Dispersedyesfullpdf 210811091252
Dispersedyesfullpdf 210811091252
Dispersedyesfullpdf 210811091252
Introduction:
Dyes are colored unsaturated organic chemical compounds capable of giving
color to a substrate (a textile), i e coloring or dyeing it. The term “disperse dye”
have been applied to the organic coloring substances which are free from
ionizing groups are or low water solubility and are suitable for dyeing
hydrophobic fiber. The dye has derived its name for its insoluble aqueous
properties and the need to apply it from in aqueous dispersion. Of all the dyes,
they are of the smallest molecular size.
Disperse dyes have substantivity for one or more hydrophobic fibers e g
cellulose acetate nylon polyester acrylic and other synthetic fibers.
The negative charge on the surface of one or more hydrophobic fibers like
polyester cannot be that reduced by any means, so non-ionic dyes like disperse
dyes are used which are not influenced by that surface charge.
History:
In 1922 Green and saunders made one type of coloured azo compound in which
a solubilizing group (for example methyl sulphate ÑCH –So3H )is attached to
amino group. In dye bath they are slowly hydrolyzed and produce azo
compound and formaldehyde bi sulphate. In dye azo compound was capable of
dyeing cellulose acetate fibers . This dye was named “ionamine” But this ion
amine did not give satisfactory result in dyeing.
Later in 1924 Baddlley and ells produced sulpho ricinoleie acid (SRA) for
dyeing acetate fibers. This SRA was used as dispersing agent later it was seen
that SRA was capable of dyeing Nylon , polyester, acrylic etc. In 1953 this dye
was named as “Disperse Dye”
1. Disperse dyes are nonionic dyes. So they are free from ionizing group.
2. They are ready made dyes and are insoluble in water or have very low water
solubility.
3. They are organic colouring substances which are suitable for dyeing
hydrophobic fibers.
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4. Disperse dyes are used for dyeing man made cellulose ester and synthetic
fibers specially acetate and polyester fibers and sometimes nylon and acrylic
fibers.
5. Carrier or dispersing agent are required for dyeing with disperse dyes.
6. Disperse dyes have fair to good light fastness with rating about 3-5.
7. The wash fastness of these dyes is moderate to good with rating about 3-4.
8. Of all dyestuffs disperse dyes are of smallest molecular size.
9. Generally disperse dyes are derivatives of azo anthroquinone nitro and
quinine groups.
10. They do not undergo any chemical change during dyeing.
11.In presence of nitrous oxide textile materials dyed with certain blue and
violet disperse dyes with an anthraquinone structure will fade. this is called gas
fading of disperse dyes which is a defect of this dye.]
1.Group A: These dyes have excellent dyeing and good fastness properties.
2. Group B : These dyes are excellent in high temperature and for carrier
dyeing with moderate fastness .
3.Group C: These dyes are moderate for carrier and high temperature dyeing
with higher fastness property than group B dyes.
4.Group D: These dyes are of excellent fastness to heat but for dyeing properties
on carrier method
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According to Energy Required:
According to energy required for dyeing there are following 3 types of disperse
dyes:
1. Low energy dyes : These dyes are used to dye with carrier For dyeing
77°C temperature is required . they have extremely poor resistance to
sublimation.
2. Medium energy dyes : These dyes are used to dye mostly in between
temperature 104°C-110°C which provides better sublimation fastness than that
of low energy dyes.
3. High energy of dyes : These dyes are used to dye at temperature above
129°C and are suitable for continuous dyeing . they provide all round fastness
properties.
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Commercial Names of Disperse Dyes:
If the amount of dye present in the dye bath is not sufficient to saturate the fiber
in the dyeing process, only the first two equilibria are established. If the fiber is
saturated, the third equilibrium is attained and the dyeing is completed. Thus
the aqueous solubility of the dye and the diffusion of the dye in the fiber are the
two factors governing the dyeing process that are more important. If these
factors are affected, the rate of dyeing, the percentage exhaustion of the dye
bath and the level dyeing characteristics of the disperse dye are also affected.
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Leveling agents:
Non-ionic leveling agents retard the rate of dyeing.
Carrier type leveling agents are used in high temperature dyeing to get
uniform dyeing.
They also help to avoid the deposition of oligomers on the fiber surface.
Antifoaming agents:
Antifoaming agents are used in a disperse dye bath to control the foam as
excess foaming gives specky dyeing.
Wetting agent:
A small quantity of wetting agent in the dye bath facilitates the dye liquor
to be absorbed uniformly and quickly.
The boundary layer on the fiber surface remains a stationary liquid layer
through which the dye has to diffuse in order to reach the fiber surface. In
principle, the dye is adsorbed on the fiber surface from the diffusional boundary
layer, which, in turn, receives the dye from the bulk of the agitated liquor. The
thickness of the diffusional boundary layer under circulation conditions in
different machines may vary, which, in turn, may vary the rate of dyeing from
machine to machine. The rate of dye transfer through boundary layer depends
on diffusion coefficient, fiber surface and the change in chemical potential in
the process.
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The mechanism of dyeing is depicted schematically in figure: The diffusion
boundary layer and the adsorption layer are clearly seen. Also seen is the
diffusion of the dye molecules and the chemicals into the fiber. The various
states of modification of the dispersed dye molecules are also clearly depicted.
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Dispersing Agent:
Disperse dyes are insoluble in water and form aqueous dispersion in water. At
first these dye molecules are formed as large particles and they are made smaller
particles by grinding .But as they are water insoluble they will give uneven
dyeing if they are directly used in dye bath. So to ensure uniform and trouble
free dyeing the dye should be present in dye bath in an uniform and very fine
and should give at stable dispersion. This is the reason for which a special
chemical is used in dye bath named dispersing agent. They should be effective
under dyeing conditions stable to hard water high temperature and other dyeing
assistants.
For example soap power turkey Red oil alkali sulphates alkyl sulphonates etc.
are some surface active agent which are recommended as dispersing agents in
disperse dyeing .
1. Effect of temperature:
In case of dyeing with disperse dye temperature plays an important role. For the
swelling of fibre temperature above 100°C is required if high temperature
dyeing method is applied again in case of carrier dyeing method this swelling
occurs at 85-90°C . In case of thermasol dyeing method if temperature is kept
more fabric is kept for less time in thermasol unit .Because in higher
temperature less time is enough for thermo fixation of dye . If it is kept for more
time, then dye sublimation and lass of fabric strength may occur. Again though
disperse dye is a water insoluble dye its solubility increases temperature.
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2. Effect of PH:
For disperse dyeing the dye bath be should be acidic and PH should be in
between 4.5-5.5. For maintaining this PH generally acetic acid is used. We may
also use any mineral acid like H3 PO4. But those are strong and costly. So mild
acid is used for controlling PH of the bath. At this PH dye Exhaustion is
satisfactory. During colour development, correct PH should be maintained
otherwise fastness will be inferior and colour will be unstable.
The process of heat setting is used to stabilize yarn twist remove residual
shrinkage increase resistance and obtain durable pleat. Polyester may shrink 7%
at boil and even more at higher temperature.
The importance of heat setting is as below.
1. To modify crystalline structure.
2. To improve dimension stability.
3. To resist wet creasing during washing
4. To increase safe ironing temperature
5. To avoid shade variation
6. Affect water inhibition
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3. Dye is fixed at 1000-1800C for 2-1 minutes by radiators.
4. Higher productivity.
5. No loss of colour.
6. Dyes with medium sublimation fastness can be applied.
7. The fabric handle is very soft.
Reduction Cleaning
In case of dark shade dyeing, we have to use more amounts of dye and
chemicals. But these chemicals should be removed from fabric after dyeing. For
this reason a special process is used in case of disperse dyeing. This cleaning
process is called reduction cleaning. A typical recipe for reduction cleaning is
given below
PROCEDURE:
1. At first, a paste of dye and dispersing agent is prepared and then water is
added to it.
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2. Dye bath is kept at 60°C temperature and all the chemicals along with the
material are added to it. Then the bath is kept for 15 min without raising the
temperature.
3. pH of bath is controlled by acetic acid at 4-5.5.
4. Now temperature of dye bath is raised to 90°C and at that temperature the
bath is kept for 60 min.
5. Then temperature is lowered to 60°C and resist and reduction cleaning is
done if required. Reduction cleaning is done only to improve the wash fastness.
6. Material is again rinsed well after reduction cleaning and then dried.
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Disadvantages of carrier Dyeing:
1. Carrier add to production cost of dyeing. Firstly, for dyeing it is used which is
costly and secondly for its removal alkali is required.
2. Carriers are unhygienic and toxic. It creates skin diseases.
3. Some dyeing machine may create carrier spot.
4. Carriers affect the light fastness property of dyed material. This effect may be
reduced by treating the material with hot air for 30 min.
5. Some carriers are dyed specific. They possess different efferent dyes, others
have compatibility with certain dyes.
Procedure:
Ø At first a paste of dye and dispersing agent is prepared and water is added to
it.
Ø PH is controlled by adding acetic acid.
Ø This condition is kept for 15 minutes at temperature 60°C.
Ø Then the dye bath temperature is raised to 130°C and this temperature is
maintained for 1 hour. Within this time, dye is diffused in dye bath, adsorbed by
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the fibre and thus required shade is obtained.
Ø The dye bath is cooled as early as possible after dyeing at 60°C.
Ø The fabric is hot rinsed and reduction cleaning is done if required.
Ø Then the fabric is finally rinsed and dried.
Dyeing Curve
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Procedure:
Ø At first the fabric is padded with dye solution using above recipe in a three
bowl padding mangle.
Ø Then the fabric is dried at 100°C temperature in dryer. For dyeing, infra red
drying method is an ideal method by which water is evaporated from fabric in
vapor form. This eliminates the migration of dye particles.
Ø Then the fabric is passed through thermasol unit where thermo fixing is done
at about 205°C temp for 60-90 seconds depending on type of fibre, dye and
depth of shade. In thermasol process about 75-90% dye is fixed on fabric.
Ø After thermo fixing the unfixed dyes are washed off along with thickener and
other chemicals by warm water.
Ø Then soap wash or reduction cleaning is done if required. And finally the
fabric is washed .
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Dyeing of polyester/cotton blends:
Different effects can be produced while dyeing these blends:
Solid phase dyeing: Both the components of the blends are dyed to the same
tone and depth of shade.
Contrast dyeing: Two components of the blend are dyed in different shade.
Reserve dyeing: Only one component of the blend is dyed whereas the second
component is left un-dyed.
Two tone dyeing: The same dyeing effect and tone is produced in different
depths of shade percentage in the two fibers.
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Printing with Disperse Dye
Introduction :
Disperse dyes are most suitable dyes for printing polyester fabric. Selected dyes
with good steaming & thermofixation fastness are suitable for printing. The
washing fastness of disperse dyes on polyester are much higher than acetate
triacetate or nylon disperse dyes have high degree of dispersibility and the
disperse dyes marketed in liquid form are easy to make in to stock thickening
without predispersing. The printing paste should contain a dispersing agent.
**Thickener used in printing with disperse dyes
Proper selection of thickener is important in printing polyester fabric with
disperse dyes. It depends on method of printing (i.e- Roller printing, screen
printing ) and method of fixation of dye. The kind of fabric to be printed also
influences the thickener choice. suitable thickener should adhere well to be
fabric and should produce an elastic flum to prevent cracking. The thickener
should be easily removal in the after treatments.
Thickening with a high solid content bring less water on hydrophobic and
produce sulpher and more level prints than those with low solid content. But the
thickening with low solid content behave better with respect to cracking and in
thermosol process for better colour yeild. But its sharpness in prints is not good
as with high solid contents thickenings.
The most commonly used thickeners used in printing with disperse dyes are
below
1. Starch ethers (best)
2. Natural Gums
3. Locust Bean Gum
4. Meyprogum
5. CMC (car boxy methyl cellulose)
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