Disperse dyes and their application to Polyester

Disperse dyes are non-ionic, have very limited solubility in water at room temperature and have substantivity for one or more hydrophobic fibres e.g. polyester and nylons. They are usually applied from a fine aqueous dispersion containing some dissolved dye. This definition stress the fact that it is the aqueous solution from which dyeing normally takes place, despite the low water solubility of the dye. Polyester Dyeing : General The four stages in the generally accepted mechanism of dyeing are as follows: 1. Some dye dissolves in the liquor 2. Dissolved dye is adsorbed unimolecularly on the surface of the fibre 3. This dye than diffuses into the fibre 4. The dye removed from the liquor is then replaced from the reservoir of solid particles. It follows that the build up of dye within the fibre depends on the solubility of the dye in the liquor and the rate of diffusion of ye into the fibre. If the dye has very low solubility in water, only a small proportion of dye will be available of absorption and the rate of dyeing will be low. Polyester dyeing : Procedures Method 1: Carrier dyeing Certain chemicals called carriers are added to the dyebath; they are, in fact, the swelling agents for the fibres. The swollen fibres permit large dye molecules to diffuse more rapidly in the fibre. Thus the carriers increase the solubility of the dye and the rate of dyeing and are absorbed by the fibre. The carrier is usually added first or is added slowly during the dyeing process because if it is added at once, the dyestuff may rush on to the material. Method of dyeing using carrier The dyebath is set with 1 gpl wetting agent, 0.5 1.0 gpl of dispersing agent and 3-5 gpl of carrier at 40 -60oC. The material is worked in the blank bath for 15 minutes taking care to see that the carrier gets uniformly absorbed. The well dispersed dye is then added and the temperature raised to boil within 30 minutes. The pH of the bath is maintained between 6.5 to 7 by adding 1 ml / l of acetic acid for liberation of phenol. The dyeing is continued at boil for 2 hours. The material after dyeing, is rinsed and soaped at boil with 2 gpl detergent and 2 to 5 ml/ l of caustic soda (72oTw) at 80 85oC for half an hour to remove residual carrier; this is important as its presence impairs the fastness to light of the dyed material and it causes

irritation of the skin and gives unpleasant odour. The last traces of the carrier can be completely removed by curing at 190oC to 200oC for 1 minutes when it sublimes. The carrier dyeing method has certain advantages as well as disadvantages. The advantages of carrier dyeing method are that: a. the material can be dyed at atmospheric pressure without using any special equipment b. the carrier helps the dyestuff in penetrating the fibre c. the dyeing can be carrier out comparatively rapidly and d. the dyeing is more of less uniform The disadvantages of Carrier dyeing method are: a. b. c. d. the carriers are costly; the cost of dyeing is, therefore considerable; the goods retain the odour of some of the carriers if not washed thoroughly the light fastness of the dyeing is badly affected; it is difficult to remove the carrier completely form the dyed material; residual carrier can cause irritation of the skin. e. The process of dyeing is rather lengthy Method 2 : High temperature high pressure dyeing The disperse dyestuffs without the use of carriers do not penetrate ( or partly penetrate) the polyester fibre even at 100oC and give only pale shades as most of the dyestuff is located on the surface of the fibres. If, however, the temperature is raised beyond 100oC say, to 120oC, the chain molecules in the fibre are much more free to move and the fibre swells to greater extent. As a result there is rapid penetration of the dyestuff molecules in the fibre structure. The dyeing time is also reduced due to faster diffusion of the dye in the fibre. The fastness properties of the dyed material are improved due to better penetration of the dye and the disadvantages of carrier dyeing are eliminated. The process, however, involves the use of pressure equipment since water dyebaths cannot be maintained at a temperature above 100oC at atmospheric pressure. The dyeing has therefore, to be carrier out at high pressure and high temperature in closed vessels. Method of HTHP dyeing The method is quite simple. The dyebath is set with 1 gpl dispersing agent and 1 gpl of ammonium sulphate. The dyebath is made acidic with formic acid to bring the pH of the liquor between 4.5 to 5. If the dyebath is alkaline, loss of strength of the fibre occurs at high temperature. The goods are entered at 60oC in the pressure vessel and the temperature raised to 130oC at the rate of heating of 1 to 1.5oC / min. The dyeing is carried out at this temperature for 30 minutes for pale shades and for 1 hour for dark shades. The liquor is than run off and the material is rinsed. If it has been dyed a heavy shade it is given a reduction clearing treatment and it is then soaped with 1 gpl non-ionic detergent at 80oC for 30 minutes, rinsed again and dried.

The components of the high temperature procedure needs to be examined in detail to find the purpose of every chemical and every step, in order to be able modify the procedure on demand for eh purpose of fitting it to any given set of circumstances. Fastness properties on Polyester The fastness properties of disperse dyes on polyester cover wide enough range for an adequate dye selection for most end uses. The same dyes generally show poorer fastness on nylon. Stripping Stripping can be accomplished by treating goods in a blank dyebath with the addition of a non-ionic levelling agent at ca. 130oC. However, if chemical destruction of dye is necessary, 1-2 gpl sodium hydroxide plus a reducing agent or a mildly acidic treatment with zinc sulfoxalate-formaldehyde (a reducing agent) or sodium chlorite (an oxidant used in bleaching) can reduce the shade to almost a white ground.

IMPORTANCE OF DISPERSING AGENT

The disperse dye should be easily dispersable in water and should not form agglomerates. Hence, dispersing agent is added in the dye powder as well as in the solution during dyeing.

Insoluble dye molecules agents Can form agglomerates

Dye molecules surrounded by anionic dispersing which avoid aggregation of the dye molecules

METAL COMPLEX DYES Chrome Mordant dyeing method is very lengthy. So metal introduced in dye were produced. They are known as pre metallised dye. Metal is either Cr or Co. There are two types of metal complex dyes 1:1 Metal complex dye - 1 metal ion and 1 dye molecule. 1:2 Metal complex dye - 1metal ion and 2 dye molecules. 1:1 Metal Complex Dyes Application of 1:1 Metal Complex Dye can be done by the following method

This dye has low affinity and so is applied at low pH 2 with use of H2SO4. At boil in presence of H2SO4 wool gets degraded and becomes rough. The advantages of this dye are good wet fastness. Dyed generally on loose wool so that later can be blended as per shade required. Wash fastness of milling acid and 1:1 Metal Complex Dye is almost equal. 1:2 Metal Complex Dyes Application of 1:2 Metal Complex Dye can be done by the following method

1:2 Metal complex dyes can withstand the alkali wash given to carpet. Very good Wash fastness and light fastness are obtained. Dye bath is cooled to 80oC for shade matching. At times ammonium sulphate or a combination of CH3COOH and ammonium sulphate is used. 1:2 MCD have very large molecule, high affinity and have various dye fibre interactions so give good fastness properties.