MXPA96006194A - Compositions of dyeed polyolephine and met - Google Patents

Compositions of dyeed polyolephine and met

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Publication number
MXPA96006194A
MXPA96006194A MXPA/A/1996/006194A MX9606194A MXPA96006194A MX PA96006194 A MXPA96006194 A MX PA96006194A MX 9606194 A MX9606194 A MX 9606194A MX PA96006194 A MXPA96006194 A MX PA96006194A
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MX
Mexico
Prior art keywords
weight
composition
ethylene
polypropylene
amount
Prior art date
Application number
MXPA/A/1996/006194A
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Spanish (es)
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MX9606194A (en
Inventor
J Sheth Paresh
Chandrashekar Venkatramana
R Kolm Roger
Original Assignee
Lyondell Petrochemical Company
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Publication date
Priority claimed from US08/384,716 external-priority patent/US5550192A/en
Priority claimed from US08/442,304 external-priority patent/US5576366A/en
Application filed by Lyondell Petrochemical Company filed Critical Lyondell Petrochemical Company
Priority claimed from PCT/US1995/006590 external-priority patent/WO1995033882A1/en
Publication of MXPA96006194A publication Critical patent/MXPA96006194A/en
Publication of MX9606194A publication Critical patent/MX9606194A/en

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Abstract

The present invention relates to a process for dyeing fibers based on polypropylene, comprising: (a) forming in a fiber a composition of about 99 to 70% by weight of a polypropylene and an ethylene copolymer comprising about 30 to 82% by weight ethylene weight and about 30 to 18% by weight of an alkyl acrylate, wherein the alkyl has 1 to 4 carbon atoms, the alkyl acrylate is present in a composition in an amount between 0.2 to 3.0% by weight of the sum of the copolymer of ethylene and polypropylene, and the ethylene of the ethylene copolymer is present in the composition in an amount of less than about 10% by weight of the sum of the polypropylene copolymer and ethylene, (b) exposing the fiber to a colored

Description

? QMPQ3T.CT, QiffiS. The present invention relates to a dyeable polyolefin composition and to a process for dyeing nonwoven fibers and materials formed from this composition. More particularly, the invention is directed to a dispersible-dyeable fiber composition, comprising polypropylene, polyester and a polar material such as ethylene copolymer. The invention further addresses a formulation and process that will allow the use of cationic dyes for polyolefin-based compositions. APtecegEits < fc »? & invnción Polyolefins are hydrophobic and difficult to stain because they lack coloring sites to which the dye molecules can be connected. One approach to coloring polyolefin fibers has been to add colored inorganic salts or organometallic pigments stable to polymer fusions before spinning the fibers. Non-volatile acids or base or materials such as polyethylene acids or metal salts, have been added to polymers prior to fiber formation to increase fiber affinity for dispersed dyestuffs, acids or dyes. Polyolefin fibers can be chemically grafted with appropriate monomers after fiber formation for improved staining ability Textil Fxbers, Dyes, Finishes, and Processes: A Concxse Guide, (Textile Fibers, Dyes, Finishes and Processes: A Detailed Guide) L. Nedles Publications, 1986, p. 191. Efforts to impart the acid staining ability to polyolefins, and particularly to polypropylene, include the use of nitrogen-based polymer additives. For example, in U.S. Pat. No. 3,361,843, various incompatible nitrogen-based polymers are added to polypropylene, treated with high concentrations of acidic chemical reagents and then colored in an acid dye bath. According to the U.S. Patent No. 3,361,843, coloring a propylene fiber is somewhat improved by the method of U.S. Pat. No. 3,361,843, but the processing is difficult due to incompatible polymer, the color fastness properties are not reliably reproducible and the dye intensities are not commercially sufficient. In the Patents of the U.S.A. No. 3,395,198; and the U.S. Patent. No. 3,653,803, various compatible nitrogen-containing copolymers of ethylene and an aminoalkyl acrylate compound are described, so that when mixed with polyolefins, they make the fibers formed from the mixture dyeable with acid. In the patent of the U.S.A. No. 5,017,658, a fiber finishing agent is employed in polypropylene fibers dyed with melt spin, which are obtained by mixing a copolymer of an ethylene aminoalkyl acrylate with polypropylene.
In the patent of the U.S.A. No. 4,557,958, a blend of 70% by weight of polypropylene homopolymer and 30% by weight of ethylene-methylacrylate copolymer, is applied to a woven polyolefin fabric as a coating strip to prevent fraying of the fabric, when the Fabric is cut In US Patent No. 4,853,290, a blend of ethylene-acrylic ethylene copolymer and ethylene-methacrylate copolymer is co-extruded onto a polypropylene film, to serve as an adhesive or a bonding layer. A second polymer In US Patent No. 4,782,110 multiplatable propellable process thermoplastic compositions are described which can be formed into various structures by compression molding, injection molding, blow molding and extrusion. crystalline polyolefin resin forming the continuous phase of the composition and an entangled elastomer of an ethylene-alkyl acrylate copolymer which forms the disconti nua of a composition. The elastomer consists of units derived from ethylene, an alkyl ester of acrylic acid, wherein the alkyl group contains 1 to 6 carbon atoms, and a monoalkyl ester of 1, -butadioic acid, wherein the alkyl group contains 1 to 6 carbon atoms. The Patents of the U.S.A. No. 3,373,222 and 3,373,223 disclose polymer blends comprising polyolefin resin, polyamide resin and any of a carboxylated polyethylene, an ethylene-acrylic copolymer or methacrylic acid. Homogeneous jolymer mixtures are useful in the preparation of films useful in the packaging industry and in the preparation of plastic bottles and other containers that require a high degree of impermeability. In the patent of the U.S.A. No. 3,454,215 discloses a dyeable polypropylene composition comprising a copolymer of polyamide and ethylene. The composition may comprise a uniform blend of polypropylene, a low molecular weight thermoplastic non-reactive polyamide and an additional polymer selected from a group consisting of copolymers of ethylene and an ethylenically unsaturated ester of a saturated fatty acid or a hydrolysed product of these copolymers . The specification of UK Patent No. 998,439 also describes a thermoplastic composition comprising polyamides and olefin copolymers. The U.S. Patent No. 5,017,658, discloses a dyeable polypropylene composition, which includes a copolymer of an aminoalkyl acrylate with polypropylene. The U.S. Patent No. 4,368,295 discloses a film produced by an extrusion or melting process, made from compositions containing a resin polymer, a linear polyester and a carboxylated polyolefin. The U.S. Patent No. 4,174,543 discloses split fiber products, and films comprising polypropylene and one or more with esters and / or polyamides.
A chapter entitled "Dyeing of Propylene Fibers" 'Dyeing of Polypropylene Fibers' in "Polypropylene Fibers Scxence and Technology" (Polypropylene Fibers, Science and Technology) by Mike Ah ed, provides a detailed study of the technology involved in dyeing fibers polypropylene from the mid-1950s to the 1980s. Section IV. With respect to stainable fibers with mordant, discusses problems concerning light firmness, firmness to washing, and firmness to the rubbing of certain dyes, the study concludes that the firmness properties of dispersed-dyeable polypropylene fibers, in general, are unacceptable to the textile trade. An article titled "Surface Dyeable Modified PP BCF Yarns "(Filament PP BCF modified dyeable surface) in Chemie fasern / Textilindustrie, Vol 41/93, in October 1991, discusses adding a modifier to a PP BCF filament. A brochure entitled "Pslyjner CompoundÍ? Gr # (Polymer Formulation) by Eastman Chemical Products Inc., discusses Epolene-43 wax, as a compatibilizer for nylon / polypropylene compounds." An article titled "Morphological and Mechanical Properties of Extruded Polypropylene / Nylon -6 Blends "(Morphological and Mechanical Properties of Polypropylene / Nylon Extruded Mixtures ~ 6) by Wan Gheluwe et al. Discusses nylon or polypropylene blends that use Zytel 211 as a compatibilizer, an article titled" New Functional Materials for Absorbent. Products "(New Materials for Absorbent Products) by Dr. Zuzuki in The New Nonwoven World," The New Non Woven World "Fall 1993, discusses new polypropylene materials for absorbent products. In an article titled "Polymer Morphology on the Dyeing Properties of Synthetic Fibers" (Polymorphism in the Synthetic Fiber Dyeing Properties) Keith Silkstone reviews some of the previous technique's efforts, with respect to proposing morphological changes in the fiber production for marginal polypropylene dye uptake. Other relevant articles are "Dyeing Sinthetic Fibers" (Dyeing Synthetic Fibers) H.E. Shroeder, C & EN, Sept., 10, 1956; "Dyes for Hydrofobic Fibers" (Dyes for Hydrophobic Fibers), H.E. Shroeder et al., Textile Research Journal, Vol. 28, April 1957; and "The Influence of Polymer Morphology on the Dyeing Properties of Synthetic Fibers" (The influence of Polymer Morphology on the Staining Properties of Synthetic Fibers). Keith Solkstone, Rev. Prog. Coloration, Vol. 2, 1982. There is a need for improved polyolefin compositions and materials that are commercially dyeable with a wide range of colorants. There is a particular need for polypropylene-based compositions that can be used to make fibers that are centrifuged and can be formed into sheets of fabric, including non-woven fibers. SUMMARY OF THE INVENTION In accordance with the present invention, there are provided Novel compositions and polyolefin articles that are more dyeable, novel methods for dyeing polyolefin articles, and novelty dyed articles, including novel dyed polypropylene fibers, produced by these processes. A novel polyolefin fiber comprises about 99% to 85% by weight of a polyolefin and a selected amount of an ethylene copolymer comprising about 70 to 82% by weight of ethylene and about 30 to 18% by weight of an alkyl acrylate, where the alkyl has from 1 to 4 carbon atoms, the composition contains 0.2 to 3.0% alkyl acrylate by weight, the sum of the ethylene polypropylene copolymer, wherein at least a portion of the copolymer is grafted to the polyolefin and an amount effective of a dispersed dye diffused in the prolipropileño, to produce colored fibers. A hydrophilic modifier can be included It comprises an onoglyceride and a long-chain hydrocarbon with a hydrophilic group. A novel process for forming polypropylene-based fibers comprises (a) combining polypropylene with a select amount of an ethylene copolymer of about 70 to 82% by weight of ethylene and about 30 to 18% by weight of an ethylene alkyl ethyl acrylate, where the alkyl group has 1 to 4 carbon atoms to form a composition; (b) extruding the composition into fibers; and (c) exposing the fibers to a bath Dispersed selective colorant containing a disperse dye, either for dyeing or printing. A novel polyolefin fiber comprises approximately 99 to 70% by weight of polypropylene; a fiber grade polyester from about 0.1 to 15%; a selected amount of a polar group material, such as an ethylene copolymer, a maleic anhydride or an acrylic acid; and a hydrophilic modifier comprising a monoglyceride and a salt of a linear alkyl. The polyester can be formulated with a hydrophilic modifier matrix / polar group / polypropylene material. The ethylene copolymer can comprise about 70 to 82% by weight of ethylene in about 30 to 18% by weight of an alkyl acrylate, wherein the alkyl has 1 to 4 carbon atoms, the alkyl acrylate is present in an amount of 0.2. at 3.0% by weight. The hydrophilic modifier may comprise a fused termination of a monoglyceride and a linear alkyl phosphate and provides additional compatability of the polypropylene and polyester. This modifier can be present in an amount of 0.1 to 2% by weight and preferably between 0.4 and 1.0% by weight, the sum of the copolymer of ethylene, polyester and polypropylene. A novel process for dyeing shaped articles based on a polyolefin, comprises (a) forming in a fiber a composition of approximately 99 to 70% by weight of a polyolefin and a selected amount of a copolymer of ethylene foot comprises approximately 70 to 82% of ethylene and about 30 and 18% by weight of an alkyl acrylate, wherein the alkyl has 1 to 4 carbon atoms; and (b) exposing the fiber to a disperse dye. A novel process for dyeing polypropylene-based fibers comprises (a) combining polypropylene with a select amount of an ethylene copolymer of about 70 to 82% by weight of ethylene in about 30 to 18% by weight of an ethylene alkyl acrylate, wherein the alkyl group has 1 to 4 carbon atoms, to form a composition; (b) extruding the composition into fibers; and (c) exposing the fibers to a select dye bath. A novel process for forming fibers based on polypropylene comprises combining isotactic polypropylene, polyester, a polar group material, and a select hydrophilic modifier. The material of the polar group can be an ethylene copolymer of about 70 to 82% by weight of ethylene in about 30 to 18% by weight of an ethylene alkyl acrylate, wherein the alkyl group has 1 to 4 carbon atoms . Alternatively, the material of the polar group can be a maleic anhydride or an acrylic acid. The hydrophilic modifier can be present in an amount of between 0.1 to 2. 0% by weight, and preferably between 0.4 and 1.0% by weight, the sum of the ethylene, polyester and polypropylene copolymer. The polyester or copolyester in this manner has excellent compatibility with the modified polypropylene. The polyester can be incorporated at a very small level of about 0.1% by weight to 15% by weight. To obtain an acceptable level of stainability with a high level of discharge and subsequent high light fastness, a desired level of polyester can be between 1 and 10% by weight, with an optimum level of about 3% by weight. The dispersed colorant allows the effective production in cost of fibers that preferably have good firmness to light, and at least in some cases, good firmness to washing, and good rubbing properties (draining). In general, the dye will have a comparatively high ratio of mass to polarity, and will only be slightly polar. The tension speed is inversely proportional to the mass of the dye and directly provide linearity and absence of bulky side chains. A dye having low water solubility and high fiber solubility is preferred. Dyes generally intended for dyeing acetate fibers or polyester fibers are likely candidates. An open amorphous fiber structure is also preferred. Based on the work done in several standard dyes, this unique composition exhibits tremendous discharge characteristics with an acceptable level of light fastness / wash and rub characteristics.
Polyolefin in these compositions and processes •• ** Preference is poly.propi.leno i.satáti.co. In the processes, the composition may be a mixture or one in which at least a portion of the ethylene copolymer is grafted to the polyolefin. The ethylene copolymer in the compositions includes ethylene methyl acrylate, ethylene ethyl acrylate and ethylene butylacrylate. It is an object of the present invention to provide an improved inert hydrophobic polyolefin-containing composition with suitable stainability characteristics. A further object of the present invention is to provide an improved polyolefin-containing web consisting of fibers, or a non-woven or fibrillated film as a cover material for various medical devices. Yet another objective is to obtain and retain high hydrophilicity and penetration properties through the sheet causing a liquid spot on the opposite side of a well nonwoven hydrophobic material Strengthened, continuous fiber that includes continuous and / or short fibers using polyolefin components A significant feature of this invention is that the polypropylene-based material can be used to form fibers having applications for either woven materials or non-woven materials, and that the fibers are centrifuged at commercially acceptable rates.Although another feature of the invention is that a polypropylene-based material can be efficiently modified to form an? aterial having a contact angle of wettability of less than about 30. An advantage of the invention is that the wettable polyolefin material according to this invention is more easily dyeable than the polyolefin fiber materials of the prior art.These and additional objects, features and advantages of the invention will be apparent to from the following detailed descriptions Detailed Description of the Invention Polyolefins usable according to this processing are crystalline polyethylene, polypropylene or their copolymers having melt indexes in the range from about 0.1 to about 80 g / 10 min. The most important polyolefin to use in fiber-forming at this time is isotactic polypropylene, which is commercially available from many sources. The polypropylene can contain f1 the usual oxidative thermal and ultraviolet light stabilizers. The fiber-forming composition can comprise polypropylene and a copolymer of ethylene and an alkyl acrylate having 2 to 30% by weight, conveniently 2 to 15%, preferably 4 to 10%, more preferably approximately 7%. According to this invention, the copolymer of ethylene and an alkyl acrylate can be grafted onto the polypropylene. The composition in alternating form may include a formulated mixture of (bolipropylene / copolymer, or both a copolymer of grafted ethylene alkyl acrylate and mixed one advantage of the ethylene alkyl acrylate copolymer is that it is both thermoplastic and compatible with polypropylene, so that processing difficulties are minimized or avoided, by the term "compatible" it is meant that the copolymer is not separated into discrete particles of the polypropylene composition that is observed under an optical microscope at a magnification of 250-500 times. The polypropylene offers an excellent bridge for optionally adhering with the polyester or copolyester The ethylene copolymer comprising ethylene alkyl acrylate in the compositions usable in this invention includes ethylene methyl acrylate, ethylene ethyl acrylate and ethylene butyl acrylate The ethylene methyl acrylate copolymer "EMA") alone or in a mixture has been used in a film, coating Extrusion, sheet, pipe, profile extrusion and coextrusion areas. Compared with low density polyethylene homopolymer it has a lower softening temperature of 59 ° C (138 ° F), a reduced flexural modulus and an improved stress cracking resistance. Ethylene copolymer has been described for use as a blending component with low density polyethylene, polypropylene, polyester and polycarbonate to improve impact strength and toughness, increased response to thermal seal and promote adhesion, reduce rigidity and increase the coefficient of superficial friction. Modern Plastics (Encyclopedia of Modern Plastics) Encyclopedia, mid-October version, 1991, p. 71-72. Ethylene-ethyl-acrylate copolymer resins ("EA") resistant, are resistant, flexible copolymers that have found application in hoses and pipes, packaging, ties, disposable examination gloves and balloons. EEA has also been used for hot melt adhesives. ... As the EEA's ethyl acrylate content increases, Copolymers become more flexible, stronger and more resilient. The polarity of high ethyl acrylate resins can improve the surface acceptance of inks and provide adhesive properties. Ethylene Butyl Acrylate ("EBA") is used for low melt index films. It produces a film resistant to low temperatures and is used primarily in the packaging of frozen foods. Particularly preferred copolymers are the random copolymers of ethylene methyl acrylate of ethylene and methyl acrylate and the random copolymers of ethylene ethylacrylate ethylene and ethyl acrylate. EMA copolymers preferably contain about 20 to 24%, and preferably about 20%, by weight of methyl acrylate. The EEA copolymers preferably contain about 15 to 30% by weight and the ethyl acrylate moiety. These copolymers have a Melt Index of 1 to 20, preferably about 18, and have thermal stability such that when the temperature rises to 10 ° C / min, under nitrogen circulation, less than 0.75% of the copolymer weight is lost at 300 ° C. A critical feature of the present invention is that the amount of alkyl acrylate in the polypropylene ethylene alkyl acrylate copolymer is present in an amount of 0.2 to 3.0% by weight and preferably between 0.5 and 2.4 by weight, in order to produce a fiber textile that has commercially acceptable processing characteristics. If the amount of alkyl acrylate component is implemented on 3.0%, a textile fiber produced therefrom loses its necessary polypropylene characteristics, degrades during high speed processing, and produces a final fiber with unacceptably low tenacity (less than about 1.5 g / denier) and excessive elongation with significantly different melting characteristics to be commercially unacceptable. For example, a mat made with fibers that have an alkyl acrylate component between 3.0 and 5.0% melts excessively when exposed to flame compared to conventional polypropylene mat to the point that dramatically fails a standard "pill test" for flame resistance, while the standard propylene passes. Furthermore, at an alkyl acrylate content of 2.4%, the fiber is melted together in the heated drawing rolls and it is basically impossible to centrifuge in modern commercial scale equipment. These subtle but commercially critical limitations were completely unexpected. An alkyl acrylate component of less than 0.2% produces a fiber with insufficient polarity performance character to impart a desired dyeing capacity to accept a desired homogenous, deep color. Accordingly, the maximum amount of alkyl acrylate component is preferred, subject to acceptable fiber production and performance character. The most preferred alkyl acrylate component is between 0.5 and 2.4% by weight for polypropylene compositions that do not include polyester, with 1.0 to 1.5% more preferred for polypropylene / polyester compositions. Polypropylene without the grafting process does not form continuous or continuous filaments in volume with polyester or copolyester. The degree of compatability to improve processability can be increased by incorporating the hydrophilic modifier such as a monoglyceride and a long chain hydrocarbon as a hydrophilic group. It is understood that polymeric additives such as ultraviolet, thermal and oxidative stabilizers that are typically found in fiber-forming polymer compositions can be added without departing from the present invention. The values of% by weight given in this application are expressed as a% by weight of the proposition that includes a polyolefin, such as polypropylene and a polar material, such as an alkyl acrylate copolymer, and preferably both a hydrophilic and polyester aodifier. The percentage values established for these materials should thus be combined uniformly at 100%. Other additives may include to dilute the polyolefin composition. If these additives are included in the composition, the proportion of polyolefin to polar material will remain constant and the values in total percent of all materials including additives, will exceed 100%. For example, if nylon can be used in the composition. that does not include polyester, the values in percent of polypropylene, copolymer and hydrophilic modifier will not change, and will still total 100%. The ethylene copolymers used in the present invention contain at least 70% ethylene, with the alkyl acrylate compound present between 2 to 30%, typically between 10 to 24%, depending on the selected alkyl acrylate. Depending on the amount of the alkyl acrylate component present in the A- ethylene copolymer, the proportion of ethylene to polypropylene copolymer can be easily adjusted to maintain the adequate amount of alkyl acrylate in the final product.
It is also important that the amount of ethylene contributed by the ethylene copolymer be kept below 10%. Accordingly, it is preferred that the higher the percentage of alkyl acrylate in the copolymer, the easier it will be to obtain the proper balance of components. By way of example, a mixture of 93% polypropylene and 7% ethylene methyl acrylate having n 20% methyl acrylate component, produces a copolymer, polypropylene / ethylene methyl acrylate composition having a methyl acrylate component of about 1.4% . Similarly, a 3% addition of the same ethylene methyl acrylate copolymer produces a 0.6% methyl acrylate component. The invention may further be understood by reference to the following examples, wherein parts and percentages will be by weight unless otherwise indicated. Example 1 A polypropylene alloy composition containing 90% by weight of a commercial grade fiber of isotactic polypropylene, with a melt flow expense of (ASTM D-1238-89, 230A.98 Kg (2.16 lb)) contains thermal, oxidative and ultraviolet light stabilizers and 10% by weight of an ethylene methyl acrylate copolymer, is prepared by first dry-blending the polymers and then melt-stirring the mixture in a 40 mm Berstorff extruder at 246 ° C. The ethylene copolymer contains 24% by weight of the methyl acrylate comonomer and has a melt index of (ASTM D-1238-89, 190 A-98 Kg (2.16 lb)), the resultant homogeneous compatible copolymer mixture is cut into tips after cooling with water, which is then fed to a melt spin apparatus and fiber 50-60 Deniers per filament is centrifuged at 230-245 ° C. A mineral oil-based finish containing anionic surfactants is applied to the fiber bundle after centrifugation, but before stretching. The fibers are stretched three times to give a final Denier of 18 to 20 per filament.
Specimens of the fibers are woven in a weaving machine to produce a tubular woven fabric. Samples of the fabric are stained according to the procedure given below. Staining process steps involving a rubbing, staining, and release reduction operation are used as explained below. In the rubbing stage, the sample is rinsed in cold water for 5 minutes and then the bath is changed. The sample is introduced in a new bath of 0.5 g / l of Keirlon TX-199 wetting agent / detergent and 0.25 g / l of commercial soda, then heated to 71 ° C (160 ° F) and maintained for 10 minutes. After cooling to 38 ° C (112 ° F), the sample is rinsed. In the staining step, the staining bath is prepared as follows: 1% dye, Triton X-100 at 1% and (surfactant) Syntrapal LFP at 1% (dispersed release agent). The pH is brought 5.5 with acetic acid and the bath is heated to 120 ° C, at 2.5 ° C per minute. The bath is kept at this temperature for 30 minutes, then cooled to 40 ° C to 3 ° C per minute. The sample is rinsed hot, extracted and dried. Optionally, for good firmness properties, an additional step, i.e. reductive release / release can be carried out as follows.
In a reduction cleaning stage, stained wash samples are placed in a series of tanks: the first tank, moistened with Triton X-100; second, third and fourth tanks, reductive release at 70 ° C with 8 g / l of sodium hydroxide at 32% concentration, 4 g / l of sodium hydroxysulfite for a total of 30 seconds. The rinse occurs in the fifth tank, and the sample is neutralized with acetic acid in the sixth tank. This process of reductive release ensures the removal of superficially adhered dyes and generally produces better, firmness results. Example 2 A polypropylene graft copolymer containing 90% by weight of a commercial grade fiber of isotactic polypropylene with a melt flow expense of (ASTM D-1238-89, 230 °, and 10% by weight of a copolymer grafted ethylene methyl acrylate (and containing thermal, oxidative and ultraviolet light stabilizers) is prepared by dry blending first the ^ polymers and then melting the mixture in an extruder Berstorff 40 mm at 246 ° C, in the presence of sufficient initiator free radical peroxide, specifically 2,5-dimethyl-2,5-di (tert-butyl peroxy) hexane for viscosity reduction by decomposition of the composition an expense product melt flow rate of 18. The ethylene copolymer containing 24% by weight of the methyl acrylate comonomer and has a melt index of (ASTM D-1238-89, 190A.98 Kg (2.16 lb)), the mixture of homogeneous compatible copolymer resulting is cut into tips After cooling with water which is then fed to a spin-spin apparatus and fibers of 50-60 Deniers per filament, it is centrifuged at 230-245 ° C. A mineral oil-based finish containing anionic surfactants is applied to the fiber bundle after centrifugation, but before being stretched. The fibers are stretched three times to give a final Denier of 18 to 20 per filament. Specimens of the fibers are woven in a weaving machine to produce a tubular fabric. Tissue samples are sifted according to the procedure given in Example 1. Example 3 A polypropylene graft copolymer containing 90% by weight of a commercial grade isotactic polypropylene fiber with a melt flow expense of (ASTM) D-1238-89, 230 ° .98 Kg (2.16 lbs)), and containing thermal, oxidative and ultraviolet light stabilizers) and 10% by weight of an alloy and grafted copolymer of ethylene methyl acrylate, is prepared at the dry mix the polymers first and then mix the mixture in a 40 mm Berstorff extruder at 246 ° C, in the presence of sufficient peroxide free radical initiator, specifically 2,5-dimethyl-2,5-di (ter) -butyl peroxy) exano for viscosity reduction by decomposition of the composition at a product melt flow rate of 35. The ethylene copolymer contains 24% by weight of the methyl acrylate comonomer, and has a melt index of (ASTM. D-1238-89, 190 °, .98 Kg (2.16 lb.) )), the resulting homogenous compatible copolymer mixture is "cut" into tips after cooling with water, which is then fed to a spin-spin apparatus and 50-60 Deniers fibers per filament are centrifuged in a partially yard operation oriented (poy) at a collection speed of 3000 RPM, and subsequently textured by false twisting to fibers from 2.0 to 2.5 dpf. Specimens of the fibers are woven in a weaving machine to produce a tubular woven fabric. A series of polymer samples made as described in Examples 1 and 2 were evaluated with a series of disperse dyes according to the dyeing procedure of Example 1. The results are set forth in Table 2. No appreciable difference was detected. with respect to the dyeing characteristics between the samples of Example 2 and Example 3. Table I lists dyes that are suitable for dyeing fibers according to the present invention. Firmness tests were also carried out on the light, and rubbing firmness on filaments at 2.20 denier per filament.
TABLE I '"Discharge of Colorant Discharge of Colorant Type of Colorant Xenon Light ATCC Firmeza al rub Download / Experienced 16E- 40 Hours ATCC 8-1985 Rend.
Scattered Dyes at 1% Dry Concentration | Humid Blue Scattered 361 4 ^ Violet Scattered 28 4-5 3-4 Scattered Blue 77 3-4 Scattered Yellow 23 5 5 5 4-5 Yellow Scattered 54 4 5 5 4 Yellow Scattered 86 4 4-5 4-5 4 Scattered Yellow 232 1 4-5 4-5 3-4 Scattered Yellow 3 5 5 5 3-4 Scattered Blue 35 4 4-5 4-5 3-4 Scattered Blue 87 4 5 5 4 Scattered Blue 291 3-4 5 5 4-5 Scattered Blue 354 1 4 4 4-5 Scattered Blue 60 5 3-4 3-4 4 Scattered Blue 118 4-5 4-5 4-5 3-4 Scattered Blue 183 1 5 Red Scattered 60 4-5 3-4 3-4 4-5 Scattered Yellow 64 5 4-5 TABLE I (Continued) Dye Discharge Dye Discharge Dye Type Xenon Light ATCC Firming to Scrub Discharge / Experienced 16E- 40 ATCC Hours 8-1985 Rend. Scattered Dyes at 1% Dry and Wet I Concentration ^ .. Red Scattered 167 3-4 4-5 4-5 3-4 Red Scattered 73 1 4 4 4 Red Scattered 127 3 3-4 Intrawhite FWA 4-5 5 5 4-5 Green Scattered 9 1 4-5 4-5 4-5 Scattered Blue 79 1 4 4 3-4 FIRMING RATING DOWNLOAD RATING 5. No Change 5. Total Discharge 4. Slight Change 4. Good Discharge 3. Notable Change 3 Moderate Discharge 2. Significant Change 2. Poor Discharge 1. Severe Change 1. Stained to Light The discharge of dye or the proportion at which the textile exhausts a staining bath, has been primarily used as the basis for determining the capacity of polyolefin staining. Other performance properties, such as light fastness, wash fastness, and rub fastness, are more a function of many other variables, such as coloring conditions, auxiliaries used in dyeing and in general the dyeing procedure and the post-treatment Consistent with the Scale Rating System of Grades designed by the ATCC, a scale of 1 to 5 is used, with 5 being an almost total exhaustion of the dye from the dye bath to the substrate and 1 simply staining the substrate, almost all the dye remains in the bath. All other grades? Between 5 and 1, including intermediates such as 3 and 4, are based on a linear scale of dye discharge from the bath to the substrate. While a rating of 5 would be the most preferred, for operational purposes a rating of 3-4 or higher is acceptable with a standard for a polymer fiber to be considered "dyeable" with a particular colorant. "Those with skill in the The technique will appreciate that in most commercial applications, the disperse dye will be a mixture of 1 or more selected dyes.The concentration of the selected dye or disperse dyes should be at least 0.1% to obtain the significant benefits of the invention. Current for mixtures of dyes are used to optimize different characteristics of specific dyes for maximum performance Rugs made from stained fibers dispersed from this polymer exhibit excellent resistance to bleaching.In a bleaching test it was found that a typical solution to the % does not produce a color change, while a 10 solution 0% produces only a moderate significant change in color. Samples of mats made from the present polymer and disperse dye are resistant to stains according to the Kool Aid test mats industrial standard. On a scale of 1 to 10, the samples scored an absolute 10, indicating that there is no staining in the samples tested. Speaking, in general, the staining results indicate that the grafted version of the present invention illustrated in Example 2 and Example 3 shows a slightly better performance than a mixed copolymer version of Example 1. The present invention is particularly useful with fibers, and fibers of various deniers can be adequately wetted both in the form of fibers or non-woven fibers worked from these fibers. Round or lobed fibers are for clothes, upholstery and threads for mats front, and can have a denier of approximately 1 to 60, without encountering problems of staining by the present technique. These fibers can also be used in the production of other articles, such as decorated ribbons or non-woven textiles. Ribbon fibers are generally used for carpet backing and are of a heavier denier, that is approximately 500 to 1500 deniers.
Fibers of fibrillated film are used for string of yarn for the front of carpet or upholstery. In order for the fibers to be fully penetrated by the dye, the centrifugation and stretching processes must be carried out in a way that produces a fiber with a uniform structure through its cross section, that is minimum structural differences of core / core. On the other hand, greater economy can be obtained from the dye used for the backing of dyeing cloth made from woven ribbons, if you have a lining / core structure. In these liner / core structures, the liner is dyeable, while the core exhibits very little dye collection. In this way, less colorant is used to dye a backing that is made from these fibers. After centrifuging the fibers, but before stretching, a spin finish may be applied to the fibers. If this material is used, it can be anionic, but preferably it is non-ionic in nature. Non-anionic spin finishes are commercially available, and one preferred is Dispersol VL. Conveniently usable is Nopcostat 2152P, which is considered a modified coconut fatty acid ester. The finishes contain mineral oil act as a plasticizer and can increase the speed of collection of dye on the surface of the fibers. A water-soluble or water-dispersible finish such as Dispersol VL is preferred. Finishing operations can optionally be used on the fibers before casting, for example, the fibers can be textured by bending or mechanical forming as described in Textile Fibers, Dyes Finishes, and Process: A Concise Guide, Howard L. Nedles, Noyes Publications, 1986. pp. 17-20 (Textile Fibers, Finishes and Processes: A Concise Guide), Howard L. Nedles, Noyes Publications, 1986. pp. 17-20 It has been found convenient in some applications to mix a polyamide such as nylon 6 or nylon 6,6 in a first composition (a copolymer composition of ethylene and polypropylene) to further improve the first composition without sacrificing the desired dyeing or spinning properties of the fiber The addition of polyamide forms a second composition (by example a composition of polypropylene / copolyro / nylon 6) with improved flammability, improved toughness and improved resilience compared to the first composition, even at a point or that the modified fiber is more resilient than polypropylene alone. The added polyamide is by weight of about 1 to 20%, preferably 5 to 15%, the weight of the first composition. When a nylon component is added, the ethylene copolymer can be reduced as long as the alkyl acrylate component does not fall below a sufficient amount to prevent the otherwise immiscible polypropylene and polyamide (usually 0.5% by weight) from separating. A preferred composition of about 1 • 4% in alkyl acrylate component 'about 7% of the ethylene copolymer) and 15% in nylon 6, with the polypropylene moiety (about 96%). For this preferred composition, the alternatively expressed phr values are 100 phr, 7.5 phr of the ethylene copolymer and 16.1 phr of nylon. When using a composition of the ethylene alkyl acrylate copolymer and polypropylene (and optionally with hydrophilic and / or polyester / copolyester modifier) it is important that the copolymer of ethylene alkyl acrylate and polypropylene be . Incorporate uniformly before forming the composition in the configured article. The combination can only be a uniform sample, but preferably and according to this invention, it is a composition wherein at least a portion of the ethylene alkyl acrylate is grafted onto the polypropylene. Mixing and / or grafting can be achieved in a separate step before forming, or the mixing and / or grafting and extrusion can be carried out in the same operation if the extruder has a convex mixing section. It can be deficient mixed and / or grafted into inhomogeneous staining, even if the remaining stages of the dyeing process are performed properly. The grafting of ethylene alkyl acrylate copolymer to polyolefin polymer preferably isotactic polypropylene, for use in this invention, is achieved by subjecting the copolymer of ethylene alkyl acrylate to co-graft polymerization in the presence of the polyolefin polymer. The method of graft polymerization is not critical and the graft polymerization can be carried out according to conventional methods employing organic free radical initiators. The polymerization conditions may be those known to those skilled in the art. The organic radical generating agent employed in this invention includes: 2,5-dimethyl-2,5-di (t-butylperoxy) hexene-3,5,5,5-dimethyl-2,5-di (t-butylperoxy) hexene; 1, 3-bis (t-butylperoxyisopropyl) benzene, 2,2-bis (t-butylperoxy) -p-diisopropylbenzene, dicumyl peroxide, di-t-butyl peroxide, t-butyl benzoate 1, 1-bis (t-) butylperoxy) -3,3,5-trimethylcyclohexane, 2,4-dichlorobenzoyl peroxide, benzoyl peroxide, azobisisobutyronitrile, and the like. Preferred are 2,5-dimethyl-2,5-di (t-butylperoxy) hexene-3,1, 3-bis (t-butylperoxyisopropyl) benzene, and 2,2-bis (t-butylperoxy) -p-diisopropylbenzene. The thermoplastic resin composition of this invention can be obtained by adding .01 to .3 part by weight, preferably .05 to .2 part by weight, of an organic radical generating agent to 100 parts by weight of a mixture consisting of from 99 to 85% by weight, preferably 96 to 90% by weight, polypropylene, and 2 to 13% by weight, preferably 4 to 10% by weight of an ethylene alkyl acrylate copolymer, and then subjecting the resulting mixture to heat treatment in a mixer (for example a Banbury mixer, a kneader) or an extruder at 170"C to 300 ° C, preferably 180 ° to 250 ° C, for .2 to 30 minutes, preferably .5 to 20 minutes Fiber-grade polyester can subsequently be introduced up to 15% by weight, preferably about 3 to 5% by weight of the entire matrix, in which case in percent in polypropylene it will decrease by the weight percent of elongated polyester. When polyester is not incorporated into the matrix the composition comprises about 99 to 85% by weight of polyolefin, preferably polypropylene, and about 1 to 13% by weight of the material of the polar group, preferably EMA. The alkyl acrylate in the composition is about 3% by weight less, and the maximum amount of ethylene is about 10% by weight. If a hydrophilic modifier is used as discussed above in the composition, it has a maximum contribution of 2% by weight in the total matrix. When polyester is incorporated into the composition, the amount of polar group material and hydrophilic modifier does not need to be changed. The .1 to 15% is added weight of polyester in the total composition in this way the polyolefin range will decrease by approximately 99 to 70% by weight. In the matrix of The polyolefin and polyester, the polyolefin comprises from 99.9 to 88%, and the polyester comprises .1 to 18% by weight. Acrylic maleic anhydride acid can be substituted for EMA as the polar group material, when polyester is included in the composition, although the weight percent of these alternate and less polar preferred materials will be less than the EMA weight percent. One embodiment of this invention deals with the synergistic phenomena between polypropylene, polyester or copolyester, J. i ethylene methyl acrylate (or maleic anhydride or acrylic acid) and preferably a hydrophilic modifier comprising monoglyceride and a linear alkyl salt. Polyolefin type polymers are the most challenging fibers to be wetted using conventional fiber production techniques. Polypropylene is practically a non-polar pololefin polymer with very low surface energy. It has been reported that the polypropylene surface energy is 28.7 lines / cm, with 26.0 and 2.7 lines / cm of scatter and polar attraction, respectively. Polypropylene can be modified with EMA at a certain level to allow the polyolefin fibers to be stained reliably with disperse dyes. However, the introduction of polar groups does not impart any "wettable" or "dyeable" characteristics. Similarly, both products modified with acrylic acid and maleic anhydride also do not result in a wettable polymer fiber.
Commercial materials such as the Polibond1 * nested material from Uniroyal Chemical Company, combine conventional monomers such as acrylic or maleic anhydrous with polyolefin, and thus form chemically grafted polyolefin copolymers. This chemically grafted polyolefin copolymer when combined with polypropylene, similarly does not produce a wettable fiber. When a preferred hydrophilic modifier such as that described herein is used in conjunction with polar substrates such as Polybond14 * EMA, the wettability of the polyolefin dramatically improves as measured by the contact angle. In some applications, this increased wettability is beneficial to obtain the desired staining capacity characteristics. A preferred modifier is a combination of nonionic and anionic structures. The non-anionic structure can be monoglyceride with a melting point of about 66 ° C, and a boiling point of about 260 ° C. Glycerol monostearate ("GMS") is the currently preferred monoglyceride. This non-ionic structure is highly distilled, with a monoglyceride content exceeding 95% by weight. In some applications, a monoglyceride without an anionic structure can be a convenient modifier. The minor component has an anionic structure and is a linear alkyl (C16 to C18) phosphate, potassium salt. The preferred ratio of these two components varies depending on the application, although the non-ionic structure is preferably 50 to 90% by weight of the modifier. A weight ratio of 80:20 of the nonionic and aionic structure is preferred. Other preferred hydrophilic modifiers are polypropylene glycol polyoxyethylates and fatty alcohol polyoxyethylates. Other hydrophilic modifiers may include alkyl phenol polyoxyethylates, polyoxyethylates of fatty acid and amide polyoxyethylates of fatty acid. A preferred hydrophilic modifier is the product No. ^ 5808 available from G.R. Goulston and Company of Monroe, North Carolina. This compound (hereinafter "5808") consists of a mixture of a food grade modifier, such as and d-glycerides of edible fats and oils and a salt of a linear alkyl phosphate. The push to migrate or exude to the surface comes from the highly distilled monoglycerol (> 90%) that does not impart surface wettability. Accordingly, it is beneficial to fuse / melt the monoglyceride with long chain hydrocarbon acid having the hydrophilic group component in order to achieve the significant impact on surface wettability. This melting / fusion operation can be carried out by a pelletizing process or a pelletizing process, such that heat transfer is carried out in a form that does not degrade the monoglyceride.
Oliefina polymers do not disperse particularly well 'the linear polyester or copolyester. While an oliefina component can theoretically be incorporated into the polyester in the polymerization stage, this would be highly disadvantageous due to the requirement to provide an injection facility for the added oliolefin or polyolefin component. Furthermore, polypropylene will be degraded dramatically during the polyester polymerization process. If the polyester is added during the polyolefin polymerization, the whole process will be poisoned, due to the molar portion. The dispersibility of the linear polyester in the olefinic polymers can be significantly improved by the incorporation of a polar group material, for example MEA, which can be further improved by a hydrophilic modifier. Linear polyester can be produced by condensing one or more di-carboxylic acids or a lower alkyl diester (eg terephthalic acid, isophthalic acid, phthalic acid, 2,5-; 2,6-; or 2,7-and naphthalene dicarboxylic acid, succinic acid, sebacic acid, adipic acid, azelaic acid, bibenzoic acid, and hexahydroterephthalic acid or bis-p-carboxyphenoxyethane) with one or more glycols, (for example ethylene glycol, 1, 3 -propanediol, 1,4-butanediol, neopentyl glycol and 1,4-cyclohexanedimethanol The preferred polyester is polyethylene terephthalate and a fiber-grade polyester will have an intrinsic viscosity of approximately 0.64.
The polyester can be a copolymer containing a mixed hydroxylic acid and / or acid forming acid groups and can be a block copolymer formed from different polyesters. The copolyester may contain polymer segments having a glass transition temperature less than 0 ° C such that the polyester is internally plasticized. The polymer used for the polymer segment should be capable of undergoing polycondensation, with the polyester segments through reactive end groups and as hydroxy or carboxyl groups or linked to polyester segments. Suitable polymeric segments are polyethylene glycol and polytetramethylene glycol, when the polyester segment is typically polyethylene terephthalate or polybutylene terephthalate. This invention in this way reduces or eliminates the disadvantages due to poor dispersibility of a polyolefin resin and a polyester resin together. A composition and process capable of providing filaments or continuous fibers, are described, which significantly improve the stainability of a polyolefin composition. As is known in the art, various specialized techniques have been developed for the application of dispersed dyes or fibers. Unless staining is carried out at 100 ° C or higher, the staining speed is slow. Staining with disperse dyes from aqueous solutions of 120-130 ° C to achieve rapid staining requires the use of closed high pressure equipment. The jet staining has been introduced, which allows high temperature staining and incidence of the colorant on the moving fabric through the use of a venturi injection system. Carriers allow faster staining at atmospheric pressure and below 100 ° C. Carriers are usually organic compounds that can be emulsified in water and have affinity for the fiber polymer. The carriers penetrate the polymer, often by swelling the fiber, and aiding "the passage of the dispersed dye through the fiber-dye solution interface to the fiber. Suitable carriers include aromatic hydrocarbons such as diphenyl and methylnaphthalene, phenolic such as o- and p-phenylphenol, halogenated aromatics such as the di- and trichlorobenzenes, aromatic esters including methyl salicylate, butyl benzoate, diethylphthalate and benzaldehyde. Carriers should be removed after staining. A preferred swelling agent is of the type described in U.S. Pat. No. 5,358,537 issued to Shaw Industries, Inc. A polypropylene-based compound as described herein, may also include a swollen agent such as n-cyclohexyl-2-pyrrolidone, diethylene glycol or n-octyl-2-pyrrolidone. . A mixture of n-cyclohexyl-2-pyrrolidone, diethylene glycol may be preferred. The mixture may also include an amphoteric agent, such as Wacogen NH600N, Chemcogen 132-N, or combinations thereof, to act as a dye wetting agent or compactant, thereby significantly improving the dyeing characteristics. For printing or staining applications, the dye mixture is preferably in the form of a paste to allow selective placement of the mixture in the yarn, cloth or mat. For these applications, the viscosity of the mixture can be adjusted from about 800 to about 3000 centipoise (at 26.7 ° C (80 ° F) as measured by the Viscometer, .Brookfield with a spindle No. 3). A select thickener from the group consisting of guar gum, gum arabic, modified cellulose, locust bean gum, xanthan gum, and their combinations, can be used to obtain the desired viscosity. A dye mixture comprising a disperse dye in the holes as described above can be applied to the polypropylene fibers. A dry heating can then be applied to the fibers and dye mixture at a temperature of from 95 ° C to about 110 ° C for a sufficient time to effect dispersion of at least a portion of the disperse dye in the polypropylene fibers. 1 minute to 10 minutes of dry heat position, you must achieve the desired dispersion. The residual dye is then removed from the fibers. In this way, a dispersed dye mixture can be applied to the polypropylene fibers in various forms. The dye mixture can be applied intermittently over the length of the fiber-formed yarn, using various well-known techniques to create a desired effect. A suitable method for dyeing fibers can be referred to as the "weaving-unweaving" dyeing technique. According to this method, the fibers are formed into a yarn which in turn is woven, typically in a tube configuration. The dye mixture is then applied intermittently to the woven tube. After drying, the tube is unraveled and the thread in this manner has an intermittent pattern. . According to an alternative printing method, the fibers are first formed in the yarn which is then woven into cloth, or tufted into the package. A conventional flat screen printing machine, as sold by Peter Zimmer, Inc., can be used to apply the dye mixture to the fabric or mat. Continuous dyeing is carried out in a dyeing zone, where the cloth or mat is continuously passed through a dyeing solution of sufficient length to reach an initial dye penetration. Some dispersed dyes may be sublimated under heat and partial vacuum in the polymer fiber by methods known in the art. Printing with the polyolefin compositions made in accordance with this invention can be achieved with disperse dyes by thermal transfer printing under pressure, with sufficient heating to cause diffusion of disperse dyes to the polyolefin. Batch processes of thermal transfer, flat screen, blocks, and processes of engraved rolls, continuous printing with rotary screen, can be used. Different dyeing solutions can be sprayed by scheduled sequence injection onto the fabric or mat made from the compositions of this invention as the fabric passes under the jets to form patterns. The dye solution can be dosed and roasted or cut into a pattern of gstitas that are dropped onto a dyed mat that runs underneath, to give a pattern on diffuse staining on the mat. Competitive polyolefin staining is useful when stylized staining mats that consist of various different fibers such as nylon, polyester, etc. and a polyolefin. Different stylized effects can occur when controlling the depth of shade in each type of fiber present. Acid, dispersed and pre-metallized dyes or their combinations, depending on the fibers present, can be used to obtain styling effects. Also, styling effects obtained from a combination of fibers can be achieved by making a cloth or mat front from polyolefin yarns containing varying amounts of ethylene alkyl acrylate copolymer. Just as tweed effects can occur on a nylon mat when tufting with nylon fibers containing different levels of amine ends, these stylized tweed effects can also be produced on a polyolefin fiber at control the concentration of ethylene alkyl acrylate dye sites. Staining can be carried out by printing, staining in space and continuous staining, with fabrics made from these threads. The invention may be further understood by reference to the following examples, wherein parts and percentages are given by weight unless otherwise indicated. In Examples 4, 5 and 66, polyester is added to the polypropylene composition. Example 4 A polypropylene alloy composition containing 82.5% by weight of a commercial grade fiber of isotactic polypropylene according to Example 1, and 7% by weight of a copolymer or ethylene methyl acrylate together with modifiers 5808 (0.5% by weight) ), it is prepared by first dry mixing the polymers and then melting the formula in a 40 mm Berstorff extruder at 246 ° C. The ethylene copolymer contains 20% by weight of the methyl acrylate comonomer and had a melt index of 18 (ASTM D-1238-89, 190 °, .98 Kg (2.16 lb)), the fiber-grade polyester is mixed in 10 % of the total matrix. The resulting homogeneous compatible copolymer mixture is cut into spikes after neutralization with water which is then fed to a melt spin apparatus and fibers of 50-60 Deniers are centrifuged per filament at 260-265 ° C. A finish based on mineral oil containing anionic surfactants is applied to the fiber bundle after centrifugation, but before stretching. The fibers are stretched three times to give final Denier 18 to 20 per filament. The physical properties of the specimens of the fibers thus prepared were tested and the test results are set forth in Table II. Specimens of the fibers were woven in a weaving machine to produce a tubular woven fabric. Samples of the fibers were also tested for wetting characteristics.A polypropylene graft composition containing 82.5% by weight of an isotactic polypropylene grade fiber according to Example 2, and 7% by weight of a grafted copolymer of ethylene methyl acrylate (and containing thermal, oxidative and oxidative stabilizers). of ultraviolet light) is prepared by first dry blending the polymers together with 0.5% by weight of the 5808 modifier. This blend is combined with the fiber grade copolyester at 10% by weight of the total matrix. The resulting mixture is melt-blended in a 40 mm Berstorff extruder at 246 ° C, in the presence of sufficient libros peroxide radical initiator according to Example 2. The ethylene copolymer contains 20% by weight of the methyl acrylate comonomer and had a melt index of 18. The resulting homogeneous compatible copolymer mixture is cut into tips after neutralization with water which is then fed to a melt spin apparatus and centrifuged to fibers of 50-60 Deniers per filament at 260-265 ° C. . A finish based on mineral oil containing anionic surfactants is applied to the fiber bundle after centrifugation, but before stretching. The fibers are stretched three times to give final Denier 18 to 20 per filament. The physical properties of the specimens of the fibers thus prepared were tested, and the test results are set forth in Table II. Specimens of the fibers were woven in a weaving machine to produce a tubular woven fabric. Samples of the fibers were also tested for wetting characteristics. TABLE II Example 4 Example 5 Properties (Homopolymer (modified PP (modified PP Physical without Modifying with grafted alloy1) Denier 1,450 1,500 1,470 (gms / 9000 meters) Traction 2.5 2.0 2.2 (gms / den) Elongation (%) 39.0 65.0 70.0 Example 6 A graft composition and polypropylene alloy containing 82.5% by weight of commercial grade isotactic polypropylene fiber having a melt index in the range of 8 to 12 (ASTM D-1238-89, 230 ° C, .98 Kg (2.16 lbs)) (and containing thermal, oxidative, and ultraviolet light stabilizers) and 7% by weight of a grafted copolymer and ethylene methyl acrylate alloy is prepared by first dry-blending the polymers together with a 5808 modifier ( 0.5% by weight) and then melt-mix the mixture with fiber-grade copolyester at 10% of the total matrix in a Berstorff extruder at 246 ° C, in the presence of sufficient peroxide fiber radical initiator according to Example 2. The copolymer of ethylene contains 20% by weight of the methyl acrylate comonomer and had a melt index of 18 (ASTM D-1238-89, 190 °, .98 Kg (2.16 Ib)). The resulting homogeneous compatible polymer mixture is cut into spikes after neutralization with water, which is then fed to a melt spin apparatus and 50-60 Deniers fibers were centrifuged per filament at 260-265 ° C. A mineral-based-oil-based finish containing anionic surfactants is applied to the fiber bundle after centrifugation by melting, but before stretching. The fibers are stretched three times to give final Denier 18 to 20 per filament. The physical properties of the specimens of the fibers thus prepared were tested, and the test results were approximately the same as those obtained with the fibers of example 5. Specimens of the fibers were woven in a machine to produce a tubular woven fabric. Samples of the fibers were also tested for staining and wetting characteristics, according to the dyeing procedure of Example 1. While the prior art illustrates the existence of incorporated polypropylene (when grafting or mixing) with ethylene-alkyl-acrylate copolymers , the foregoing examples illustrate that, in only certain limited quantities, a particular ethylene copolymer with a suitable combination with polyester and hydrophilic modifier, has the surprising ability to make a centrifugal textile fiber.Commercially acceptable polypropylene that can accept sufficient disperse dyes to produce a colorless fiber with superior physical characteristics. Those with skill in the fiber-making technique have for a long time considered that any additive of __. Acrylate produces a resin composition that can not be centrifuged at the high modern production speeds without separating the components. In addition, the addition of many additives, including acrylates and acetates, imparts unpleasant sensation and odor to the finished fiber products, partially as a result of degradation during the spinning and drawing process. The fabricated fiber typically imparts tremendous shear forces to a polymer composition and "stretched to shrink" ratios of 20-100: 1, which makes fiber-forming polymers very intolerant of many additives routinely employed in compositions that others have. applications. Any interruption or lack of uniformity in a polymer composition can result in a break when the fiber is stretched or stretched with reduction to its final diameter, often very thin. As a consequence, those skilled in the fiber making technique have generally not sought compositions for other end uses as acceptable in A- fiber applications, particularly in areas where historical experience suggests unacceptability. The critical nature of the invention is seen in that a limitation of .2 to 2.0% by weight in the alkyl acrylate component in the composition, and in combination with less than about 10% by weight of ethylene content contributed by the alkyl copolymer Acrylate, is required to produce the desired results sufficient to achieve commercial acceptability. The modifier, «. Hydrophilic provides additional compatibilization to bridge polyester with polypropylene. The ethylene copolymer is incorporated into the polypropylene either by grafting or by physical mixing. Those skilled in the fiber-making art have recognized that polypropylene / EVA compositions can not produce a centrifugal fiber under conditions of modern fiber production, but instead this composition degrades very rapidly to produce harmful amounts of acetic acid . No other known copolymers are considered to produce commercially acceptable dyeable fibers in combination with polypropylene. A series of samples is processed as described in Example 5 and evaluated with a series of disperse dyes according to the previously described dyeing process. The results are established in Table III. Tests of firmness to light and firmness to rubbing were also performed on yarns of 2 to 20 deniers per filament. Comparable results are expected for both samples of Example 4 and Example 6. TABLE III Discharge of Dye Scattered Xenon Light (ATCC Firmness to Scrub Discharge / 16E- 40 Hours) (ATCC 8-1985) Rend. (3% Concentration) Dry Humid Yellow Scattered 5 5 5 5 5 Yellow Scattered 86 5 4-5 4-5 5 Scattered Blue 35 5 5 5 5 Scattered Blue 87 5 5 4-5 5 Scattered Blue 291 5 5 4-5 5 Scattered Blue 60 5 4 4 5 Red Scattered 60 5 4 4 5 Ana Anj do Disperso 25 5_ 5 5 5 Dye discharge established in the last column, has been used as the basis to identify suitable dyes for the polymer. Of all battle dyes that are known to exist, most disperse dyes will produce acceptable results if polyester is added to the polypropylene mixture. The most important criteria for colorant selection in contemporaneous times are dye discharge and firmness retention. It is important that the substrate In a woven, tufted, woven or non-woven product, easily collect the dye from the bath and hold it, thus reducing environmental waste and improving the economical utility of the expensive colorant. Differences hardly appear when these criteria are used to evaluate performance and dye between 100% polyester fabric and improved polyolefin fabric. While those skilled in the fiber-making technique have recognized that polyester fiber is well accepted for disperse dye applications, polyester at a very low level (approximately 0.1% by weight of the polyolefin resin matrix) will create gaps that will tremendously improve dye absorption. The processability of this composition is also significantly improved by adding a hydrophilic modifier. Although not bound by any theory, it is considered that the increased wettability due to the combined nature of polarity and hydrophilicity (the polar group material combined with monoglyceride and linear alkyl phosphate) and morphological changes caused by the addition of polyester, causes Dispersed dyes diffuse into a fiber very quickly (ie high discharge) and tend to remain (ie, increased firmness characteristics to light). The above composition is much more dyeable than the polypropylene-based materials of the prior art. It is speculated that the combination of polar and dispersive functions increased, substantially exceeds the surface energy that is critical for adequate wetting to occur on polyolefin surfaces. Neither a polar material nor a hydrophilic mmodifier by itself are capable of imparting this highly convenient characteristic which produces good dispersion and therefore homogeneous staining. With a lower barrier to overcome, the above material is therefore comparatively easy to dye "compared to conventionally modified polypropylene materials. The hydrogen bonding of the dye molecule to the carbonyl oxygen of the ester grouping in methyl acrylate is considered the mode of connection of the disperse dye. The disperse dye exhibits excellent retention, indicating strong chemical activity between the functionality and an ester group and dyes. Penetration of dye molecules is facilitated by creating a hydrophilic structure with voids created by the incorporation of polyester. To improve the characteristic of the dyeing capacity, especially with cationic dyes, various attempts were made to introduce a sulfonic group into a polymer. A sulfonic group of a polymer should improve staining, especially using cationic dyes instead of disperse dyes. This invention describes a method for causing sulphonic acid to react with an olefin (or polyolefin or an alkyl acrylate copolymer). Sulfo polyesters were prepared by the polycondensation reaction of the selected dicarboxylic acids (A's) and glycols (G's) to produce a linear structure illustrated below in a simplified form. HO-G-A-G-A-G-A-G-A-G-OH I I S03Na + S03Na * _ ,, A = A portion of aromatic dicarboxylic acid G = An aliphatic or cyclopiphatic glycol residue -OH = Hydroxy end groups. The polycondensation reaction in which a carboxyl group (-C00H) reacts with a hydroxyl group (-0H) to form ester bonds, is carried out at high temperatures (275 ° to 290 ° C) and low pressure (<1 torr) to produce numerical average molecular weight in the 10,000 to 15,000 range. The thermal stability of a polymer formed under these extreme conditions and is suitable for most fiber spinning process applications. Adding a sulphonic group to polyester is much easier than adding a polypropylene sulfonic group. It may be possible, however, to predict a sulphonated hydrophilic modifier. As indicated in the above structure, some of the aromatic dicarboxylic units have sodium sulfo (-S03Na *) substitutents connected. The characteristic sulfo '? The polyester of this invention requires more ionic groups in order to make the entire fiber structure more acceptable to cationic dyes. The hydrophilic nature of these ionic groups also imparts enhanced dispersed staining ability. Several basic dyes were tried on a fiber composed of polypropylene, alkyl acrylate copolymer and sulfo polyester with and without additional hydrophilic modifier. Extensive dyes have been used extensively to "dye silk fibers, cellulose acetate and polyacrylonitrile (acrylic or modified acrylic). The positively charged color ion of the basic dye, the cation, is strongly attracted by the negatively charged ions in the fiber. Fibers dyed with basic colorants, usually exhibit good firmness to light and washing. As a class, basic dyes have a high color value and are characterized by bright shadows. In this way basic dyes are well suited Za¬ for application to fibers composed of negatively charged polymer molecules. Since basic or ionic dyes contain positively charged ions, bonds can easily form between the cation of these dyes and ionic sites in the fibers. At the end of the staining cycle, the coloring cations are almost completely absorbed or completely discharged by the fiber.
Based on this interpretation, a group is introduced sulfonate to the polyester component of the polypropylene mixture by a grafting technique, as described above. Tests were performed using basic battle dyes, including basic blue 41 and basic red 46. Each of these dyes, when employed in conjunction with a polypropylene blend, including a sulfopolyester as described above, gave bright hues to the fibers. A grafting technique of preference is employed to include the group ..sulfonated in the polyester. From the above examples, it can be understood that the addition of both the polar group material and the hydrophilic modifier to a polypropylene-based material will result in a material that is hydrophilic and thus "wettable". The material of the polar group can be an EMA material as described above or it can already be an acrylic acid comprising approximately 0.1 to 2% by weight of the polypropylene, A maleic anhydride comprising about 0.1 to 10%, and preferably 1 to 2% by weight of the polypropylene. The hydrophilic modifier can be a nonionic or anionic material and can be used in compositions wherein the hydrophilic modifier is present in the amount between 0.1 and 2% and preferably between .4 and 1.0% of the weight of the polypropylene and polar group material. The addition of the polyester in this manner is facilitated by this compatibilizing characteristic.
The polymers as described above in this manner have significantly improved hydrophilic characteristics which allow the polymers to be formed into fibers suitable for fabrics or in injection molded films. These polymers provide improved dyeability and particularly make the polymer make the polymer dyeable with a wide range of disperse dyes. This feature of increased staining capacity is of great importance because certain molecules of disperse dye are too large to diffuse into the fiber core of the polypropylene fibers of the prior art, but these same molecules can penetrate into the fibers of the prior art. improved polypropylene of this invention. The selection of dye therefore becomes less complex and the final hue of the dyed product is brighter, more intense and more marked than the compositions of the prior art. This wettability characteristic should also provide excellent discharge of the dyed products, since the dye molecules, once in place in a fiber, should tend to remain in place. Improved results of firmness to washing and firmness to rubbing in this way can be expected and the product must be both wettable and dyeable for various applications. A dyeable and hydrophilic wettable polymer provides highly desirable material characteristics such as permanence, wicking capacity and extra comfort. These attributes are highly desirable in product applications such as diapers, incontinence products for adults and sanitary napkins, where a nonwoven web comes into contact with the body or access point for any fluid penetration. The composition of this invention can be used to form both a highly wettable and dyeable polyolefin as well as a resilient polyolefin. The composition is particularly suitable for forming polyolefin based on improved polypropylene. To substantially increase the acceptance of polypropylene as a convenient replacement for various applications as discussed above, it requires increased staining capacity and increased wettability. Still further, the polypropylene composition of this invention can be easily formed as a fiber that is centrifuged and can ideally be formed into a sheet of fabric including non-woven fibers. Polypropylene and polyester are generally not considered compatible materials to form continuous fibers due to a significant difference between softening and melting temperatures. The ethylene alkyl acrylate acts as a compatibilizer to allow the polyester to adhere to the polypropylene. This compaction is improved by the inclusion of the hydrophilic modifier as discussed above. This modifier also improves the processability of the composition to form centrifuged fibers and imparts a desired resilience and softness to the fabric formed by these fibers. While the techniques of the present invention are particularly well suited for increasing both the dyeability and wettability characteristics of polypropylene, it will be understood that the selected polar group material such as ethylene copolymer including alkyl acrylate as described above, in combination with a hydrophilic modifier as described above, it can be used to substantially increase the wettability characteristics of other polymeric materials, such as polyester, nylon and acetate, all of which can be used to form fibers. Those skilled in the art will also appreciate that fibers made from a polyolefin material as described herein, can be used for various woven or non-woven applications to form fabrics or mats. The fibers may also be combined with other common materials or raw materials, such as pulp or paper stock, to form a wettable and breathable fabric or mat. As previously explained, the concept of the present invention can also be used to form materials such as fibrillated films that do not include fibers. Various modifications in the modified polypropylene fibers and the techniques described herein for forming and dyeing these fibers should be apparent from the foregoing description and those preferred embodiments. Although the invention in this manner has been described in detail for these embodiments, it will be understood that this explanation is for illustration and that the invention is not limited to these embodiments. Alternating fibers and dyeing and forming techniques will thus be apparent to those skilled in the art in view of this description and these fibers and alternative techniques can be made without departing from the spirit of the invention, which is defined by the claims.

Claims (61)

  1. REIVXNPICAC? QNEg 1. Process for dyeing fibers based on polypropylene, comprising: (a) forming in a fiber a composition of approximately 99 to 70% by weight and a polypropylene and an ethylene copolymer comprising approximately 30 to 82% by weight ethylene weight and about 30 to 18% by weight of an alkyl acrylate, wherein the alkyl has 1 to 4 carbon atoms, the alkyl acrylate is present in a composition in an amount between 0.2 to 3.0% by weight of the sum, ._... of the ethylene and polypropylene copolymer, and the ethylene of the ethylene copolymer is present in the composition in an amount of less than about 10% by weight of the sum of the copolymer of polypropylene and ethylene; (b) exposing the fiber to a colorant. 2. The process according to claim 1, wherein the alkyl acrylate is present in an amount between 0.5 to
  2. 2.4% by weight.
  3. 3. The process according to claim 1, wherein at least a portion of ethylene copolymer is grafted onto the polypropylene.
  4. 4. The process according to claim 1, wherein the ethylene copolymer is melt-mixed in the polypropylene.
  5. 5. The process according to claim 1, wherein the ethylene copolymer is ethylene methyl acrylate.
  6. 6. The process according to claim 1, wherein the ethylene copolymer is ethylene ethyl acrylate.
  7. 7. A stained polyolefin fiber, wherein it comprises: (a) about 97 to 70% by weight of a polypropylene; (b) an ethylene copolymer comprising about 70 to 82% by weight of ethylene and about 30 to 18% by weight of an alkyl acrylate, wherein the alkyl acrylate has 1 to 4 carbon atoms, wherein the alkyl acrylate is present in an amount between 0.2 to 3.0% by weight, and wherein the ethylene of the ethylene copolymer is present in an amount of less than about 10% by weight; and (c) an effective amount of a colorant to produce a colored fiber.
  8. 8. The fiber according to claim 7, wherein the ethylene copolymer is ethylene methyl acrylate.
  9. 9. The fiber according to claim 7, wherein the alkyl acrylate is present in an amount of 0.5 to 2.4% by weight.
  10. 10. The fiber according to claim 7, wherein it further comprises a hydrophilic modifier comprising at least 50% by weight of a monoglyceride and a linear alkyl ester salt, the hydrophilic modifier being in a weight amount of about 0.1. to 2.0.
  11. 11. The fiber according to claim 7, wherein at least a portion of the ethylene copolymer is grafted to the polypropylene.
  12. 12. The fiber according to claim 7, wherein the ethylene copolymer is ethylene ethyl acrylate.
  13. 13. A process for forming a dyeable polyolefin composition, wherein it comprises: (a) forming a composition comprising about 99 to 70% by weight of polyolefin, 0.1 to 15% by weight of polyester, and a material of polar group, the polar group material is selected from a group consisting of (1) an ethylene copolymer, the ethylene copolymer comprises about 70 to 82% by weight of ethylene and about 30 to 18% by weight of an alkyl acrylate , wherein the alkyl has 1 to 4 carbon atoms, the alkyl acrylate is present in the composition in an amount of 0.2 to 3.0 wt.% of the composition, (2) a maleic anhydride comprising about 0.1 to 10% in weight of the composition and (3) an acrylic acid comprising about 0.1 to 2.0% by weight of the composition; and (b) exposing the composition to a colorant.
  14. 14. The process according to claim 13, wherein the polyester comprises from 1 to 10% by weight of the composition.
  15. 15. - The method according to claim 13, wherein it further comprises: a hydrophilic modifier comprising at least 50% by weight of a monoglyceride and a linear alkyl ester salt, the hydrophilic modifier is in a weight amount of about 0.1 to 2% by weight of the composition.
  16. 16. The process according to claim 15, wherein the linear alkyl ester salt is alkyl phosphate having a hydrocarbon chain length? from 14 to 18 carbon atoms, and the monoglyceride and the linear alkyl and phosphate salt are fused.
  17. 17. The process according to claim 13, wherein further comprises: introducing a sulfonic group during the polyester polymerization process; and step (b) comprises exposing the composition to a cationic dye.
  18. 18. The method according to claim 13, wherein it further comprises: providing a dye mixture comprising the disperse dye and a turgid agent; and step (b) comprises subjecting the composition and dye mixture at a temperature from about 95 ° C to about 110 ° C to disperse the disperse dye in the composition.
  19. 19. - The method according to claim 13, wherein the polar group material is an ethylene copolymer.
  20. 20. The process according to claim 19, wherein the ethylene copolymer is ethylene methyl acrylate.
  21. 21. The process according to claim 13, wherein the polar group material is a copolymer of ethylene and the ethylene copolymer is present in an amount from 12 to 13% by weight of the composition.
  22. 22. A polyolefin composition, comprising: (a) about 99 to 70% by weight polyolefin; (b) 0.1 to 15% by weight of polyester; and (c) a selected amount of a polar group material selected from the group consisting of: (1) an ethylene copolymer, comprising 70 to 82% and about 30 to 18% by weight of alkyl acrylate, wherein the alkyl acrylate has 1 to 4 carbon atoms, the alkyl acrylate is present in an amount from 0.2 to 3.0% by weight of the composition, (2) a maleic anhydride comprising approximately 0.1 to 10% by weight of the composition and (3) an acrylic acid comprising about 0.1 to 2.0% by weight of the composition.
  23. 23. A polyolefin composition according to claim 22, wherein the polyester comprises 1 to 10% by weight of the composition.
  24. 24. - A polyolefin composition according to claim 22, wherein the polar group material is a copolymer of ethylene and at least a portion of the ethylene copolymer is grafted to the polyolefin.
  25. 25. A polyolefin composition according to claim 22, wherein the polar group material is a copolymer of ethylene and the alkyl acrylate is present in an amount of 0.5 to 2.4% by weight of the composition.
  26. 26. A polyolefin composition according to claim 22, wherein the polar group material is an ethylene copolymer and the ethylene copolymer is present in an amount from 2 to 13% by weight of the composition.
  27. 27. A polyolefin composition according to claim 22, wherein it further comprises: a hydrophilic modifier in an amount by weight from .1 to 2.0% of the composition, the hydrophilic modifier comprises a monoglyceride and a linear alkyl ester salt .
  28. 28. A polyolefin composition according to claim 27, wherein the linear alkyl ester salt comprises alkyl phosphate, the monoglyceride is glycerol monostearate and the linear alkyl phosphate salt are fused.
  29. 29. A process for forming dyed fibers from a composition based on polypropylene, wherein it comprises: (a) combining polypropylene with an ethylene copolymer of about 70 to 82% in ethylene weight and about 30 to 18% in weight of an ethylene alkyl acrylate wherein the alkyl group has 1 to 4 acrylon atoms to form a composition, the alkyl acrylate is present in the composition in an amount from 0.2 to 3.0% by weight of the polypropylene; (b) adding a polyester by weight from 0.1 to 15% of the composition; (c) extruding the composition into fibers; and (d) exposing the fibers to a dye to dye the fibers.
  30. 30. The process according to claim 29, wherein further comprises: that the polypropylene is 99 to 70% by weight of the composition; and graft the ethylene copolymer into the propylene before adding the polyester.
  31. 31. The process according to claim 29, wherein the polyester comprises from 1 to 10% by weight of the composition.
  32. 32. The process according to claim 29, wherein it further comprises: a hydrophilic modifier comprising at least 50% by weight of a monoglyceride of a linear alkyl ester salt, the hydrophilic modifier being in a weight amount of approximately 0.1 to 2% of the composition.
  33. 33. The process according to claim 29, wherein further comprises: introducing a sulfonic group during the polymerization process of the polyester; and step (d) comprises exposing the fibers to a dye • Cationic.
  34. 34. The method according to claim 29, wherein further comprising providing a dye mixture comprising a disperse dye and a turgid agent; and step (d) comprises subjecting the composition and the dye mixture to a temperature from about 95 ° C to about 110 ° C to disperse the disperse dye in the composition. r ». *
  35. 35.- A fiber composition based on polypropylene, comprising: (a) about 99 to 70% by weight of polypropylene; (b) approximately 0.1 to 15% by weight of the polyester; and (c) an ethylene copolymer comprising 70 to 82% and about 30 to 18% by weight of an alkyl acrylate wherein the alkyl acrylate has 1 to 4 carbon atoms, the alkyl acrylate is present in an amount of 0.2 to 3.0% by weight of the composition.
  36. 36.- The composition according to claim 35, wherein the polyester comprises from 1 to 10% by weight of the composition.
  37. 37.- The composition according to claim 35, wherein at least a portion of the ethylene copolymer is grafted onto the polypropylene.
  38. 38. - The composition according to claim 35, wherein the alkyl acrylate is present in an amount of 0.5 to 2.4% by weight of the composition.
  39. 39.- A polyolefin composition according to claim 35, wherein it further comprises: a hydrophilic modifier in an amount by weight from .1 to 2.0% of the composition, the hydrophilic modifier comprises a monoglyceride and a linear alkyl ester salt .
  40. 40.- A polyolefin composition according to claim 39, wherein the linear alkyl salt comprises alkyl phosphate.
  41. 41. A polyolefin composition according to claim 39, wherein the monoglyceride is glycerol monostearate and the monostearate is glycerol and the linear alkyl ester salt are fused.
  42. 42.- A dyed polypropylene fiber, wherein it comprises: (a) approximately 99 to 70% by weight of polypropylene; (b) approximately 0.1 to 15% by weight of the polyester; and (c) an ethylene copolymer comprising 70 to 80% and about 30 to 18% by weight of an alkyl acrylate, wherein the alkyl acrylate has 1 to 4 carbon atoms, the alkyl acrylate is present in an amount of 0.2. at 3.0% by weight; (d) a hydrophilic modifier in an amount by weight from .1 to 2.0%, the hydrophilic modifier comprises a monoglyceride and a linear alkyl ester salt; and (e) an effective amount of dye to produce a colored fiber.
  43. 43.- The fiber according to claim 42, wherein the polyester comprises from 1 to 10% by weight.
  44. 44. The fiber according to claim 42, wherein the alkyl acrylate is present in an amount of from 0.5 to 2.4 by weight.
  45. 45. The fiber according to claim 42, wherein the polyester includes a sulphonic group introduced during polymerization of the polyester and the dye is a cationic dye.
  46. 46. A process for forming a dyeable polyolefin composition, comprising: (a) introducing a sulfonic group during the polymerization of polyester to form a polyester sulfo; (b) forming a composition comprising from about 99 to 70% by weight of polyolefin, 0.1 to 15% by weight of sulfopolyester, and a material of the polar group, the material of the polar group is selected from a group consisting of (1) ) an ethylene copolymer, the ethylene copolymer comprises about 70 to 82% by weight of ethylene and about 30 to 18% by weight of an alkyl acrylate, wherein the alkyl has 1 to 4 carbon atoms, the alkyl acrylate is present in the composition of an amount from 0.2 to 3.0 wt. in weight of the composition, (2) a maleic anhydride comprising approximately 0.1 to 10% by weight of the composition and (3) an acrylic acid comprising approximately 0.1 to 2.0% by weight of the composition; and (c) exposing the composition to a cationic dye.
  47. 47.- The procedure according to claim 46, wherein the polyester comprises from 1 to 10% by weight of the composition.
  48. 48. The process according to claim 46, wherein it further comprises: a hydrophilic modifier comprising at least 50% by weight of a monoglyceride and a linear alkyl ester salt, the hydrophilic modifier being in a weight amount of approximately 0.1 to 2% by weight of the composition.
  49. 49.- The process according to claim 46, wherein the salt of a linear ester comprises alkyl phosphate having a hydrocarbon chain length of 14 to 18 carbon atoms.
  50. 50.- The process according to claim 46, wherein the monoglyceride and the linear alkyl phosphate salt are fused.
  51. 51.- The process according to claim 46, wherein the monoglyceride is glycerol monostearate.
  52. 52. The method according to claim 46, wherein the polar group material is an ethylene copolymer.
  53. 53. - The process according to claim 52, wherein the ethylene copolymer is ethylene methyl acrylate.
  54. 54.- A polyolefin composition, comprising: (a) about 99 to 75% by weight of polyolefin; (b) 0.1 to 15% by weight of sulfo polyester formed by introducing a sulfonic group during polyester polymerization; and (c) a selected amount of a polar group material selected from the group consisting of: (1) an ethylene copolymer, comprising 70 to 82% and about 30 to 18% by weight of an alkyl acrylate, wherein the alkyl acrylate has 1 to 4 carbon atoms, the alkyl acrylate is present in an amount from 0.2 to 3.0 by weight of the composition, (2) a maleic anhydride comprising about 0.1 to 10% by weight of the composition and (3) an acrylic acid comprising about 0.1 to 2.0% by weight of the composition.
  55. 55.- A process for forming dyed fibers from a composition based on polypropylene, wherein it comprises: (a) combining polypropylene with an ethylene copolymer of about 70 to 82% by weight of ethylene and about 30 to 18% by weight of an ethylene alkyl acrylate, wherein the alkyl group has 1 to 4 carbon atoms to form a composition, the alkyl acrylate is present in the composition in an amount of 0.2 to 3.0% by weight of the polypropylene; (b) adding a sulfopolyester by weight from 0.1 to 15% of the composition, the sulfo polyester includes a sulphonic group introduced during the polymerization of the polyester; (c) extruding the composition into fibers; and (d) exposing the fibers to a cationic dye to dye the fibers.
  56. 56.- A fiber composition based on polypropylene, comprising: (a) approximately 99 to 70% by weight of polypropylene; (b) 0.1 to 15% by weight of sulfo polyester, the sulfopolyester includes a sulphonic group introduced during the polyester polymerization; and (c) an ethylene copolymer, which,. it comprises 70 to 82% and about 30 to 18% by weight of an alkyl acrylate, wherein the alkyl acrylate has 1 to 4 carbon atoms, the alkyl acrylate is present in an amount of 0.2 to 3.0 by weight of the composition.
  57. 57. The polyolefin composition according to claim 56, further comprising: a hydrophilic modifier in an amount by weight from .1 to 2.0% of the composition, the hydrophilic modifier comprises a monoglyceride and a linear alkyl ester salt.
  58. 58.- A polyolefin composition according to claim 56, wherein the polyester comprises from 1 to 10% by weight of the composition.
  59. 59. A polyolefin composition according to claim 56, wherein at least a portion of the ethylene copolymer is grafted onto the polypropylene.
  60. 60. - A polyolefin composition according to claim 56, wherein the alkyl acrylate is present in an amount of 0.5 to 2.4% by weight of the composition.
  61. 61.- A polyolefin composition according to claim 56, wherein the ethylene copolymer is present in an amount of 2 to 13% by weight of the composition.
MX9606194A 1995-02-03 1995-05-23 Dyeable polyolefin compositions and method. MX9606194A (en)

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
US254,974 1994-06-07
US08384716 1995-02-03
US08/384,716 US5550192A (en) 1992-12-07 1995-02-03 Dyeable polyolefin compositions and dyeing polyolefin compositions
US08/442,304 US5576366A (en) 1995-02-03 1995-05-16 Dyeable polyolefin compositions and method
US442,304 1995-05-16
US442304 1995-05-16
PCT/US1995/006590 WO1995033882A1 (en) 1994-06-07 1995-05-23 Dyeable polyolefin compositions and method
US254974 2002-09-26

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