6/17/2014 Textile Technology: Disperse Dye

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Disperse Dye

Introduction:

Dyeing of natural fibers such as cotton, wool, silk etc, which are hydrophilic in nature, are done by direct,

acid, vat, sulphur etc. Dyes which are water soluble or made soluble by reduction. When hydrophobic

fibers made their appearance, soon after first world war, faced a problem in dyeing as the ─OH group has

been blocked by ─COOCH3 group. Therefore affinity for dyes has been checked. Scientists took attemps

of creating new dyes and developed acetate dyes or disperse dye. The term disperse dyes means free

from ionizing groups, low water solubility and are suitable for dyeing hydrophobic fibers from colloidal

dispersion.

What is Disperse Dye:

A dye that is almost totally insoluble in water. Disperse dye exist in the dye bath as a suspension or

dispersion of microscopic particles, with only a tiny amount in true solution at any time. They are the only

dyes that are effective for “Normal” polyester. Some types are used for Nylon and Acetate. Polyester is

dyed with disperse dyes by boiling with carrier chemicals or by heating the liquor to about 130°C which

requires elevated pressure (Like a pressure cooker), Therm sol dyeing,

Where the fabric is padded with dye liquor then dried and heated to about 200°C for about 90 seconds, is

also used for polyester and for coloring the polyester component of polycotton blends. Disperse dyes are

also used for sublimation printing of synthetic fibres and are the colorant used in crayons and inks sold for

making “Iron-ON” transfers.

The first dyes for cellulose acetate fibres were water soluble. The dye molecules contained a methylamino

sulphonate group (-NHCH2SO3Na) introduced by reaction of a primary amino group with formaldehyde and

sodium bisulphate (Ionamine dyes, 1922). During dyeing, this group hydrolysed to the less soluble parent

amine (on figure-01).

Dye-NH-CH2SO3Na (aq) + H2O → Dye-NH2(s) + CH2O(aq) + NaHSO3(aq)

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6/17/2014 Textile Technology: Disperse Dye

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Figure-01

It was soon recognized that it was this compound that the cellulose acetate absorbed. The first true

disperse dyes were simple, relatively insoluble azo and anthraquinone compounds dispersed in water using

the sodium salt of sulphated ricinoleic acid (on figure-02).

Dye(s) ↔ Dye (aq) ↔ Dye(fiber)

Figure-02

Many of these dyes are obsolete but their development provided the technology for preparing fine aqueous

dispersions by grinding the dye with dispersing agents. A fine dispersion is essential for rapid dyeing and

avoids deposition of larger dye particles on the material.

Classification of Disperse dye for Polyester:Disperse dyes for a compound shade on polyester can have quite incompatible dyeing properties.The SDC classification of disperse dyes is based on migration ability during exhaust dyeing, colourbuild-up, sensitivity to changes in temperature and the rate of dyeing.

This type of dye is often classified on the basis of dyeing rate and sublimation fastness, particularlyfor polyester dyeing. These two properties are a function of molecular weight and the number ofpolar groups in the dye molecule. The most common classifying is given bellow :

01.Low energy.

02.Medium energy.

03.High energy.

1. Low Energy Disperse Dye:

Most dyeing and fastness properties change gradually with increase in molecular size. Small dye molecules

with low polarity are leveling, rapid dyeing dyes with poor heat resistance. These are called low energy

disperse dye.

2. Medium Energy Disperse Dye:

Most of the dyeing and fastness properties change gradually with increase in molecular size. Moderate dye

molecules with moderate polarity are leveling, rapid dyeing dyes with moderate heat resistance. These are

called medium energy disperse dye.

3. High Energy Disperse Dye:

More polar, higher molecular weight dye has low dyeing rates, poor migration during dyeing but good heat

and sublimation fastness. These constitute the high energy disperse dye.

Selection Properties:

Disperse dyes have some general properties which are given bellow –

· Solubility: Disperse dyes are insoluble in water or slightly soluble in water. It makes fine dispersionwith water with water with dispersing agent. Dissolves in organic solvents like benzene, toluene etc.· Fastness to washing: The fabric dyes with disperse dyes shows moderate to good washingfastness.· Light Fastness: Most of the disperse are very fast to washing. The minimum light fastness ratingis 4-5.· Sublime ability: Due to stable electronic arrangement disperse dyes have good sublime ability.· Gas Fading: Fabrics dyed with certn blue & violet disperse dyes conaining anthraquinone structurebecome fade in presence of nitrous oxide. This nitrous oxide may be made in nature from varioussources such as open gas fire, electric heating arrangement.

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6/17/2014 Textile Technology: Disperse Dye

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Commercial (Trade name) Name of Disperse Dyes: · Terasil.

· Foron.

· Palanil.

· Resolin.

· Samaron.

· Dispersol .

Dispersing Agent: The actual disperse dye is formed as relatively large particles and in this form it is unsuitable for

application on hydrophobic fibers. If these big particles are used in dyeing as such, they produce uneven

and specky dyeing and their full colour value is not realized. In order to ensure uniform dyeing, the dye

should be present in the dye bath in a uniform and very fine form, which should be stable under dyeing

condition. This requires a large amount of suitable dispersing agents followed by grinding. The dispersing

agent should be effective under the dyeing conditions and should be stable to hard water, high

temperature and other dyeing assistants.

Soap powder, Turkey Red Oil, Alkylsulphates, Alkylarylsulphonates, Fatty Alcholethylene Oxide

condensates, Naphthalene-β-sulphonate and formaldehyte etc are the recommended dispersing agent

performs many functions. It assists the process of particle size reduction of the dye. It also enables the

dye to be formed in the powder form. When the powder is added to the dye bath, it facilitates the recon

version of the powder in to a dispersion, it is required for carrying out the dyeing. Finally, it maintains the

dispersion in a fine form in the dye bath throughout the dyeing process. Dispersing agents increase the

solubility of the disperse dye in water. It is seen that solubility of the dye in water is considerably

increased by the dispersing agent and that different dispersing agents affect the solubility to different

extents. It can be noted that the dyeing rate increase with increasing solubility the dyeing rate actually

decreases.

Where the solubility is very high as in the case of direct dyes, practically no dyeing takes place.

Commercial (Trade name) Name of Dispersing agent:

1. Setamol -BASF.

2. Edalon -Sandoz.

3. Calsolene Oil HS –A.C.I.

4. Hipogal –Hoechst.

Commercial (Trade name) Name of Carrier:

1. Tumescal –A.C.I.

2. Matexil –A.C.I.

3. Levagol –Bayer.

4. Dilatin –Sandoz.

5. Invalon –Ciba.

6. Hisogal –Hoechst.

Method of the Dyeing Synthetic fibres with Disperse Dyes:There are three common method of dyeing

with disperse dyes which are as follows:-

1. Carrier method of dyeing.

2. High temperature dyeing.

3. The thermosol process of dyeing.

1. Carrier method of dyeing:Polyester shrinks about 7% in boiling water and even more at higher

temperature. To avoid this it is heat set. As a general rule it can be stated that a material (Synthetic) will

be dimensionally stable if set at a temperature 30°-40°C higher than that to which it will been subjected

during use. Fabrics are usually heat-set on pin stenters over temperature ranges 180°C and 200°C but

garments can be set in steam autoclave machines at steam pressures between 20-25 pcs (pound per

square inch). Terylene is highly crystalline and highly hydrophobic.

Therefore, dyes with large molecules can not easily penetrate in to this fibre. It has no chemically active

group and can not combine with dye anions and cat ions. In practice, polyester fibres are dyed with

disperse dye.

A considerable advance in the dyeing of polyester fibres was made when the carrier method was

introduced. It was discovered that quite a number of organic compounds such as phenols, amines or

aromatic hydrocarbons, when either dissolved or suspended in the dye bath, accelerated the absorption of

disperse dyes by the fibre. The way in which carriers produce the effect is not clearly understood but they

do cause some swelling of the fibre. It seems that they can enter into the fine structure of the polyester

and push adjacent long-chain molecules apart. This loosens up the molecular pattern and facilitates the

entry of the large dyestuff molecules. The water insoluble carriers also appear to from a surface film on

the fibre in which the disperse dye is highly soluble. The transfer of dye, in such circumstances, does not

take place between the aqueous phase and the fibre but between dyestuff dissolved in the carrier and

fibre.

But it is found that there is a maximum concentration of the carrier above which the take-up of the dye

by the fibre decreases. This optimum carrier concentration corresponds approximately with the amount

necessary to saturate both fibre and dye bath phase of the system. Excess will introduce a third phase,

namely undissolved carrier, which will compete with the fibre for the dye.

Two carriers which have proved success are diphenyl (Matexil CA-DP) and O-Pheny Pheny (Matexil CA-

OPE). Diphenyl is a cream-coloured powder, insoluble in water, but in a readily- dispersable stat. Mateil

CA-DP is a disphenyl carrier supplied in self-emulsifiable flakes. The emulsion i9s prepared by stirring the

flakes into water at 80°C or hooter than this if desired and added to the dye bath at 60°C. The

recommended concentration of carrier in the dye bath is 4 to 6 parts per liter. Matexil CA-OPE shouldbe

used in the dye bath as 7.5 parts per litter and is added directly to the dye bath at 50°C t o 60°C.

The addition of dispersing agent should precede that of Matexil CA-OPE. There are many other carriers

which can be used in the carrier dyeing methods. A typical recipe of carrier dyeing is given bellow:

Recipe:

Dyestuff – 3% (20-30g/liter) on the weight of material

Carrier – 15g/liter

Dispersing Agent – 2 to 3g/liter

Acetic Acid – 5cc/liter

Material liquor Ratio – 1:20

phenomenon where dye molecul...

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6/17/2014 Textile Technology: Disperse Dye

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Temp – Boil

Time – 1hour to 1.5 hour

The dye bath is made up with 1/2 - 2 kg (.5 – 1g/liter) of an anionic surface active agent and 3-4kg

carrier per 1000 liters. The temperature should be 40°C and after dye has been added, the liquor is slowly

brought up to 100°C. After 15 minutes at this temp 5cc acetic acid is added. Boiling is continued for a

further 1 hr after the addition of acetic acid. After dyeing the goods are washed out with a detergent and

some NaOH to ensure the complete removal of carrier.

2. High temperature dyeing:There are many advantages associated with dyeing polyester at

temperature range between 120°C and 130°C. Heavy shade can be dyed pleated because of the

permanency of the crease so formed. When dyeing at atmospheric pressure, only dyes of low molecular

weight which tends to sublime during pleating can be used, the more satisfactory colours with higher

molecular weights can be applied at 120°C -130°C. There is no perceptible loss of elasticity or tensile

strength when polyester fibres are dyed under neutral or slightly acid conditions at 130°C. But if any alkali

is used there is degradation in strength and elasticity. Any alkali used in scouring must be removed entirely

before high temperature dyeing. The fibre should be heat-set before dyeing.

The following disperse dyes are recommended for high temperature dyeing:

C.I Disperse Yellow 1, 39

C.I Disperse Orange 13

C.I Disperse Red 11, 13

C.I Disperse Violet 26

C.I Disperse Blue 26

The dye bath is made up with dyestuff, dispersing agent (Matexil DN-VI) or some similar product which is

stable up to 130°C.

The dyeing should be started at 70°C, the temperature raised slowly to 120°C-130°C and maintained for a

period of 30-60 minutes. When very heavy shades have been dyed it may be necessary to give a

“Reduction Clearing” to avoid lack of fastness to rubbing. The goods are treated for 20 minutes at 45°C-

50°C with 6kg NaOH(68), 2kg Na2S2O4 and 2kg Matexil Sc-A50 per 1000kg of water. Owing to the

hydrophobic nature of polyester fibre only, surface dye will be reduced and the chemicals will not

penetrate to react with the absorbed colour. After high temperature dyeing the goods should always have

a final wash-off at 70°C for 15-20 minutes with suitable detergent.

3. The thermosol process of dyeing:This dyeing process is not suitable for garments dyeing, Because of

it is Unhygienic.

The Problem of Dyeing Polyester:

Polyester fibres are essentially undyeable bellow 70-80C, leaving only a 20-30C range for increasing the

dyeing rate before recharging the boiling temperature. At any temperature, the rate of dyeing of polyester

with a given disperse dye is very much lower than for cellulose acetate or nylon fibres.

The rate of diffusion of disperse dyes into the polyester bellow 100C is so low than that dyeing at the boil

does not give reasonable exhaustion.

The rate of dyeing is higher for dyes of small molecular size that have higher diffusion coefficients. Dyeing

is faster when using fibre swelling agent called carriers to improve the fibre accessibility, or when dyeing

at higher temperatures above 100C increase the dye diffusion rate. Fibres of the most common polyester,

polyethylene terephthalate (PET or PES), are quite crystalline and very hydrophobic. Hot water does not

swell them and large dye molecules do not easily penetrate into the fibre interior. Polyesters have no ionic

groups and are dyed almost exclusively with disperse dye. The better diffusion at the boil of low molecular

weight dyes results in moderate migration during dyeing dyeing but then the washing fastness is only fair.

Many of the more recent disperse dyes are specifically for dyeing polyester. These are of higher molecular

weight to provide adequate fastness to sublimation during heat treatments. Some of these produce a

reasonable depth of shade by dyeing at the boil. Most, however, require higher dyeing temperatures or

carriers for satisfactory results. Dyeing of polyester with disperse dyes have good light fastness. This does

not always correlate with the light fastness on other fibres such as cellulose diacetate.

The disperse dyes provide a full range of colours with adequate to good build-up on PET fibres.

Uneven filament texturising or heat setting can lead to barre but higher dyeing temperatures, or addition

of some carrier, will promote migration to minimize this, Again, a full black requires aftertreatment of the

dyeing by diazotization of an amino disperse dye and cupling with a suitable component, often BON acid.

Concurrent dyeing with a mixture of the amino disperses dye and dispersed BON acid, followed by

treatment with sodium nitrate and hydrochloric acid, is a common procedure. Some blacks are mixtures of

dull yellow, red and blue dyes.

Posted by Quamrul Ahsan Shishir

4 comments:

+1 Recommend this on Google

Amelia Davis June 11, 2013 at 6:34 AM

Woah! I’m really loving the stuff of this blog. It’s simple, yet effective. A lot oftimes it’s challenging to get that “perfect balance” between user friendliness andvisual appearance. I must say you have done a amazing job with this. ExcellentBlog!

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+1 Recommend this on Google

BINU SOMARAJAN June 14, 2013 at 10:16 AM

good

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Amelia Davis June 14, 2013 at 10:52 PM

Woah! I’m really loving the stuff of this blog. It’s simple, yet effective. A lot oftimes it’s challenging to get that “perfect balance” between user friendliness andvisual appearance. I must say you have done a amazing job with this. ExcellentBlog!

ink for | ciss for | printer for | ciss | cis | continuous ink supply system | inksupply system | dye ink | pigment ink | pigment ink for | hp dj | hp designjet |formujet | indigo imaging | for plotter | Formujet ink | ink manufacturer | cissmanufacturer | cartridge refilling | refill cartridge | idcard printing | lanyardprinting .

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Anonymous September 18, 2013 at 1:45 AM

Plagiarised from: 'Basic Principles of Textile Coloration' by Arthur D. Broadbent.

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