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Dyeing of Polyester With Disperse Dyes

This document discusses the process of dyeing polyester fibers with disperse dyes. It explains that disperse dyes are used because they have small particle sizes that allow them to penetrate the closely packed crystalline structure of polyester fibers. There are three main dyeing methods - carrier dyeing at 100°C, high temperature dyeing at 120-130°C, and thermosol dyeing at 200-220°C. High temperature dyeing is preferred because it does not require toxic carriers and allows deep shades to develop through improved dye diffusion into the fibers at higher temperatures. Proper pH control between 4.5-5.5 using acetic acid is also important for good dye exhaustion and fastness.

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362 views21 pages

Dyeing of Polyester With Disperse Dyes

This document discusses the process of dyeing polyester fibers with disperse dyes. It explains that disperse dyes are used because they have small particle sizes that allow them to penetrate the closely packed crystalline structure of polyester fibers. There are three main dyeing methods - carrier dyeing at 100°C, high temperature dyeing at 120-130°C, and thermosol dyeing at 200-220°C. High temperature dyeing is preferred because it does not require toxic carriers and allows deep shades to develop through improved dye diffusion into the fibers at higher temperatures. Proper pH control between 4.5-5.5 using acetic acid is also important for good dye exhaustion and fastness.

Uploaded by

irfanfakhar2
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Polyester dyeing

Introduction

➢The most commonly used synthetic fibres are


➢Polyester , nylon and acrylic
➢All can be dyed with disperse dyes.
➢Acrylic fibres are usually very well dyed with basic dyes.
➢polyester fibers have more crystalline region which are
closely packed (more compact structure). On the other hand
disperse dye molecule size is smaller, that is why disperse
dyes are used for these fibers.
Disperse Dyes

✓Non‐ionic,
✓Have very small particle size usually in the range 0.5–1.0 μm.
✓ Disperse dyes have the smallest molecules of all the common dye
classes. A feature of disperse dye molecules is their lack of polar
groups, evidenced by the insolubility of disperse dye.
✓Developed for synthetic fibers which are hydrophobic.
✓The problem of insolubility in water can be tackled by
incorporating a surface‐active agent, through which dye
dispersion is made.
✓Dispersing agents are surface active agents added to render the
dye powder easily dispersible in water and to maintain the
stability of the dispersion during dyeing
✓This dispersion produces a uniform distribution of dye in the
dyebath, allowing uniform dyeing to be obtained.
Disperse Dyes

• Because the dyes are applied from a dispersion, they are


called disperse dyes.
• The main class of dyes for polyester.
• Disperse dyes do not contain the chemical groups
commonly incorporated to confer water solubility.
Structure of disperse dyes
Dyeing

• The dyeing process is controlled by either:


1. Accelerating dyeing by raising the temperature or
2. Slowing it down by using a higher concentration of
dispersing agent
• The latter expedient assists levelling of the dye in the fibre
and prevents the build‐up of dye particles on the surface of
the fibre filaments, a fault that otherwise leads to poor
rubbing and wet fastness.
• The dyeing of polyester presents a particular problem
because the polymer chains are closely packed.
Dyeing methods

• There are three methods of disperse dyeing

• Carrier Method
• (at 100°C temp.)

• High Temperature Method/HT Method


• (at 120-130°C temp. without carrier)

• Thermosoling Method
• (at 200-220°C)
Dyeing methods

• The fibres do not swell, even as the temperature of the dye


liquor is raised, so diffusion of dye molecules into the fibre
at temperatures up to the boil is so low that adequate
dyebath exhaustion cannot be achieved.
• Dyes of lower molecular weight show slightly better
diffusion than those of larger molecular weight, but their
wet fastness is not good.
• Consequently the disperse dyes used are those with higher
molecular weight, their problems of exhaustion being
overcome by either dyeing in the presence of carriers or by
high‐temperature dyeing.
Carrier dyeing method
• Actually carriers enter the polyester fiber and open
(swells which results in easy water diffusion) its structure
so that dye molecules easily penetrate into it. Also gives
the transportation to the disperse dye molecules means
accelerates the rate of dyeing.
• This change opens up space through which the dye
molecules can diffuse; consequently even deep shades
can be obtained at the boil.
• It is necessary to remove all of the carrier from the fibres
after dyeing since they have objectionable smells and
further, they are toxic.
• This has implications for the environment, and for these
reasons carrier dyeing is not preferred, the
high‐temperature dyeing method being favoured.
• Carrier dyeing involves high cost. If remain in fabric these can impair
light fastness properties.
Carrier dyeing method
High temperature dyeing method

• The high‐temperature dyeing method involves dyeing at


temperatures of about 130 °C using pressurized vessels.
• At this higher temperature, the rate of dyeing is considerably
increased and the use of dyes with high molecular weights is
possible.
• High temp. and pressure causes the polyester fiber to swell
and helps in penetration of the disperse dye molecules into
the fiber polymer system.
High temperature dyeing method

• Advantages:
• (1) At these high temperatures, migration is very good
• (2) The use of dyes of high molecular weight means that the fastness
properties, especially to light, washing and sublimation, are much
better.
• Dark shades can be produced.
• Fast exhaustion of dye molecules.
• No carrier cost.
• Complete penetration of dye molecules in polyester.
• In a typical high‐temperature dyeing operation, the dyes,
dispersing agent and sufficient acetic acid to give a pH of 5.5
are entered into the dyeing machine.
• The temperature is raised to 130 °C and dyeing is carried out
at this temperature for 45–90 minutes, before allowing to
cool.
High temperature dyeing method
Thermosole process

• High temp. is used in dyeing of polyester fiber under the name of


“Thermosol Process”.

• When polyester is heated to high tem. (200-230°C), it is softened and


its internal structure is opened up.

• The dye molecules can now diffuse into the fiber very easily.

• The diffusion of the dye molecules takes place with in few seconds to
one minute.
Thermosol process
Effect of temperature on disperse dyeing

• Polymeric chains of polyester are closely packed and held together by


strong forces
• For penetration dye molecules must overcome these forces
• Dye molecule can penetrate only when it finds space(void) in the
compact polymer structure
Such voids are formed due to thermal mobility of polymeric chains on
application of heat
Higher the temperature., greater is the thermal mobility and greater
the channces of voids formation and dye penetration
Effect of pH on Disperse Dyeing

• For disperse dyeing the dye bath should be acidic and pH should be
in between 4.5-5.5.

• For maintaining this pH, generally acetic acid is used. At this pH dye
exhaustion is satisfactory. During color development, correct pH
should be maintained otherwise fastness will be inferior and color
will be unstable.

• Strongly alkaline or acidic conditions, such as higher than pH 9 and


lower than pH 4, induce hydrolysis of the fiber as well as
decomposition of disperse dyes.
Removal of unfixed dye

• Rinse only (for very light shades)


• Rinse with surfactants (for light-med. Shades)
• Alkaline reduction clearing (dark shades)
• 1-2 g/l detergent/dispersant
• 4-6 ml/l caustic soda
• 1-3 g/l reducing agent (sodium dithionite)
• Neutralization
• 1 ml/l acetic acid
Thank you

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