Hydrophilic yarn dyed polyester process

Information

  • Patent Grant
  • 6238441
  • Patent Number
    6,238,441
  • Date Filed
    Wednesday, July 29, 1998
    26 years ago
  • Date Issued
    Tuesday, May 29, 2001
    23 years ago
Abstract
A process for preparing moisture wicking polyester fabrics is disclosed which comprises the steps of: winding hydrophobic polyester yarn onto a package; subjecting the wound package to a dyebath including at least one dye and an agent rendering the polyester yarn hydrophilic while subjecting the yarn to elevated temperatures, pressures or both to dye the polyester yarn and render the polyester fibers hydrophilic; and preparing the thus dyed and treated polyester yarn into a fabric, biaxially stretching and heat-setting the fabric.
Description




BACKGROUND OF THE INVENTION




This invention relates to a process for preparing polyester yarn capable of wicking away moisture from the body and making the wearer more comfortable by treating polyester fibers in the form of yarn to make the normally hydrophobic polyester fibers hydrophilic.




Traditionally piece dyed goods have been processed and treated in fabric form with finishes to render the polyester hydrophilic and this limits the styling possibilities to solid shades.




Various proposals have been made to impart hydrophilic properties to synthetic fibers, particularly nylon and polyester, in the piece goods or fabric form. For example, fleece type sweatshirt fabrics in the form of a composite textile fabric having a first layer of a polyester or nylon material rendered hydrophilic and a second layer or a moisture absorbent material such as nylon are disclosed in U.S. Pat. No. 5,312,667 to Lumb et al. After knitting the fabric, the nylon or polyester component of the two layer fabric is rendered hydrophilic by treating the fabric in a dye bath to which a low molecular weight polyester such as Milease T (I.C.I.), Scotchguard FC-226 (3-M) or Zelcon (DuPont) has been added. The nylon- or polyester-containing layer of the composite is treated and dyed in fabric form.




Colored polyester fibers having hydrophilic groups grafted onto them are described in JP-A (Kokai) 48-96828 (1973). Colored graft fibers, prepared from solution (pigment) dyed polyester fibers placed in a dyeing machine with a hydrophobic radical initiator, organic solvent and hydrophilic monomer to graft polymerize the hydrophilic monomer onto the surface of the polyester fibers. The resultant product is said to have antistatic, moisture absorption, water absorption, soil resistance and thermal stability properties. This procedure requires the use of organic solvents insoluble in water, initiators and monitors, etc. all maintained under graft polymerization temperature and pressure conditions to fundamentally alter the characteristics of the polyester fibers, conditions not particularly convenient to conventional polyester yarn dyeing and processing.




It would be advantageous to include within the usual polyester dyeing process a treatment to render the normally hydrophobic polyester fibers hydrophilic and, in particular, to include this treatment in an otherwise conventional package dyeing operation. The resulting yarns may be knitted into either solids or styles such as jacquards, scoured and heatset without reducing the hydrophilic properties imparted concurrently during the dyeing operation.




DETAILED DESCRIPTION OF THE INVENTION




The present invention provides finishing procedures capable of rendering normally hydrophobic polyester fibers hydrophilic while the fibers are in yarn form, conveniently concurrently with the yarn dyeing process, to produce suitably treated and colored yarns which are then knitted in solid or multicolored jacquards, scoured, heatset and constructed into garments or the like. Hydrophilic treatment is easily incorporated into the package yarn dyeing operation by including the additional finish or finishes and agents into the dyebath into existing processing without changes or substantial changes in equipment and operating personnel.




According to the invention, the yarn may be dyed in the form of a package in which the yarn is placed on a “package” such as a skein, cone, beam or spool. The package is sealed in a dyeing machine and subjected to elevated pressures and/or temperatures to force the dyebath, which includes the hydrophilic chemical, to pass back and forth through tightly wrapped yarns to accomplish the desired treatment, in this case both dyeing and rendering the normally hydrophobic fibers of the polyester yarns hydrophilic. U.S. Pat. No. 3,878,575 to Wedler and U.S. Pat. No. 4,097,232 to Negola et al are illustrative of the equipment and procedures for dyeing and treating packages of polyester yarn. Subsequent to package dyeing and hydrophilic finishing, the yarn may be knit into a tube, or other configuration, optionally scoured with a soap or detergent, then biaxially stretched such as in a tenter frame or oven and heatset all using conventional fluids, equipment and procedures.




The process is suited to a wide variety of polyester yarns suited to the practical weight of the product to be produced. They may be spun yarns such as prepared by ring, OE or air jet spinning or filament yarns. The agent providing the desired hydrophilic properties to the polyester yarn is selected from a variety of commercially available materials including Hydrolon (Consolidated Chemical) and Scotchguard FC-226 (3M)











EXAMPLE




Polyester yarn (18/1 ring spun) wound onto a package was dyed with a disperse dye including a hydrophilic agent in the dye bath. The yarn was loaded into the dye kier and the kier filled with water and heated to 160° F. For dyeing to light shades a dyebath was prepared containing the following components (in percent by weight):



















disperse dye(s)




depending upon color













acetic acid (20%)




1.2%







leveling agent




2.0%







hydrophilic agent (Scotchguard FC-226)




1.5%







magnesium chloride




2.0%















The dyebath was circulated at 160° F. for 5 minutes, heated to 200° F. at 3 F/minute, then heated to 265° F. at 2 F/minute and circulated at 265° F. for 20 minutes. Next the bath was drained, the unit overflowed with water at 90° F. for 10 minutes then the water was drained. The unit was then filled with water at 160° F. and circulated for 10 minutes then overflowed with water at 90° F. for 5 minutes, then the water was drained.




For medium to dark shades a reduction clearing step is added to include, after the above steps, filling the kier with water and heating to 160° F., adding a mixture of 2% soda ash and Pres Clear Wrm 2%, heating to 180° F. at maximum heating rate and circulated for 15 minutes then drained, filled with water and heated to 160° F. at maximum heating rate and circulate for 10 minutes, then overflowed with water at 90° F. for 5 minutes. The yarn was then dried and wound for knitting into the desired construction.




The knit fabric was next finished as a knit tube in a batch process first scoured in a beck using soap (Sedgescour LCP, 2 grams/liter) and a defoamer (Hipochem NSD, {fraction (


1


/


4


)} gram/liter), then heated to 140° F. and circulated for 30 minutes, overflowed with water at 120° F. for 20 minutes then drained The beck was again filled with water then the fabric was unloaded and slit to open the fabric. Final processing and setting was conducted on a tenter frame where the slit fabric was padded with water (only), biaxially stretched and heat set at 350° F.




Shrinkage was under 7% in the length and width after three standard washings and dryings. Water absorbency was tested by dropping plain water on the fabric; water so applied must be absorbed within 3 seconds to be acceptable for this particular test. The fabric should retain this characteristic for up to 50 washings and dryings to assure durability of the hydrophilic agent on the polyester.




While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.



Claims
  • 1. A process for preparing moisture wicking polyester fabrics comprising the successive steps of:(a) winding hydrophobic polyester yarn onto a package; (b) subjecting the wound package to a dyebath including at least one dye and an agent rendering the polyester yarn hydrophilic while subjecting the yarn to elevated temperatures, pressures or both to dye the polyester yarn and render the polyester fibers hydrophilic; and (c) preparing the thus dyed and treated polyester yarn into a fabric, biaxially stretching and heatsetting the fabric to provide a fabric constructed entirely of the moisture wicking polyester yarn that retains its hydrophilic properties after multiple washings.
  • 2. The process according to claim 1 in which the polyester yarn is a filament yarn.
  • 3. The process of claim 1 in which the polyester yarn is a spun yarn.
  • 4. The process of claim 1 in which the dyed, treated polyester yarn is knit into a fabric in step (c).
US Referenced Citations (17)
Number Name Date Kind
3618609 Glick Nov 1971
3773463 Cohen et al. Nov 1973
3821136 Hudgin et al. Jun 1974
3878575 Wedler Apr 1975
3960341 Thelen Jun 1976
4097232 Negola et al. Jun 1978
4287237 Prudhomme et al. Sep 1981
4300251 Santens et al. Nov 1981
4442249 Lees et al. Apr 1984
4727611 Schwartzman Mar 1988
4874019 Whetstone Oct 1989
4925726 Whetstone May 1990
5172443 Christ Dec 1992
5240660 Marshall Aug 1993
5297296 Moretz et al. Mar 1994
5312667 Lumb et al. May 1994
5387263 Marlowe et al. Feb 1995
Foreign Referenced Citations (8)
Number Date Country
1034651 Jan 1968 GB
72-023718 Jan 1972 JP
48-096828 Jan 1974 JP
48-067882 Jan 1974 JP
51-026397 Jan 1976 JP
59-106517 Jan 1984 JP
9-291429 Jan 1997 JP
9411322 Jan 1996 KR