United States Patent (19) 11 Patent Number: 4,699,627 Bailey 45) Date of Patent: Oct
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United States Patent (19) 11 Patent Number: 4,699,627 Bailey 45) Date of Patent: Oct. 13, 1987 (54) INDIGO-DYEABLE POLYESTER FIBERS Attorney, Agent, or Firm-Robert H. Falk; David M. AND PRETREATMENT OF POLYESTER TO Carter; Jeffrey S. Boone PRODUCE SAME 57 ABSTRACT 75) Inventor: Bobby J. Bailey, Candler, N.C. A new and useful indigo-dyeable polyester is disclosed, 73 Assignee: ; Akzona Incorporated, New York, and process for making same, for which a suitable poly ester has had applied to its surface an amount of a suit N.Y. able indigo dye retaining compound effective to pro 21 Appl. No.: 473,489 vide said polyester with indigo fastness properties simi lar to cotton. The new indigo dyeable polyester may be 22 Filed: Mar. 9, 1983 employed in the manufacture of a staple material 51) Int. Cl." .............................................. C09B 67/00 blended with cotton in predetermined amounts depend 52 U.S. Cl. ........................................... 8/602; 8/581; ing on the end use desired, e.g., 50:50 by weight for 8/606; 8/653; 8/922 cotton denims (e.g., jeans). Preferable indigo dye retain 58) Field of Search ................... 8/495, 581, 653, 602, ing compounds comprise monomers dioleylamine and 8/606 dicocoamine. Other suitable indigo dye retaining mono mers are disclosed, inter alia, having the formula: 56) References Cited U.S. PATENT DOCUMENTS R T100,201 : 1/1981 Logulio ................................... 8/495 3,504,998 4/1970 Speier ...... 8/581 R 3,527.556 9/1970 Riley ... ... 8/17 R 3,793,341 2/1974 Genta ........... 8A653 3,960,479 6/1976 Tsujimoto et al ... 8A650 wherein R is alkyl or alkenyl of about 10-18 carbons; 4,313,732 2/1982 Teague et al. ...... ... 8/54 R2 is alkyl, alkylaryl, or alkenyl of about 8-18 carbons, 4.335,185 6/1982 Adeiman et al. ... 8/115.6 R-CH2-NO2, R-CH-NH, where R is alkyl or 4,369,213 1/1983 Adelman et al. .................... 8/115.6 alkenyl from one to eighteen carbons; and R3 is hydro FOREIGN PATENT DOCUMENTS gen or alky from one to about twelve carbons. A pro cess is also disclosed for treating a meltspun suitable 54.77778 6/1979 Japan . polyester fiber with an amount (e.g., about 0.25%-2.0% OTHER PUBLICATIONS by weight) of a suitable indigo dye retaining compound “Ultrablue Denims", Canadian Textile, p. 16, (Oct. effective to provide said polyester fiber with indigo 1982). fastness properties similar to cotton. Primary Examiner-A. Lionel Clingman 2 Claims, 3 Drawing Figures Washfastness of indigo Dye on Polyester Pretreated with Amine Compounds OO 8O Ar Polyester Pretreated with Dioleylamine (2.0%) BF Polyester Pretreated with Dicocoamine (2.O.) O SO 50 4 O 3O Untreated Polyester O 2 3. 4. 5 AATCC A Washes Accelerosted rests an O 5 O 5 2O 25 Sintilated one Leunderings U.S. Patent Oct 13, 1987 Sheet 1 of 3 4,699,627 º#7oolºvIIsausomv U.S. Patent Oct. 13, 1987 Sheet 2 of 3 4,699,627 Polyester Staple Fiber Manufacturing Process Showing Points For Possible Addition (k) of indigo Dye able Additive Spinning Spin Finish/Indigo Dyeable sk Additive Application Collection of Yarns From Spinning Mochine into Contoiners Collection of Yorns From Containers to Make O Large Tow Finish Bath/Indigo Dyeable Additive Application K (~70 - 75c) Drawing Crimping Drying Cutting Baling Shipping FIGURE 2 U.S. Patent Oct. 13, 1987 Sheet 3 of 3 4,699,627 Polyester Filament Yarn Mann facturing Process Showing Points For Possible Addition (k) of indigo Dye able Additive Spin Finish/Indigo Dyeable Additive Application (%) Winding Draw texturing After oil/lindigo winding Dye able Additive Application (k) Afteroil/indigo Afteroll/Indigo Dye able Additive Dyeable Additive Application (k) Application (k) Shipping Shipping Shipping FIGURE 3 4,699,627 2 polyester is also said to give controlled fading during INDGO-DYEABLE POLYESTER FIBERS AND "wash-down' to a soft lighter blue coloration. CANA PRETREATMENT OF POLYESTER TO PRODUCE DIAN TEXTILE at 16 (October 1982). SAME Defensive Publication T100,201 to Logulio (pub lished Jan. 6, 1981) of DuPont further discloses a poly BACKGROUND TO THE INVENTION meric Salt coating having the following repeating units: 1. Field of the Invention The instant invention relates to the field of man-made fibers and, in particular, to the manufacture of polyester fibers used in wear apparel. Further, the instant inven 10 tion relates to the indigo-dyeing of polyester fiber. Spe (CH-C) cifically, the present invention relates to coated polyes O=cC-O-R-N-R: X ter fibers which are indigo-dyeable and possess wash R4 / N R down and crocking resistance similar to indigo-dyed cotton fibers, and to processes for preparing such fibers. 5 Problems of the classic prior art in indigo polyester 2. Description of the Prior Art, and Other Informa dyeing are exemplified by the teaching of U.S. Pat. No. ton 3,527,556 to Riley, where artisans are taught to dye Indigo is a vat dye, known in India since the earliest poly(glycol terephthalate) with natural or synthetic periods for which historical records exist. Indigo has had for centuries such as aura of mystique that Sir Issac indigo at the boil, in an aqueous bath between about pH Newton included it as one of the colors of the spectrum. 4 and 6 in the presence of sodium ions and sodium hy Dating back to early times, indigo has been used in drosulfite, to transform the indigo into the yellow so dyeing of textiles and printing; cultivation of the indigo dium leuco form, followed by oxidizing the indigo to its plant in India and other countries and its extraction, blue form; in other words, to dye polyester with indigo commercial manufacturing of indigo from anthraqui 25 dye in a similar manner as with other vat dyes. We have none, and indigo dyeing of cotton and wool have been found this type of process to be unsatisfactory insofar as the subject of much interest and reporting in the litera the indigo-dyed polyester does not simulate the fastness ture. See CIBA Review, No. 85 (April 1957); Trotman, properties of indigo-dyed cotton, e.g., denim. DYEING AND CHEMICAL TECHNOLOGY OF U.S. Pat. No. 3,504,998 to Speier discloses a process TEXTILE FIBERS (Griffin Publ. Co., London, 4th for coloring non-siliceous textile fibers, e.g., acrylics, edition, 1970) at 474-487; B. Kramrisch, "Dyeing and polyesters and saran, with: Printing With Indigo", AMERICAN DYESTUFF (1) an aqueous solution of an organo-silicon com REPORTER at 34-38 (November 1980); THE THE pound selected from the group consisting of ORY OF COLORATION OF TEXTILES (C. L. Bird (A) water soluble reaction products of water and a et al., editors, Dyers Co. Publications Trust London, 35 polyaminoalkylsilane of the formula: 1975) at 43, 120; and THE APPLICATION OF VAT DYES (American Association of Textile Chemists & Colorists, 1953), AATCC Monograph No. 2 at 1-3 and 220-23. where x is an integer from 0 to 1 inclusive, each R vat dyes are insoluble in water and cannot be used for dyeing without 40 is an alkyl radical of less than 4 carbon atoms; R' is modification. When treated with reducing agents, vat dyes are con an aliphatic hydrocarbon radical containing a num verted into leuco compounds-all of which are soluble in water in the presence of alkalis. ber of carbon atoms selected from the group con Indigo dye and its homologues are now used almost sisting of 1 and more than 2 carbon atoms and exclusively on cotton (cellulosics) in the production of having a valence of n+1 where n is an integer of at denims. It has poor color fastness properties which are 45 least 1; Z is a monovalent radical attached to R' by aesthetically appealing for this end-use and which fade a carbon-nitrogen bond and is composed of carbon, in a predictable manner. It is applied by multiple pad nitrogen, and hydrogen atoms, and further contains ding of leuco indigo dye at ambient temperature foll at least two amine groups, the ratio of carbon lowed by air oxidation after each padding. atoms to nitrogen atoms in the substituent -R'Zn Unfortunately, this method of application to polyes 50 being less than 6:1; and R' is a monovalent hydro ter results in only staining of the polyester to a light carbon radical free of aliphatic unsaturation; and color. Therefore, when polyester is used either in inti (B) water soluble acid salts of (A); and mate blends or as filament yarns in combination with (2) a textile dye stuff. cotton for producing denim fabrics, the classic result is U.S. Pat. No. 3,793,341 to Genta and U.S. Pat. Nos. an undesirable contrast of the stained polyester with the 55 3,960,479 and 4,032,539, each to Tsujimoto et al., are deeply dyed cotton. illustrative of the prior art in that novel synthetic in U.S. Pat. No. 4,335,185 and its divisional U.S. Pat. digoid compounds are claimed which are alleged to be No. 4,369,213 to Adelman et al. of duPont de Nemours more active in dyeing with polyester fibers than the and Co. ("duPont'), Wilmington, Del, disclose a cross natural indigo dye counterparts. However, it can be linked polyvinyl alcohol polymer-coated polyester fiber 60 fairly said in the fastness properties of the resulting dyed wherein the underlying polyester fiber is dyed with a polyester, the public has been unsatisfied with the re dye other than indigo dye in order to provide a base sults vis-a-vis cotton, e.g., denim.