One‐step dyeing of polyethylene terephthalate fabric,combining pretreatment and dyeing using alkali‐stable disperse dyes

In the conventional dyeing process, polyester and its blended fabrics are usually dyed in a weak acidic medium. In order to reduce cost and improve production efficiency, a new dyeing method – one‐step dyeing of polyethylene terephthalate fabrics, combining pretreatment and dyeing in alkali conditions – was investigated. The alkali‐stable disperse dyes Red 900, Red 902, Yellow BROB and Blue 825 were used to dye polyethylene terephthalate fabrics. The dyeing properties of polyethylene terephthalate fabrics in the case of one‐step dyeing at various pH values or sodium hydroxide concentrations were discussed in terms of colour yield, colour parameters and fastness. The performance of one‐step dyeing using alkali‐stable disperse dyes was excellent. The dyed fabric had good fastness. Wet processing could be combined and shortened. One‐step dyeing of polyethylene terephthalate fabrics could reduce the consumption of water and energy and improve production efficiency. One‐step dyeing of polyethylene terephthalate has potential application in cleaner textile production.     

Thermal migration of selected disperse dyes on poly(ethylene terephthalate) and poly(lactic acid) (Ingeo†) fibres

A study has been carried out to correlate the wet fastness properties of dyed knitted fabrics, derived from both poly(ethylene terephthalate) and poly(lactic acid) (Ingeo) fibres, with the thermal migration properties of the disperse dyes during heat treatment. The results indicate a greater amount of disperse dye at the surface of the Ingeo fibre fabric than the poly(ethylene terephthalate) fabric, after post heat‐setting using the conditions needed for fabric stabilisation, correlating well with its slightly lower wash fastness properties.     

Organoclays assisted vat and disperse dyeing of poly(ethylene terephthalate) nanocomposite fabrics via melt spinning

Polyethylene terephthalate nanocomposites containing six modified montmorillonite nanoclays were prepared by a melt compounding technique. The effect of intercalated compounds of montmorillonite on textile mechanical properties of resultant polyethylene terephthalate nanocomposite fabrics was investigated. Winding was not possible, when the polymers were first compounded with the desired amount of montmorillonite and then spun, as filament breakage occurred. Spinable polymer were only obtained by mixing polyethylene terephthalate master batches with 4 wt% montmorillonite, which contained tallow intercalating compound with pure untreated polyethylene terephthalate to a montmorillonite content of 0.5 wt%, thus decreasing the concentration of thermally degraded polymer chains. After spinning the fibres were drawn and knitted into fabric samples for further testing. The prepared polyethylene terephthalate nanocomposite fabrics using montmorillonite exhibited higher colour strength using vat and disperse dyes compared with those of the reference fabrics made from fibres spun without montmorillonite clay content and regular fabrics. The carbocyclic‐based vat dyes have higher colour strength values on polyethylene terephthalate nanocomposite fabrics if compared with heterocyclic‐based vat dyes. The colour fastness ratings for both vat and disperse dyeings secured very good to excellent washing and perspiration fastness on polyethylene terephthalate nanocomposite fabrics. All dyed fabrics showed excellent light fastness using vat and disperse dyes. The preparation of polyethylene terephthalate nanocomposite fabrics with improved textile mechanical and vat dyeing properties needs further investigations.     

Study of the removal of a disperse dye stain from a polyester/elastane blend

Polyethylene terephthalate and elastane fabrics were treated with azo disperse dyes in the same dyebath at 130 °C for 0, 30 and 60 min and then reduction cleared. The dyes adsorbed on each fabric were extracted using monochlorobenzene, in order to determine the amount of disperse dye in each of the polyethylene terephthalate and elastane fabrics, as the dyeing time was increased. It was observed that the amount of dye on the polyethylene terephthalate increased, while that on the elastane decreased, as the time at 130 °C increased from 0 to 60 min. After reduction clearing, the partition ratio of disperse dyes between the polyethylene terephthalate and the elastane increased. The dyed polyethylene terephthalate/elastane blend indicated that those dyes, which exhibited high partition ratios (polyethylene terephthalate:elastane), exhibited correspondingly higher wet fastness properties.     

Dyeing and fastness properties of phthalimide‐based alkali‐clearable azo disperse dyes on poly(ethylene terephthalate)

The properties of a series of phthalimide‐containing azo disperse dyes and azo dyes with N‐methyl phthalimide moieties in their diazo component were investigated and compared when used to colour polyethylene terephthalate. The N‐substitution of the phthalimide gave a hypsochromic effect on the colour change and better colour yields on poly(ethylene terephthalate) fabrics, probably because of the electron‐donating property of the methyl group and the higher hydrophobicity of phthalimide‐containing azo dyes compared with those containing phthalimide moieties. The results show that phthalimide‐based azo disperse dyes have excellent dyeing fastness properties and that high wash fastness can be achieved using alkali clearance. This alternative clearance method is important for reducing the environmental impact of the dyeing process by replacing reductive clearing and, in particular, by removing the need for sodium hydrosulphite, which creates a high biological oxygen demand when released in conventional disperse dyeing effluent and which generates aromatic amines.     

Synthesis of temporarily solubilised azo disperse dyes containing a β‐sulphatoethylsulphonyl group and dispersant‐free dyeing of polyethylene terephthalate fabric

Disperse dyes containing a β‐sulphatoethylsulphonyl group have temporary solubility and can be applied for dispersant‐free dyeing of hydrophobic fibre. Six novel temporarily solubilised azo disperse dyes having a β‐sulphatoethylsulphonyl group in their structures were synthesised, and their dyeing properties on polyester were investigated. As a dye intermediate, a diazo component having dibromo groups was prepared, and 4‐diethylamino‐4′‐(2‐sulphatoethylsulphonyl‐4,6‐dibromo)azobenzene dyes were prepared by a diazo‐coupling reaction. Then, the dyes containing dicyano groups were prepared by cyanation of corresponding dyes with dibromo groups. The absorption maxima of the dyes were affected by the substituents in the diazo and coupling component rings and varied from 434 to 616 nm in dimethylformamide. Polyethylene terephthalate woven fabric could be dyed with the synthesised temporarily solubilised dyes without using any dispersants. Dyebath pH affected the K/S value at maximum absorption as well as percentage exhaustion on polyethylene terephthalate fabric, and the optimum pH was 5. The dyes gave brownish orange, red, purple, and greenish blue hues on polyethylene terephthalate fabrics, and colour build‐up was good. Wash fastness was good to excellent, rubbing fastness was moderate to excellent, and light fastness was poor to moderate.     

Correlation between the shade of an azo disperse dye on poly(ethylene terephthalate) and poly(lactic acid) fibres with its spectroscopic properties in selected organic solvents

A series of azo disperse dyes was synthesised and the purified, synthesised dyes were characterised by proton nuclear magnetic resonance, thin‐layer chromatography and melting point measurement. The spectroscopic properties of the dyes in solution were studied by dissolving the dyes in ethyl acetate and methyl benzoate. These were seen as mimicking the environment of the dye when inside dyed poly(lactic acid) and poly(ethylene terephthalate), respectively. Reflectance spectra of the dyes on both polyester substrates were also measured in order to correlate with the spectroscopic properties of the dyes in solution. The absorbance spectra of the dyes in solution exhibited a hypsochromic (lower wavelength of maximum exhaustion) shift when dissolved in ethyl acetate, compared with methyl benzoate. The occurrence of this yellow shift was attributed to the lower polarity of ethyl acetate compared with methyl benzoate. The colour of the dyes in ethyl acetate solution was also brighter and stronger (higher molar extinction coefficients) than that in methyl benzoate. Most of the synthesised dyes exhibited high levels of exhaustion onto the two polyester fabrics. However, the visual colour yields, for those dyes having approximately the same high level of exhaustion, were different, the dyed poly(lactic acid) being stronger (higher K/S value) as well as being yellower and a trace brighter than the dyed poly(ethylene terephthalate). This difference correlated well with the solvatochromic study of the dyes in ethyl acetate and methyl benzoate solution.     

Ozone applications for after‐clearing of disperse‐dyed poly(lactic acid) fibres

In this study, the effectiveness of the ozonation process, in neutral distilled water at room temperature, as a clearing process for disperse‐dyed poly(lactic acid) fibre fabrics is investigated. The efficiency of simultaneous decolorisation of dyebath effluent and clearing of dyed poly(lactic acid) in the cooled dyebath after completion of the poly(lactic acid) dyeing cycle is also explored. Conventional alkaline reduction clearing with sodium dithionite was chosen as a control clearing process for comparison. Wash fastness, colour difference, colour removal (in Hazen) and chemical oxygen demand values were determined and compared. Long ozone treatment times at high ozone dose resulted in unacceptable colour differences. The colour difference problem was solved by use of lower ozone dose; however, a warm soaping step had to be added to the after‐clearing sequence in order to achieve the desired fastness properties. A 33% reduction on the chemical oxygen demand load of the total process (dyeing + after‐clearing) could be achieved by ozone after‐clearing instead of using a conventional reduction clearing treatment. The addition of the warm soaping step to improve the fastness properties of the ozonated samples increased the total chemical oxygen demand of the process (dyeing + ozonation in water + warm soaping), but a 12–18% reduction on the chemical oxygen demand load of the total process was observed when compared with the conventional treatment sequence (dyeing + reduction clearing).     

Dispersant‐free dyeing of poly(lactic acid) fabric with temporarily solubilised disperse dyes from azopyridone derivatives

Poly(lactic acid) fibre is derived from annually renewable crops and known to be 100% compostable. In order to extend its environmental friendliness into the dyeing process, dispersant‐free dyeing of poly(lactic acid) fabric with three temporarily solubilised azo disperse dyes based on hydroxypyridone moiety containing a β‐sulphatoethylsulphonyl group was investigated. The dyes were successfully applied to poly(lactic acid) fabric without the use of dispersants. The colour yields of the dyes on poly(lactic acid) fabric were observed to be dependent on dyebath pH and dyeing temperature. The optimum results were obtained at pH 4–5 and 110 °C. One of the dyes showed a colour yield as good as that of a commercial disperse dye and good build‐up on poly(lactic acid) fabric. All of the dyes could be alkali cleared owing to ionisation of the dye under mild alkaline conditions. Wash fastness was good to very good, and light fastness was good. The chemical oxygen demand levels of the poly(lactic acid) dyeing effluent from the dyes were considerably lower than those from a commercial disperse dye.     

Afterclearing of disperse dyed polyester with gaseous ozone

The efficiency of ozone treatment for the clearing of disperse dyed polyethylene terephthalate fibres has been examined. The ozone treatment for the clearing of the dyed samples was performed by blowing the ozone gas from the ozone generator on to the wet fabric samples. The results indicated that 3‐ and 5‐min ozonation times were appropriate to achieve comparable wash fastness results with conventional reduction clearing without significant colour differences (ΔE* value) for the samples dyed with CI Disperse Yellow 23 and CI Disperse Blue 79, respectively; however, the ozonation time had to be increased to 15 min for CI Disperse Red 82. Tensile strength tests and scanning electron microscopy analysis indicated that the ozone treatment did not cause any severe damage to the fabrics. Ozone treatment for the afterclearing of disperse dyed polyester fabric can lead to energy and time savings and environmental load reduction when compared with conventional reduction clearing. This study tested a new method of ozone application for clearing of disperse dyed polyester by blowing ozone directly on to the fabric samples. This new method of application has the advantage of being readily adoptable for continuous treatment lines and lower water consumption.     

One‐bath union dyeing of wool/polytrimethylene terephthalate blends†

The one‐bath dyeing of blends of polytrimethylene terephthalate (PTT) staple and wool has been investigated. The exhaustion of selected Terasil disperse dyes on PTT fibre and Lanasol reactive dyes on wool was measured as a function of temperature, together with the cross‐staining of the Terasil dyes on the wool component and the Lanasol dyes on PTT component. Most Terasil disperse dyes achieved satisfactory dye uptake on PTT at 110 °C, whereas on conventional polyester (polyethylene terephthalate) temperatures of up to 130 °C are required. An optimised union‐dyeing technique for wool/PTT blends was developed which minimised the staining of Terasil disperse dyes on wool and produced dyed goods with high levels of wet colour fastness. Carriers were not required to enhance the dyeability of PTT at low temperatures. The wool component appeared to be protected against damage at 110 °C by the reactive dyes. The results indicate the potential for blending PTT fibre and wool to produce fabrics that are easier to dye at lower temperatures than conventional wool/polyester blends.     

Dyeing poly(lactic acid) fibres in supercritical carbon dioxide

A study has been conducted into the dyeing of poly(lactic acid) fibres in supercritical carbon dioxide. The fibres were completely dyed using disperse dyes at 50 °C as shown by fibre cross-sections, although high colour depths in dark shades still prove challenging. Dye uptake increased significantly at temperatures ≥80 °C. At 95 °C in supercritical carbon dioxide, shrinkage and hardening of raw poly(lactic acid) were observed which could partly be overcome by the supercritical carbon dioxide extraction step. Afterclearing with cold supercritical carbon dioxide (to remove unfixed dye after dyeing) decreased the colour depth and led to non-uniform dyeing results on poly(lactic acid). Wash and rub fastness was good to very good also when poly(lactic acid) was not aftercleared in supercritical carbon dioxide. Fibre damage and elongation at break in supercritical carbon dioxide were similar to water.     

Influence of different finishing conditions on the wet fastness of selected disperse dyes on polylactic acid fabrics

This study investigates the influence of different finishing conditions on the amount of thermal migration and the wet fastness properties of selected red disperse dyes on polylactic acid fabrics. A comparison was made with a correspondingly finished polyethyleneterephthalate fabric, with a specific objective being to identify the conditions that would give optimum wet fastness to the polylactic acid fabric. A greater thermal migration of dye was observed on the polylactic acid compared with polyethyleneterephthalate fabric under the same heat treatment conditions, resulting in a lower level of wet fastness. The lowering in wet fastness of dyed polylactic acid fabric on processing occurs mainly as a result of thermal migration of disperse dyes during the drying stage at 110 °C.     

A new dye‐modified poly(ethylene oxide)–poly(propylene oxide) polymer used as a dispersant for CI Disperse Red 60

A new dye‐modified poly(ethylene oxide)–poly(propylene oxide) polymer, in which the dye molecule (CI Disperse Red 60) is bonded onto polyether monoamine via a triazine ring, was synthesised for the preparation of dye aqueous dispersions and was characterised by Fourier Transform‐infrared spectroscopy, ¹H nuclear magnetic resonance spectroscopy and elemental analysis. This polymer exhibits unique dispersing performance for CI Disperse Red 60. The mechanism behind the improved performance is briefly discussed with the help of adsorption isotherms. The results indicated that the hydrophobic dye group of this polymer can strongly adsorb onto the dye particle surface through π–π interaction while its long hydrophilic poly(ethylene oxide) chains allow the formation of a thick layer around the dye particles. It was speculated that the adsorbed polymer molecule on the dye surface would form a brush‐like monolayer conformation. The dyeing performance of the prepared dye dispersions on polyester fabrics was also investigated. It was found that this polymer can effectively increase the apparent solubility of disperse dye. The dyed fabrics showed very good to excellent fastness to washing and rubbing, while the dyeing effluent was colourless.     

Ammonia/acetylene plasma deposition: An alternative approach to the dyeing of poly(ethylene terephthalate) fabrics at low temperatures

It has long been recognized that dyes other than disperse dyes would play a much larger industrial role if they could be applied to poly(ethylene terephthalate) (PET) fabrics at low temperatures. This research is related to a new process for the dyeing of hydrophobic PET with hydrophilic acid dyestuffs. The process is based on low‐pressure plasma polymerization using an ammonia/acetylene gaseous mixture, which provides a nanoporous plasma coating containing accessible amine groups. Surface functionalization and crosslinking have been analyzed with X‐ray photoelectron spectroscopy. The color strength (absorption coefficient/scattering coefficient) of dyed PET is evidently improved by the attachment of dye molecules to the plasma polymer coating. The dyeability strongly depends on the plasma exposure time, gaseous mixture, and energy input. The permanency of the bond between the dye molecules and the plasma film can be characterized as the fastness property of dyed PET. The stability of the plasma coating has been examined with an abrasion and pilling tester. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Enhanced dyeability of poly(ethylene terephthalate)/organoclay nanocomposite filaments

This study deals with the generation of poly(ethylene terephthalate)/organoclay nanocomposite filaments by the melt‐spinning method and with the investigation of their morphological and dyeing properties. Different montmorillonite types of clay (Resadiye and Rockwood) were modified using different intercalating agents, and poly(ethylene terephthalate) nanocomposite filaments containing 0.5 and 1 wt% organoclays were prepared. Afterwards, the filaments were dyed with two disperse dyes (Setapers Red P2G and Setapers Blue TFBL‐NEW) at different temperatures (100, 110, and 120 °C) in the absence/presence of a carrier. Organoclays and poly(ethylene terephthalate)/organoclay nanocomposites showed an increased d‐spacing between clay layers. Irrespective of clay and surfactant type, poly(ethylene terephthalate)/organoclay nanocomposite filaments dyed at 120 °C in the presence of only a very small amount of carrier showed appreciable dyeability in comparison with neat poly(ethylene terephthalate). The dyeability of the organoclay‐containing poly(ethylene terephthalate) samples was found to be better in spite of having increased degrees of crystallinity. Moreover, the colour fastness properties of the clay‐containing samples were not affected adversely.     

Synthesis,spectral and dyeing properties of phenylazopyrazolone‐containing acylamide disperse dyes designed for poly(lactic acid)

A series of phenylazopyrazolone disperse dyes containing an acylamide moiety were synthesised from carboxyl‐containing acid dyes via chlorination and amidation with different sorts of amines. The structures of these new dyes were confirmed by Fourier Transform–infrared, proton nuclear magnetic resonance, mass spectroscopy and elemental analysis. Their solvatochromic properties in different solvents were also investigated and the absorbance spectra of the acylamide dyes in solution exhibited a red shift when dissolved in dimethylformamide, compared with acetone. Their dyeing behaviour, including dye sorption, colour build‐up and colour fastness properties on poly(lactic acid) fibres, was also determined, whereupon it was found that the tertiary acylamide dyes simultaneously exhibited high dye sorption and satisfactory colour build‐up and fastness properties on the poly(lactic acid) fabric.     

Improving the colour fastness of dyed nylon‐6 fabric by graft copolymerisation and curing of acrylic acid

The influence of grafting and grafting–curing of acrylic acid on the colour fastness of nylon‐6 fabric dyed with an acid dye of low wash fastness was investigated. The variables involved in grafting were initially optimised for pristine nylon‐6 fabric prior to grafting the same monomer onto the dyed fabrics. The highest graft yield achieved for the pristine and dyed nylon‐6 fabrics was 44 and 14% respectively. Grey scale testing and colorimetric analysis revealed that the highest colour fastness and the smallest drop in colour strength belonged to the dyed–grafted–cured nylon‐6 fabric. The colour components were measured, and the total colour difference of each sample after five washing cycles was computed. The specific colour difference showed that the implementation of either grafting or grafting–curing processes will alter the reference colour of the dyed fabric. The tensile strength of the grafted and grafted–cured fabrics was respectively 2.7 and 6.3% lower than that of dyed nylon‐6.     

Dyeing and finishing of lyocell union fabrics: an industrial study

Lyocell union fabrics, namely lyocell/silk and lyocell/polyester fabrics, were woven in different fabric constructions and dyed with reactive dyes, acid dyes and a disperse dye. The resulting dyed fabrics were given a resin finishing treatment and their wash fastness was measured. With appropriate dye selection and control of dyeing conditions, some bright solid shades and effective cross‐dyed shades were obtained. The dyed and finished fabrics had a smooth, lustrous handle, ideal for lightweight garments.     

Dyeing nylon-6,6 with some hydrophobic reactive dyes by supercritical processing

Nylon-6,6 fibers, spun from the polyamide (polyhexamethylene diamine adipate), are increasingly required to be dyed with high washing fastness. Nylon-6,6 were dyed with hydrophobic reactive dyes synthesized in our laboratory, using supercritical carbon dioxide as the solvent system. Structures of four hydrophobic reactive dyes and their covalent force with nylon-6,6 fibers were confirmed by FTIR, MS and NMR analysis. Nylon-6,6 were also dyed with C.I. disperse red 2 to compare the result with specimen dyed by hydrophobic reactive yellowish red dye (dye I), which further demonstrated that covalent force was formed between dye-fiber interaction. Dye uptake was moderate to good and the dyed fabrics had very good fastness properties. Results of the latter studies indicated that dyeing nylon-6,6 in supercritical carbon dioxide is feasible.