. The results are compared in the following table:

TABLE-US-00001 CSF mL after x minutes blending Example NSF CV 0 9 18 27 36 45 No. [U] [%] min min min min min min 1 943 48 678 633 607 574 542 512 2 819 64 677 627 575 531 477 455 3 597 85 716 152 4 502 86 702 39 5 285 41 691 599 354 175 97

[0118] Example 3 is an example according to the state of the art known from EP 0 538 977. It can be seen that while the wet abrasion value of these fibers seems to be sufficient, the CSF value drops down significantly after 9 minutes of blending.

[0119] In example 4, due to the conditions employed in the contacting step, more than 50% part of the SDTB was dissolved. Again, a significant decrease in the CSF value is observed.

[0120] Examples 1, 2 and 5 are examples according to the present invention. All examples show satisfying wet abrasion values, but, in addition, also show still very high CSF values after blending, i.e. more than 85% of the original value after 9 minutes of blending.

[0121] Resistance of Fibrillation Property Against Fabric Processing Steps

[0122] Fibers according to the invention were processed into knitted fabrics.

[0123] The knitted fabrics were subjected to various wet processing treatments common for fabrics, including both acidic and alkaline environments. It was found by optical assessment that the surface of the knitted fabrics stayed clean without showing a hairy appearance caused by fibrillation or pills of entangled fibrils, and, as determined by wet abrasion values, that the fibrillation property stayed conserved at least to a certain extent after having been subjected to various conditions, such as reactive (alkaline) dyeing as well as dyeing under conditions suitable for polyester dyeing (acid dyeing).

[0124] Single jersey fabric having a basic weight of about 130 gsm were produced using a ring yarn Nm 50/1 alpha 105 out of fibers according to the invention.

[0125] Before dyeing, the fabric samples were washed for 20 minutes at 80° C. in a 5 liter beaker using the Labomat Type BFA-12 produced by Mathis, Switzerland, liquor ratio 1:30, rotation 20 rpm.

[0126] The following washing solution was prepared: 1 g/l detergent for textile finishing e.g. Kieralon JET trademark of BASF, 1 g/l sodium carbonate, 1 g/l wetting agent like Albaflow FFA by Huntsman and 1 g/l lubricant e.g. Persoftal L Tanatex Chemicals. After washing the fabrics were rinsed warm and cold.

[0127] The dyeing of the fabrics was also carried out in the Labomat Type BFA-12 in a 5 liter beaker, liquor ratio 1:30, rotation 20 rpm.

Example 1 Warm Reactive Dyeing (Alkaline)

[0128] Composition of Dye Bath Using Softened Water:

[0129] 4.0% Novacron marineblau FG trademark by Huntsman

[0130] 40 g/l Sodium sulphate (Salt)

[0131] 6 g/l Sodium carbonate

[0132] 1 g/l Lubricant

[0133] 1 g/l Antifoam

[0134] The fabric and the dye bath were heated up in the labomat to 60° C. at a heating rate of 6° C. per minute. When the dye bath had reached 60° C. the dye stuff, lubricant and antifoam were added. After 25 minutes the salt was added and five minutes later Sodium carbonate was added. After 15 minutes at 60° C. the bath was drained and the fabric was rinsed in 20° C. water for 10 mins then drained. The fabric was then treated with 1 ml/l acetic acid (60%) at 40° C. for 10 mins. The water was then drained and the fabric was then rinsed with 40° C. water for 10 mins. This bath was drained and then the soapening followed which means the fabric was treated at 90° C. with a detergent solution (1 g/l Kieralon JET in softened water). The bath was drained and the fabric was rinsed one final time with 20° C. tap water for 10 mins then drained. The fabrics were then hung on a needle frame and allowed to dry at room temperature.

[0135] After this procedure the surface of the blue fabric stayed completely clean showing no fibrillation. Fibers taken out of the dyed fabric showed no loss of the NSF value compared to the NSF value of the original fiber before dyeing.

[0136] The washing performance of the dyed fabric was tested by doing 10 household washings at 40° C. in a household washing machine using mild detergent. After each washing step the fabric was tumble dried. After this procedure the visual inspection showed that the surface of the fabric was still good, showing no pills or greying and only little negligible fiber splice.

Example 2 High Temperature Acid Dyeing (“Polyester Dyeing”)

[0137] Composition of Dye Bath Using Softened Water:

[0138] 1.0% Dianix blue FBL trademark DyStar

[0139] 1 g/l Sodium acetate

[0140] 1 g/l lubricant

[0141] 1 g/l anionic crease prevention agent

[0142] Adjustment of dye bath pH to 4.5 with acetic acid.

[0143] The dye bath with the fabric was heated up to 130° C. at a heating rate of 2° C. per minute and held at 130° C. for 60 minutes. After cooling down to 70° C. at 2° C. per minute, warm and cold rinsing was done followed by reductive cleaning.

[0144] Composition of Reductive Cleaning Bath:

[0145] 2 g/l sodiumhydrosulfite

[0146] 2 ml/l 34% percent caustic soda solution

[0147] 1 g/l lubricant

[0148] The fabric and the cleaning bath with a liquor ratio 1:30 were heated at 6° C./minute to 80° C. in the labomat at 20 rpm. After 20 minutes at 80° C. the bath was drained and the fabric was rinsed in 20° C. water for 10 mins then drained. The fabric was then treated with 1 ml/l acetic acid (60%) at 40° C. for 10 mins. The water was then drained and the fabric was then rinsed with 40° C. water for 10 mins. This bath was drained and the fabric was rinsed a final time with 20° C. water for 10 mins then drained. The fabrics were then hung on a needle frame and allowed to dry at room temperature.

[0149] After this procedure the surface of the light blue fabric stayed completely clean showing no fibrillation. Fibers taken out of the dyed fabric showed no loss of the NSF value compared to the NSF value of the original fiber before dyeing.

[0150] The washing performance of the dyed fabric was tested by doing 10 household washings at 40° C. in a household washing machine using mild detergent. After each washing step the fabric was tumble dried. After this procedure the surface of the fabric was no different to dyed fabric before washing by visual inspection. The acid dyeing conditions do not negatively affect the washing performance of the fabric.