Method for dyeing and removing colored impurities

Disclosed herein is a method for dyeing and removing colored impurities, which includes providing a polyester fabric and an adsorption material, spraying a coloring material onto a surface of the polyester fabric to form a colored layer, subjecting the polyester fabric thus dyed to a heating treatment for the colored layer to adhere to the surface of the polyester fabric, attaching or applying the adsorption material onto the colored layer and subsequently heating and/or applying a pressure to the adsorption material so that the adsorption material is coated on the colored layer to adsorb colored impurities therefrom, and removing the adsorption material.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority of Taiwanese Patent Application No. 109107476, filed on Mar. 6, 2020.

FIELD

The present disclosure relates to a method for dyeing and removing colored impurities.

BACKGROUND

Polyester is strong in strength, light in weight, high in hydrophobicity, and low in moisture regain, and has excellent plastic memory characteristics. Polyester is crease-resistant and quick-drying, retains its shape in garments, is abrasion-resistant, and requires minimum care. Fabrics made of polyester multifilaments are in wide use as various cloth materials for sportswear, casual wear, coats and the like or as clothes such as down-proof fabrics, and umbrella cloths.

Since polyesters are liable to a high degree of densification, have great crystallinity, and lack a reactive group, polyester fabric is difficult to dye. There are many dyeing or printing methods for applying a decorative pattern on the surface of a polyester fabric, and one of the most cost-effective methods of dyeing a polyester fabric is spray dyeing. Spray dyeing includes conventional spraying as well as atomization and electrostatic applications. With most spray dyeing methods, the redundant polymer and excess dye must be removed by washing with water after the fixation of the print. Generally, a large amount of water is required for complete removal of excess dye due to the risk of back-staining during the process, i.e., redeposit on the fabric of already dissolved dye. This will cause an appreciable amount of liquid waste containing pollutants.

In view of the foregoing, the applicant attempted to develop a more efficient and also more environmentally friendly method for removing colored impurities.

SUMMARY

Accordingly, in a first aspect, the present disclosure provides a method for dyeing and removing colored impurities, which includes:a) providing a polyester fabric and an adsorption material that is non-viscous and ductile at room temperature;b) spraying a coloring material onto a surface of the polyester fabric to form a colored layer on the surface of the polyester fabric, so as to dye the polyester fabric;c) subjecting the polyester fabric thus dyed to a heating treatment, so that the colored layer adheres to the surface of the polyester fabric, the colored layer containing colored impurities;d) attaching the adsorption material onto the colored layer, followed by heating and applying a pressure to the adsorption material, so that the adsorption material is softened and coated on the colored layer, and the colored impurities in the colored layer are adsorbed by the adsorption material; ande) removing the adsorption material,

In a second aspect, the present disclosure provides a method for dyeing and removing colored impurities, which includes:a) providing a polyester fabric and an adsorption material which is in the form of one of a liquid and a slurry at room temperature;b) spraying a coloring material onto a surface of the polyester fabric to form a colored layer on the surface of the polyester fabric, so as to dye the polyester fabric;c) subjecting the polyester fabric thus dyed to a heating treatment, so that the colored layer adheres to the surface of the polyester fabric, the colored layer containing colored impurities;d) applying the adsorption material onto the colored layer, followed by heating the adsorption material, so that the adsorption material is cured into a film and is coated on the colored layer, and the colored impurities in the colored layer are adsorbed by the adsorption material; ande) removing the adsorption material.

DETAILED DESCRIPTION

Unless defined otherwise, all technical and scientific terms used herein have the meaning commonly understood by a person skilled in the art to which the present disclosure belongs. One skilled in the art will recognize many methods and materials similar or equivalent to those described herein, which could be used in the practice of the present disclosure. Indeed, the present disclosure is in no way limited to the methods and materials described.

Referring toFIGS. 1 to 2, a first embodiment of a method for dyeing and removing colored impurities according to the present disclosure includes:a) providing a polyester fabric10and an adsorption material30that is non-viscous and ductile at room temperature;b) spraying a coloring material onto a surface11of the polyester fabric10to form a colored layer20on the surface11of the polyester fabric10, so as to dye the polyester fabric10;c) subjecting the polyester fabric10thus dyed to a heating treatment, so that the colored layer20adheres to the surface11of the polyester fabric10, the colored layer20containing colored impurities22;d) attaching the adsorption material30onto the colored layer20, followed by heating and applying a pressure to the adsorption material30, so that the adsorption material30is softened and coated on the colored layer20, and the colored impurities22in the colored layer20are adsorbed by the adsorption material30; ande) removing the adsorption material30.

According to the present disclosure, the polyester fabric10may be made of a polyester fiber, or may be made by blending the polyester fiber with a fabric material.

According to the present disclosure, the polyester fabric10may be made by methods well known in the art, including but not limited to knitting and weaving (e.g., non-woven weaving and plain weaving).

According to the present disclosure, the fabric material may be selected from the group consisting of cotton, linen, silk, nylon, rayon, a chemical fiber other than the aforesaid chemical fibers, a natural fiber other than the aforesaid natural fibers, and combinations thereof.

In step (a) of this embodiment, the adsorption material30is in the form of a film, and may be selected from the group consisting of nylon, polyvinylchloride (PVC), thermoplastic polyurethane (TPU), polyurethane (PU), ethylene-vinyl acetate (EVA) copolymer, polycarbonate (PC), polymethylmethacrylate (PMMA), an acrylic resin, and combinations thereof.

According to the present disclosure, the adsorption material30in the form of a film has an inner surface31that is attached to the colored layer20, and an outer surface32that is opposite to the inner surface31.

According to the present disclosure, the heating treatment in step (c) and the heating in step (d) are conducted using a heating equipment100(such as an oven).

In step (a) of this embodiment, the adsorption material30in the form of a film is coiled in a roll, which. is to be rolled out and overlaid on the colored layer20in step (d) of this embodiment.

In step (d) of this embodiment, a positive pressure is applied to the outer surface32of the adsorption material30using a pressurizer200equipped with the heating equipment100.

In step (d) of this embodiment, after heating and applying a pressure to the adsorption material30, the adsorption material30is softened and coated on the colored layer20, and may partially permeate into the colored layer20.

FIG. 3illustrates that a product1is obtained after the colored impurities22have been removed using the method of the present disclosure.

FIG. 4illustrates a second embodiment of the method according to the present disclosure. The second embodiment differs from the first embodiment in that, in step (d) of the method, a negative pressure is applied to the adsorption material30using a vacuumizer300, so that a suction force is produced on the surface11of the polyester fabric10.

Referring toFIG. 5, a third embodiment of the method according to the present disclosure includes:a) providing a polyester fabric10and an adsorption material30′ which is in the form of a liquid or a slurry at room temperature;b) spraying a coloring material onto a surface11of the polyester fabric10to form a colored layer20on the surface11of the polyester fabric10, so as to dye the polyester fabric10;c) subjecting the polyester fabric10thus dyed to a heating treatment, so that the colored layer20adheres to the surface11of the polyester fabric10, the colored layer20containing colored impurities22;d) applying the adsorption material30′ onto the colored layer20, followed by heating the adsorption material30′, so that the adsorption material30′ is cured into a film and is coated on the colored layer20, and the colored impurities22in the colored layer20are adsorbed by the adsorption material30′; ande) removing the adsorption material30′.

The first and third embodiments differ from each other only in the form of the adsorption material30,30′ provided in step (a) and the approach to coat the the adsorption material30,30′ on the colored layer20in step (d) Nevertheless, the strategy that aims to coat the adsorption material30,30′ on the colored layer20is the same in the first and third embodiments.

In addition, in step (a) of the third embodiment, the adsorption material30′ may be selected from the group consisting of nylon, polyvinylchloride (PVC), thermoplastic polyurethane (TPU), polyurethane (PU), ethylene-vinyl acetate (EVA) copolymer, polycarbonate (PC), polymethylmethacrylate (PMMA), an acrylic resin, an ester, and combinations thereof.

In step (d) of the third embodiment, the adsorption material30′ may be sprayed onto the colored layer20.

In step (d) of this embodiment, after heating the adsorption material30′, the adsorption material30′ is cured into a film and is coated on the colored layer20, and may permeate into the colored layer20.

No matter whether the adsorption material30,30′ is overlaid on the colored layer20in the form of a non-viscous film (see the first and second embodiments) or is sprayed on the colored layer20in the form of a liquid or a slurry (see the third embodiment), the adsorption material30,30′ can be completely coated on the colored layer20after heating and/or pressurizing the adsorption material30,30′, and hence can effectively adsorb the colored impurities22. Therefore, the method according to the present disclosure can directly take away the colored impurities22by removing the adsorption material30,30′ without water washing, thereby preventing water consumption and generation of pollutional liquid waste.

In the description above, for the purposes of explanation, numerous specific details have been set forth in order to provide a thorough understanding of the embodiments. It will be apparent, however, to one skilled in the art, that one or more other embodiments may be practiced without some of these specific details.