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Reduction Clearing of Simulated Disperse Dyed PLA Fabrics and Their Tensile Properties

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Reduction Clearing of Simulated Disperse Dyed PLA Fabrics and Their Tensile Properties Indian Journal of Fibre & Textile Research Vol. 38, March 2013, pp. 22-28 Reduction clearing of simulated disperse dyed PLA fabrics and their tensile properties Gulzar A Baiga University College of Textile Engineering, B.Z.U 60800 Multan, Punjab, Pakistan Received 18 October 2011; revised received and accepted 19 March 2012 Polylactic acid (PLA) knitted fabric has been subjected to various textile wet processes, viz. scouring, bleaching and simulated disperse dyeing. Reduction clearing (RC) has been performed at various process conditions such as concentrations of sodium dithionite and sodium carbonate, bath temperature and process time and a full factorial experiment is designed. The results show that the pretreatment processes and RC parameters have pronounced effects on tensile properties of PLA yarns. Statistical analysis of variance is performed which show significant differences at a confidence interval of 99%. Attenuated total reflectance infrared spectroscopy of the PLA fabric is carried out to investigate chemical changes on fibre surface. Scanning electron microscopy reveals that the bleaching causes the formation of slits in the fibres. Since bleached fibres are already porous, the strength of PLA yarns is further decreased during simulated disperse dyeing and reduction clearing processes. Keywords: Disperse dye, Fibres, Polylactic acid fabric, Reduction clearing wash, Tensile strength 1 Introduction surface cohesion PLA produces sound when fibres are Polylactic acid (PLA) is a renewable and rubbed against one another – scroopiness9. biodegradable polyester material1. The biodegradable PLA has been dyed with disperse dyes10,11. DyStar materials are broken down into smaller molecules in recommends dyeing PLA at 110oC and pH 4.5-5.0 for the presence of aerobic or anaerobic microorganisms2, 30 min12. At these process conditions, PLA does not 3. PLA is one of the first melt spun aliphatic polyester degrade appreciably. At the end of dyeing some of the fibres whose raw material is obtained from annually dye particles remain deposited on the surface of grown crops 4. PLA is prepared from lactic acid fibres. It is necessary to remove these loosely held monomer obtained from the enzymatic action on starch dye particles, particularly in medium and heavy 5, 6. Since PLA is a sustainable material, it does not shades, so that during laundering these dyes do not depend on fossil resources. Cargill Dow (now bleed and tint the light-dyed and white clothes13. NatureWorks) LCC, USA are producing PLA fibres Reduction clearing (RC) is the process that is carried under the brand name of IngeoTM and have a out to remove surface adsorbed dye14,15. RC is carried manufacturing capacity of 140,000 tons per year7. out with suitable reducing agents e.g. sodium Although PLA is being used in the medical industry as dithionite in the acidic or alkaline pH region although suture, it is only recently that it has been knitted and the later is preferably employed16. In the alkaline woven into textile fabrics. PLA possesses a number of region sodium dithionite has powerful reducing good properties that makes this material a possible action17. Reduction clearing may damage the fibres if substitute for other polyesters, e.g. PET8. PLA is excessive amounts of reducing agent, alkali, high lightweight, transparent to UV and IR, low specific process temperature or extended times are employed. gravity, higher refractive index and good moisture Avinc et al.18 studied the alkaline reduction clearing management properties. The disadvantages of PLA as of PLA and concluded that RC washing for 15 min at compared to PET include its high sensitivity to pH in 60oC in the presence of 2 g/L each of sodium carbonate aqueous medium. Particularly in the alkaline region, and ‘hydros’ are adequate to achieve optimised wash PLA loose mechanical properties rapidly at higher fastness. Burkinshaw et al.19 studied the effects of temperatures when processed for longer times. PLA water, ECE detergent and RC on the colorimetric cannot withstand very high ironing temperature. Due to properties of disperse dyed PLA in the presence of _______ ultrasonic waves and concluded that ultrasonic waves aE-mail: [email protected] do not affect the effectiveness of either ECE detergent BAIG: REDUCTION CLEARING OF DYED PLA FABRICS & THEIR TENSILE PROPERTIES 23 or reduction clearing processes. Phillips et al.20 RC finally rinsed in cold water. All other chemicals were washed PLA fabric in the alkaline and acidic pH. The of laboratory grade. Scoured and bleached PLA knitted alkaline RC washing was carried out in the presence of fabrics were subjected to simulated dyeing conditions 3 g/L sodium dithionite and 5 ml/L sodium hydroxide of 110oC, 5 pH and LMR of 10:1 for 30 min followed (50% w/w) while acidic one was carried out in the by reduction clearing (Fig. 1). Factors included in presence of 2ml/L Cyclanone ECO at 70°C for 20 min, reduction clearing were sodium dithionite the pH being 3.5 in the later case. They reported almost concentration, sodium carbonate concentration, no deleterious effects on molecular weight or tensile temperature and time. A full factorial experiment 2k properties. There was hardly any literature available was designed, where k is the number of factors (k = 4). about the detailed investigation of the effects of RC The experiment was full factorial of resolution V. Total parameters on the mechanical properties of PLA yarns. number of runs were 24, number of replicates was 01 The present work deals with the degradation of PLA and number of blocks were 2 with 4 centre points per yarns during pretreatments and dyeing processes in block. The blocks denoted the scoured and bleached general and with reduction clearing in particular. fabrics subjected to simulated high temperature dyeing. Greige knitted PLA fabric was subjected to scouring 2.3 Tensile Measurements and bleaching processes followed by simulated Yarns were taken out from control and each of the disperse dyeing conditions. The pretreatment and treated knitted fabrics and then conditioned at standard dyeing were carried out at commercial process conditions of 25oC and 65% R.H before testing. Tests conditions. The scoured-dyed (SD) and bleached-dyed were performed according to BS EN ISO 2062:1995, (BD) fabrics were then subjected to reduction clearing using Instron (Model 1122) tensile tester with a gauge at selected process conditions. The parameters of length of 100 mm and at a strain rate of 1 min-1. Ten reduction clearing were reducing agent and alkali tests were performed on each of the yarn samples and concentrations, temperature and time. At the end of the the results acquired through desktop computer reduction clearing process, pH of the bath was also interfaced to the testing machine. The data were measured. PLA yarns were taken from knitted fabrics received and analyzed through computer software QT. and tensile strength measured. A detailed statistical analysis of tensile strength was carried out. Infrared 2.4 FTIR Spectroscopy spectroscopy and scanning electron microscopy (SEM) The attenuated total reflectance fourier transform were used to investigate morphology of PLA fibres. infrared spectroscopy (ATR-FTIR) spectra of PLA fabric was recorded to determine the effect of various 2 Materials and Methods textile processes and reduction clearing on functional 2.1 Materials groups of PLA polymer. The ATR-FTIR was performed PLA fabric of pique´ structure was knitted on a lab using a Perkins Elmer (Model spectrum 2000). The scale knitting machine from spun yarn of count Ne 30s. spectrometer was used in the absorption mode with a -1 -1 High temperature (HT) infrared (IR) dyeing machine resolution of 4 cm in the range of 4000-500 cm . Labomat BFA-12 was used to process PLA samples. 2.5 SEM Analysis Tensile measurements of yarns were carried out on Surface morphology of the PLA fabric was Instron 1122 interfaced to a dedicated PC. S 3000N investigated using scanning electron microscope. scanning electron microscope (Hitachi, Japan) was used Samples were sputter-coated with Au in Polaron in observing the surface morphology of PLA fibres. 2.2 Treatments The PLA knitted fabric was given a mild scour with o 2 g/L Na2CO3 at 60 C for 20 min at a liquor-to-material ratio (LMR) of 10:1 followed by overnight drying at ambient conditions. Half of the fabric was bleached with 5 mL/L hydrogen peroxide (35% w/w), 3 g/L sodium hydroxide, 1 g/L Baystabil DB (hydrogen peroxide stabilizer, BASF) at 90oC for 30 min at LMR o of 10:1. Fabric was then washed in hot water (60 C) followed by neutralization with acetic acid (1 g/L) and Fig. 1 Schematic profile of RC washing of PLA fabric 24 INDIAN J. FIBRE TEXT. RES., MARCH 2013 coating unit (Model E5100), followed by loading viscose or TencelTM fibres, pretreatments would not sample holder in the Hitachi SEM (Model S-3000N). damage PLA due to mild process conditions being Gun-to-sample distance was 8-9 mm and voltage of employed in the processing of polyester-regenerated 5kV was applied to accelerate electron toward the cellulosic fibre blends. Normally PLA fibres do not samples under high vacuum. Electron beam focusing, require bleaching; however, if blended with cotton the image magnification and brightness/contrast were H2O2 bleaching severely damages the PLA fibres. If adjusted to take the photographs. SmatSEM software the effects of scouring and bleaching on tensile strength was used to acquire the photographs. are to be minimized then either bleaching with hydrogen peroxide should have been carried out at low 3 Results and Discussion temperature or alternative bleaching agents e.g. sodium 3.1 Mechanical Properties of Yarns hypochlorite and chlorites must be employed. Table 1 shows the effects of various textile wet Ahmad21carried out a study on the bleaching of PLA processes, viz.
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