US20070079453A1 - Method of dyeing a semi-finished product - Google Patents
Method of dyeing a semi-finished product Download PDFInfo
- Publication number
- US20070079453A1 US20070079453A1 US11/633,797 US63379706A US2007079453A1 US 20070079453 A1 US20070079453 A1 US 20070079453A1 US 63379706 A US63379706 A US 63379706A US 2007079453 A1 US2007079453 A1 US 2007079453A1
- Authority
- US
- United States
- Prior art keywords
- dye
- semi
- finished product
- percent
- bath
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000011265 semifinished product Substances 0.000 title claims abstract description 75
- 238000000034 method Methods 0.000 title claims abstract description 58
- 238000004043 dyeing Methods 0.000 title claims abstract description 19
- 150000002009 diols Chemical class 0.000 claims abstract description 57
- -1 alkylene glycol Chemical compound 0.000 claims abstract description 38
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 35
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 30
- 239000008188 pellet Substances 0.000 claims abstract description 21
- LYCAIKOWRPUZTN-UHFFFAOYSA-N ethylene glycol Natural products OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims abstract description 13
- VPWNQTHUCYMVMZ-UHFFFAOYSA-N 4,4'-sulfonyldiphenol Chemical class C1=CC(O)=CC=C1S(=O)(=O)C1=CC=C(O)C=C1 VPWNQTHUCYMVMZ-UHFFFAOYSA-N 0.000 claims abstract description 10
- 239000000843 powder Substances 0.000 claims abstract description 9
- 125000000217 alkyl group Chemical group 0.000 claims abstract description 7
- 125000003118 aryl group Chemical group 0.000 claims abstract description 7
- 229930185605 Bisphenol Natural products 0.000 claims abstract description 6
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 claims abstract description 6
- 125000004432 carbon atom Chemical group C* 0.000 claims abstract description 5
- 125000006702 (C1-C18) alkyl group Chemical group 0.000 claims abstract description 4
- 125000003236 benzoyl group Chemical group [H]C1=C([H])C([H])=C(C([H])=C1[H])C(*)=O 0.000 claims abstract description 4
- 125000001797 benzyl group Chemical group [H]C1=C([H])C([H])=C(C([H])=C1[H])C([H])([H])* 0.000 claims abstract description 4
- 125000004122 cyclic group Chemical group 0.000 claims abstract description 4
- 229910052736 halogen Inorganic materials 0.000 claims abstract description 3
- 150000002367 halogens Chemical class 0.000 claims abstract description 3
- 239000000975 dye Substances 0.000 claims description 254
- 239000000203 mixture Substances 0.000 claims description 47
- 230000003068 static effect Effects 0.000 claims description 26
- 239000004416 thermosoftening plastic Substances 0.000 claims description 23
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 claims description 21
- 239000006082 mold release agent Substances 0.000 claims description 14
- 239000004094 surface-active agent Substances 0.000 claims description 13
- 229920000515 polycarbonate Polymers 0.000 claims description 12
- 239000004417 polycarbonate Substances 0.000 claims description 12
- 229920001577 copolymer Polymers 0.000 claims description 11
- 239000006096 absorbing agent Substances 0.000 claims description 10
- 239000012963 UV stabilizer Substances 0.000 claims description 9
- 239000004599 antimicrobial Substances 0.000 claims description 8
- 230000001617 migratory effect Effects 0.000 claims description 6
- 239000002216 antistatic agent Substances 0.000 claims description 5
- 239000004005 microsphere Substances 0.000 claims description 5
- 230000003287 optical effect Effects 0.000 claims description 5
- 239000003017 thermal stabilizer Substances 0.000 claims description 5
- SIKJAQJRHWYJAI-UHFFFAOYSA-N Indole Chemical compound C1=CC=C2NC=CC2=C1 SIKJAQJRHWYJAI-UHFFFAOYSA-N 0.000 claims description 4
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 4
- DMBHHRLKUKUOEG-UHFFFAOYSA-N diphenylamine Chemical compound C=1C=CC=CC=1NC1=CC=CC=C1 DMBHHRLKUKUOEG-UHFFFAOYSA-N 0.000 claims description 4
- 239000000986 disperse dye Substances 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 claims description 4
- 150000002989 phenols Chemical class 0.000 claims description 4
- 239000000049 pigment Substances 0.000 claims description 4
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 4
- 239000004926 polymethyl methacrylate Substances 0.000 claims description 4
- 125000003003 spiro group Chemical group 0.000 claims description 4
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 claims description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 3
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Natural products C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 3
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 3
- 239000002280 amphoteric surfactant Substances 0.000 claims description 3
- 239000003945 anionic surfactant Substances 0.000 claims description 3
- 150000001562 benzopyrans Chemical class 0.000 claims description 3
- 125000000959 isobutyl group Chemical group [H]C([H])([H])C([H])(C([H])([H])[H])C([H])([H])* 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 3
- 229920002635 polyurethane Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 150000004670 unsaturated fatty acids Chemical class 0.000 claims description 3
- 235000021122 unsaturated fatty acids Nutrition 0.000 claims description 3
- 239000004952 Polyamide Substances 0.000 claims description 2
- UWHCKJMYHZGTIT-UHFFFAOYSA-N Tetraethylene glycol, Natural products OCCOCCOCCOCCO UWHCKJMYHZGTIT-UHFFFAOYSA-N 0.000 claims description 2
- 239000000987 azo dye Substances 0.000 claims description 2
- 239000011521 glass Substances 0.000 claims description 2
- 239000002736 nonionic surfactant Substances 0.000 claims description 2
- JLFNLZLINWHATN-UHFFFAOYSA-N pentaethylene glycol Chemical compound OCCOCCOCCOCCOCCO JLFNLZLINWHATN-UHFFFAOYSA-N 0.000 claims description 2
- 229920002647 polyamide Polymers 0.000 claims description 2
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 claims description 2
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims 1
- 239000001000 anthraquinone dye Substances 0.000 claims 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 36
- 239000007788 liquid Substances 0.000 description 18
- 238000007654 immersion Methods 0.000 description 15
- 239000000654 additive Substances 0.000 description 14
- 238000000926 separation method Methods 0.000 description 12
- 230000002708 enhancing effect Effects 0.000 description 11
- 239000003381 stabilizer Substances 0.000 description 8
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 7
- 235000014113 dietary fatty acids Nutrition 0.000 description 7
- 239000000194 fatty acid Substances 0.000 description 7
- 229930195729 fatty acid Natural products 0.000 description 7
- 239000008367 deionised water Substances 0.000 description 6
- 238000002156 mixing Methods 0.000 description 6
- 238000002360 preparation method Methods 0.000 description 6
- 239000000047 product Substances 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 5
- 229910021641 deionized water Inorganic materials 0.000 description 5
- 150000004665 fatty acids Chemical class 0.000 description 5
- YBGZDTIWKVFICR-JLHYYAGUSA-N Octyl 4-methoxycinnamic acid Chemical compound CCCCC(CC)COC(=O)\C=C\C1=CC=C(OC)C=C1 YBGZDTIWKVFICR-JLHYYAGUSA-N 0.000 description 4
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 4
- 239000003086 colorant Substances 0.000 description 4
- 239000000982 direct dye Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 238000005213 imbibition Methods 0.000 description 4
- 238000010348 incorporation Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 4
- QUAMTGJKVDWJEQ-UHFFFAOYSA-N octabenzone Chemical group OC1=CC(OCCCCCCCC)=CC=C1C(=O)C1=CC=CC=C1 QUAMTGJKVDWJEQ-UHFFFAOYSA-N 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 150000003254 radicals Chemical class 0.000 description 4
- 125000004178 (C1-C4) alkyl group Chemical group 0.000 description 3
- BCMCBBGGLRIHSE-UHFFFAOYSA-N 1,3-benzoxazole Chemical class C1=CC=C2OC=NC2=C1 BCMCBBGGLRIHSE-UHFFFAOYSA-N 0.000 description 3
- POAOYUHQDCAZBD-UHFFFAOYSA-N 2-butoxyethanol Chemical compound CCCCOCCO POAOYUHQDCAZBD-UHFFFAOYSA-N 0.000 description 3
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- NLZUEZXRPGMBCV-UHFFFAOYSA-N Butylhydroxytoluene Chemical compound CC1=CC(C(C)(C)C)=C(O)C(C(C)(C)C)=C1 NLZUEZXRPGMBCV-UHFFFAOYSA-N 0.000 description 3
- 239000004594 Masterbatch (MB) Substances 0.000 description 3
- XEFQLINVKFYRCS-UHFFFAOYSA-N Triclosan Chemical compound OC1=CC(Cl)=CC=C1OC1=CC=C(Cl)C=C1Cl XEFQLINVKFYRCS-UHFFFAOYSA-N 0.000 description 3
- 239000002253 acid Chemical class 0.000 description 3
- PYKYMHQGRFAEBM-UHFFFAOYSA-N anthraquinone Natural products CCC(=O)c1c(O)c2C(=O)C3C(C=CC=C3O)C(=O)c2cc1CC(=O)OC PYKYMHQGRFAEBM-UHFFFAOYSA-N 0.000 description 3
- QRUDEWIWKLJBPS-UHFFFAOYSA-N benzotriazole Chemical compound C1=CC=C2N[N][N]C2=C1 QRUDEWIWKLJBPS-UHFFFAOYSA-N 0.000 description 3
- 239000012964 benzotriazole Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- YCIMNLLNPGFGHC-UHFFFAOYSA-N catechol Chemical group OC1=CC=CC=C1O YCIMNLLNPGFGHC-UHFFFAOYSA-N 0.000 description 3
- 230000008859 change Effects 0.000 description 3
- 238000004040 coloring Methods 0.000 description 3
- 239000000470 constituent Substances 0.000 description 3
- 150000005205 dihydroxybenzenes Chemical class 0.000 description 3
- 238000007598 dipping method Methods 0.000 description 3
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 3
- KWIUHFFTVRNATP-UHFFFAOYSA-N glycine betaine Chemical compound C[N+](C)(C)CC([O-])=O KWIUHFFTVRNATP-UHFFFAOYSA-N 0.000 description 3
- 125000005843 halogen group Chemical group 0.000 description 3
- 229920001519 homopolymer Polymers 0.000 description 3
- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- JLZIIHMTTRXXIN-UHFFFAOYSA-N 2-(2-hydroxy-4-methoxybenzoyl)benzoic acid Chemical compound OC1=CC(OC)=CC=C1C(=O)C1=CC=CC=C1C(O)=O JLZIIHMTTRXXIN-UHFFFAOYSA-N 0.000 description 2
- ZMWRRFHBXARRRT-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4,6-bis(2-methylbutan-2-yl)phenol Chemical compound CCC(C)(C)C1=CC(C(C)(C)CC)=CC(N2N=C3C=CC=CC3=N2)=C1O ZMWRRFHBXARRRT-UHFFFAOYSA-N 0.000 description 2
- IYAZLDLPUNDVAG-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4-(2,4,4-trimethylpentan-2-yl)phenol Chemical compound CC(C)(C)CC(C)(C)C1=CC=C(O)C(N2N=C3C=CC=CC3=N2)=C1 IYAZLDLPUNDVAG-UHFFFAOYSA-N 0.000 description 2
- ZBCATMYQYDCTIZ-UHFFFAOYSA-N 4-methylcatechol Chemical compound CC1=CC=C(O)C(O)=C1 ZBCATMYQYDCTIZ-UHFFFAOYSA-N 0.000 description 2
- 239000004322 Butylated hydroxytoluene Substances 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 2
- 244000060011 Cocos nucifera Species 0.000 description 2
- 235000013162 Cocos nucifera Nutrition 0.000 description 2
- KCXVZYZYPLLWCC-UHFFFAOYSA-N EDTA Chemical compound OC(=O)CN(CC(O)=O)CCN(CC(O)=O)CC(O)=O KCXVZYZYPLLWCC-UHFFFAOYSA-N 0.000 description 2
- ULGZDMOVFRHVEP-RWJQBGPGSA-N Erythromycin Chemical compound O([C@@H]1[C@@H](C)C(=O)O[C@@H]([C@@]([C@H](O)[C@@H](C)C(=O)[C@H](C)C[C@@](C)(O)[C@H](O[C@H]2[C@@H]([C@H](C[C@@H](C)O2)N(C)C)O)[C@H]1C)(C)O)CC)[C@H]1C[C@@](C)(OC)[C@@H](O)[C@H](C)O1 ULGZDMOVFRHVEP-RWJQBGPGSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- OJMMVQQUTAEWLP-UHFFFAOYSA-N Lincomycin Natural products CN1CC(CCC)CC1C(=O)NC(C(C)O)C1C(O)C(O)C(O)C(SC)O1 OJMMVQQUTAEWLP-UHFFFAOYSA-N 0.000 description 2
- SJEYSFABYSGQBG-UHFFFAOYSA-M Patent blue Chemical compound [Na+].C1=CC(N(CC)CC)=CC=C1C(C=1C(=CC(=CC=1)S([O-])(=O)=O)S([O-])(=O)=O)=C1C=CC(=[N+](CC)CC)C=C1 SJEYSFABYSGQBG-UHFFFAOYSA-M 0.000 description 2
- 239000004433 Thermoplastic polyurethane Substances 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 239000012932 acetate dye Substances 0.000 description 2
- 239000000980 acid dye Substances 0.000 description 2
- 150000001412 amines Chemical class 0.000 description 2
- 150000004056 anthraquinones Chemical class 0.000 description 2
- RWCCWEUUXYIKHB-UHFFFAOYSA-N benzophenone Chemical compound C=1C=CC=CC=1C(=O)C1=CC=CC=C1 RWCCWEUUXYIKHB-UHFFFAOYSA-N 0.000 description 2
- 239000012965 benzophenone Substances 0.000 description 2
- 229960003237 betaine Drugs 0.000 description 2
- 229920001400 block copolymer Polymers 0.000 description 2
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 2
- 235000010354 butylated hydroxytoluene Nutrition 0.000 description 2
- MYSWGUAQZAJSOK-UHFFFAOYSA-N ciprofloxacin Chemical compound C12=CC(N3CCNCC3)=C(F)C=C2C(=O)C(C(=O)O)=CN1C1CC1 MYSWGUAQZAJSOK-UHFFFAOYSA-N 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 238000013329 compounding Methods 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- TUXJTJITXCHUEL-UHFFFAOYSA-N disperse red 11 Chemical compound C1=CC=C2C(=O)C3=C(N)C(OC)=CC(N)=C3C(=O)C2=C1 TUXJTJITXCHUEL-UHFFFAOYSA-N 0.000 description 2
- 239000012153 distilled water Substances 0.000 description 2
- 229960001484 edetic acid Drugs 0.000 description 2
- 239000003995 emulsifying agent Substances 0.000 description 2
- 229940093476 ethylene glycol Drugs 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 239000011874 heated mixture Substances 0.000 description 2
- 125000003187 heptyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 2
- BXWNKGSJHAJOGX-UHFFFAOYSA-N hexadecan-1-ol Chemical compound CCCCCCCCCCCCCCCCO BXWNKGSJHAJOGX-UHFFFAOYSA-N 0.000 description 2
- 125000004051 hexyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 2
- 229910052740 iodine Inorganic materials 0.000 description 2
- 125000001449 isopropyl group Chemical group [H]C([H])([H])C([H])(*)C([H])([H])[H] 0.000 description 2
- 125000001400 nonyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 2
- GLDOVTGHNKAZLK-UHFFFAOYSA-N octadecan-1-ol Chemical compound CCCCCCCCCCCCCCCCCCO GLDOVTGHNKAZLK-UHFFFAOYSA-N 0.000 description 2
- 125000002347 octyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 2
- 125000001147 pentyl group Chemical group C(CCCC)* 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 2
- 235000013772 propylene glycol Nutrition 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- GHMLBKRAJCXXBS-UHFFFAOYSA-N resorcinol Chemical group OC1=CC=CC(O)=C1 GHMLBKRAJCXXBS-UHFFFAOYSA-N 0.000 description 2
- 230000000717 retained effect Effects 0.000 description 2
- YGSDEFSMJLZEOE-UHFFFAOYSA-N salicylic acid Chemical compound OC(=O)C1=CC=CC=C1O YGSDEFSMJLZEOE-UHFFFAOYSA-N 0.000 description 2
- 159000000000 sodium salts Chemical class 0.000 description 2
- 238000002798 spectrophotometry method Methods 0.000 description 2
- PJANXHGTPQOBST-UHFFFAOYSA-N stilbene Chemical class C=1C=CC=CC=1C=CC1=CC=CC=C1 PJANXHGTPQOBST-UHFFFAOYSA-N 0.000 description 2
- 239000012815 thermoplastic material Substances 0.000 description 2
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 2
- 238000001429 visible spectrum Methods 0.000 description 2
- DNIAPMSPPWPWGF-VKHMYHEASA-N (+)-propylene glycol Chemical compound C[C@H](O)CO DNIAPMSPPWPWGF-VKHMYHEASA-N 0.000 description 1
- CIDUJQMULVCIBT-MQDUPKMGSA-N (2r,3r,4r,5r)-2-[(1s,2s,3r,4s,6r)-4-amino-3-[[(2s,3r)-3-amino-6-(aminomethyl)-3,4-dihydro-2h-pyran-2-yl]oxy]-6-(ethylamino)-2-hydroxycyclohexyl]oxy-5-methyl-4-(methylamino)oxane-3,5-diol Chemical compound O([C@@H]1[C@@H](N)C[C@H]([C@@H]([C@H]1O)O[C@@H]1[C@@H]([C@@H](NC)[C@@](C)(O)CO1)O)NCC)[C@H]1OC(CN)=CC[C@H]1N CIDUJQMULVCIBT-MQDUPKMGSA-N 0.000 description 1
- 125000003837 (C1-C20) alkyl group Chemical group 0.000 description 1
- MINDHVHHQZYEEK-UHFFFAOYSA-N (E)-(2S,3R,4R,5S)-5-[(2S,3S,4S,5S)-2,3-epoxy-5-hydroxy-4-methylhexyl]tetrahydro-3,4-dihydroxy-(beta)-methyl-2H-pyran-2-crotonic acid ester with 9-hydroxynonanoic acid Natural products CC(O)C(C)C1OC1CC1C(O)C(O)C(CC(C)=CC(=O)OCCCCCCCCC(O)=O)OC1 MINDHVHHQZYEEK-UHFFFAOYSA-N 0.000 description 1
- QMMJWQMCMRUYTG-UHFFFAOYSA-N 1,2,4,5-tetrachloro-3-(trifluoromethyl)benzene Chemical group FC(F)(F)C1=C(Cl)C(Cl)=CC(Cl)=C1Cl QMMJWQMCMRUYTG-UHFFFAOYSA-N 0.000 description 1
- YPFDHNVEDLHUCE-UHFFFAOYSA-N 1,3-propanediol Substances OCCCO YPFDHNVEDLHUCE-UHFFFAOYSA-N 0.000 description 1
- 229940035437 1,3-propanediol Drugs 0.000 description 1
- OCQDPIXQTSYZJL-UHFFFAOYSA-N 1,4-bis(butylamino)anthracene-9,10-dione Chemical compound O=C1C2=CC=CC=C2C(=O)C2=C1C(NCCCC)=CC=C2NCCCC OCQDPIXQTSYZJL-UHFFFAOYSA-N 0.000 description 1
- CBCKQZAAMUWICA-UHFFFAOYSA-N 1,4-phenylenediamine Chemical compound NC1=CC=C(N)C=C1 CBCKQZAAMUWICA-UHFFFAOYSA-N 0.000 description 1
- VCRZAKVGPJFABU-UHFFFAOYSA-N 10-phenoxarsinin-10-yloxyphenoxarsinine Chemical compound C12=CC=CC=C2OC2=CC=CC=C2[As]1O[As]1C2=CC=CC=C2OC2=CC=CC=C21 VCRZAKVGPJFABU-UHFFFAOYSA-N 0.000 description 1
- ULQISTXYYBZJSJ-UHFFFAOYSA-N 12-hydroxyoctadecanoic acid Chemical compound CCCCCCC(O)CCCCCCCCCCC(O)=O ULQISTXYYBZJSJ-UHFFFAOYSA-N 0.000 description 1
- OLFNXLXEGXRUOI-UHFFFAOYSA-N 2-(benzotriazol-2-yl)-4,6-bis(2-phenylpropan-2-yl)phenol Chemical compound C=1C(N2N=C3C=CC=CC3=N2)=C(O)C(C(C)(C)C=2C=CC=CC=2)=CC=1C(C)(C)C1=CC=CC=C1 OLFNXLXEGXRUOI-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
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- C08J7/065—Low-molecular-weight organic substances, e.g. absorption of additives in the surface of the article
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
- D06P1/60—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing polyethers
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- D—TEXTILES; PAPER
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- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
- D06P1/60—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing polyethers
- D06P1/613—Polyethers without nitrogen
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
- D06P1/60—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing polyethers
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
- D06P1/60—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing polyethers
- D06P1/613—Polyethers without nitrogen
- D06P1/6131—Addition products of hydroxyl groups-containing compounds with oxiranes
- D06P1/6135—Addition products of hydroxyl groups-containing compounds with oxiranes from aromatic alcohols or from phenols, naphthols
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
- D06P1/64—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing low-molecular-weight organic compounds without sulfate or sulfonate groups
- D06P1/651—Compounds without nitrogen
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
- D06P1/64—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders using compositions containing low-molecular-weight organic compounds without sulfate or sulfonate groups
- D06P1/651—Compounds without nitrogen
- D06P1/65106—Oxygen-containing compounds
- D06P1/65118—Compounds containing hydroxyl groups
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/02—Material containing basic nitrogen
- D06P3/04—Material containing basic nitrogen containing amide groups
- D06P3/24—Polyamides; Polyurethanes
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/79—Polyolefins
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
Definitions
- the present invention relates to a method of dyeing a semi-finished product.
- the semi-finished product is immersed at least partially in a dye bath which includes one or more dyes, water, at least one carrier (e.g., ethyleneglycol butyl ether), and a diol (e.g., diethylene glycol).
- a dye bath which includes one or more dyes, water, at least one carrier (e.g., ethyleneglycol butyl ether), and a diol (e.g., diethylene glycol).
- Colored semi-finished products can be prepared by means of incorporating (e.g., by means of compounding) pigments and/or dyes directly into the polymeric materials from which the products are prepared.
- Such direct incorporation methods result in the colorant being dispersed substantially throughout the semi-finished product.
- Direct incorporation methods are not particularly well suited for the preparation of semi-finished products that are only slightly colored or tinted (e.g., less than opaque), such as in the case of sunshade lenses. It is typically difficult to adequately and sufficiently disperse the small amounts of colorant required to prepare slightly colored or tinted semi-finished products, by means of direct incorporation methods.
- the preparation of colored semi-finished products by means of applying a dye composition to the surface of the semi-finished product is generally known. Such dyeing methods are more suited to the preparation of slightly colored or tinted semi-finished products, as only small and controlled amounts of colorant are incorporated into the surface thereof.
- the dye compositions may be aqueous or non-aqueous.
- a method of dyeing a semi-finished product comprises:
- the dye bath used in the method of the present invention includes at least one carrier according to formula I, as described previously herein.
- Linear or branched alkyls from which R of formula I may be selected include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl and octadecyl, and structural isomers thereof (e.g., iso-propyl, i-butyl, t-butyl, etc.).
- R may also be selected from benzyl, benzoyl and phenyl groups, each of which may independently and optionally be substituted with 1 to 5 groups selected from halo groups (e.g., chloro, bromo and fluoro), linear or branched C 1 -C 9 alkyl groups (e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl and nonyl,), and aromatic groups (e.g., phenyl).
- halo groups e.g., chloro, bromo and fluoro
- linear or branched C 1 -C 9 alkyl groups e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl and nonyl
- aromatic groups e.g., phenyl
- n is 2 and R is selected from n-butyl, i-butyl and t-butyl. In a particularly preferred embodiment of the present invention, n is 2, and R is n-butyl.
- the carrier is typically present in the dye bath in an amount of less than or equal to 30 percent by weight, preferably less than or equal to 25 percent by weight, and more preferably less than or equal to 20 percent by weight.
- the carrier is also typically present in the dye bath in an amount of at least 10 percent by weight, preferably at least 15 percent by weight, and more preferably at least 17 percent by weight.
- the carrier may be present in the bath in an amount ranging between any combination of these upper and lower values, inclusive of the values thereof.
- the carrier may be present in the dye bath in an amount typically from 10 to 30 percent by weight, more typically from 15 to 25 percent by weight, and further typically in an amount of from 17 to 20 percent by weight.
- the percent weights being based on the total weight of the dye bath, in each case.
- the dye bath also further includes a diol selected from at least one of linear or branched C 2 -C 20 aliphatic diols, poly(C 2 -C 4 alkylene glycol), cycloaliphatic diols having from 5 to 8 carbon atoms in the cyclic ring, monocyclic aromatic diols, bisphenols and hydrogenated bisphenols.
- a diol selected from at least one of linear or branched C 2 -C 20 aliphatic diols, poly(C 2 -C 4 alkylene glycol), cycloaliphatic diols having from 5 to 8 carbon atoms in the cyclic ring, monocyclic aromatic diols, bisphenols and hydrogenated bisphenols.
- linear or branched C 2 -C 20 aliphatic diols include, but are not limited to, ethylene glycol, propylene glycol, 1,3-propane diol, 1,2- and 2,3-butane diol, pentane diols, hexane diols, heptane diols, octane diols, nonane diols, decane diols, undecane diols, dodecane diols, tridecane diols, tetradecane diols, pentadecane diols, hexadecane diols, hetadecane diols, octadecane diols, nonadecane diols and icosane diols.
- poly(C 2 -C 4 )alkylene glycols from which the diol (iv) may be selected include, but are not limited to, di-, tri-, tetra-, penta- and higher ethylene glycols, di-, tri-, tetra-, penta- and higher propylene glycols, and di-, tri-, tetra-, penta- and higher butylene glycols.
- Cycloaliphatic diols having from 5 to 8 carbon atoms that may be used as diol (iv) include, but are not limited to, cyclopentane diol, cyclohexane diol, cyclohexane dimethanol, cycloheptane diol and cyclooctane diol.
- Examples of monocyclic aromatic diols that may be used as diol (iv) include but are not limited to, benzene diol, e.g., 1,2-dihydroxy benzene and 1,3-dihydroxy benzene; C 1 -C 4 alkyl substituted benzene diol, e.g., 4-tert-butyl-benzene-1,2-diol, 4-methyl-benzene-1,2-diol, 3-tert-butyl-5-methyl-benzene-1,2-diol and 3,4,5,6-tetramethyl-benzene-1,2-diol; halo substituted benzene diol, e.g., 3,5-dichlorobenzene-1,2-diol, 3,4,5,6-tetrabromo-benzene-1,2-diol and 3,4,5-trichloro-benzene-1,2-diol; and C 1 -C 4 alkyl and
- Bisphenols and hydrogenated bisphenols that may be used as diol (iv) may be represented by the following general formula II,
- R 1 and R 2 are each selected independently from each other and independently for each p and q from C 1 -C 4 alkyl (e.g., methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl and tert-butyl), chlorine and bromine;
- p and q are each independently an integer from 0 to 4;
- —X— is a divalent linking group selected from —O—, —S—, —S(O 2 )—, —C(O)—, —CH 2 —, —CH ⁇ CH—, —C(CH 3 ) 2 —, and —C(CH 3 )(C 6 H 5 )—; and represents a benzene ring or a cyclohexane ring.
- An example of a bisphenol that may be used as diol (iv) is 4,4′-isopropylidenebisphenol (i.e., bisphenol A).
- An example of a hydrogenated bisphenol that may be used as diol (iv) is 4,4′-isopropylidenebiscyclohexanol.
- diol (iv) is a poly(C 2 -C 4 alkylene glycol) selected from diethylene glycol, triethylene glycol, tetraethylene glycol, pentaethylene glycol and mixtures thereof. Particularly preferred diols are ethylene glycol and diethylene glycol.
- the diol is typically present in the dye bath in an amount of less than or equal to 20 percent by weight, preferably less than or equal to 15 percent by weight, and more preferably less than or equal to 12 percent by weight.
- the diol is also typically present in the dye bath in an amount of at least 1 percent by weight, preferably at least 5 percent by weight, and more preferably at least 10 percent by weight.
- the diol may be present in the bath in an amount ranging between any combination of these upper and lower values, inclusive of the values thereof.
- the diol may be present in the dye bath in an amount typically from 1 to 20 percent by weight, more typically from 5 to 15 percent by weight, and further typically in an amount of from 10 to 12 percent by weight.
- the percent weights being based on the total weight of the dye bath, in each case.
- the dye that is present in the dye bath may be selected from static dyes, photochromic dyes and combinations thereof.
- static dyes means a dye that does not substantially change color upon exposure to (or being shielded from) ultraviolet (UV) light.
- photochromic dyes as used herein and the claims means dyes that reversibly change color upon exposure to UV light, as is known to the skilled artisan.
- a photochromic dye upon exposure to a particular wavelength of UV light, a photochromic dye will be converted into an open or activated form which is colored (within a particular portion of the visible spectrum).
- the open/activated photochromic dye Upon removal of the UV light source, the open/activated photochromic dye returns to a closed/inactivated from which is not colored, or which is at least less colored than the activated form.
- Static dyes that may be included in the dye bath include, for example, fabric dyes and disperse dyes as well as dyes that are known in the art as being suitable for tinting semi-finished products, such as thermoplastic polycarbonate articles.
- suitable disperse dyes include, but are not limited to, Disperse Blue #3, Disperse Blue #14, Disperse Yellow #3, Disperse Red #13 and Disperse Red #17.
- the classification and designation of the static dyes are recited herein in accordance with “The Colour Index”, 3 rd edition published jointly by the Society of Dyes and Colors and the American Association of Textile Chemists and Colorists (1971), which is incorporated herein by reference.
- Dyestuffs can generally be used either as a sole dye constituent or as a component of a dye mixture depending upon the color desired.
- the term static dye as used herein includes mixtures of static dyes.
- Direct Dyes The static dye class known as Direct Dyes is useful in the practice of the present invention.
- Direct Dye examples include, but are not limited to, Solvent Blue 35, Solvent Green 3 and Acridine Orange Base. However, it has been observed that Direct Dyes, typically do not color (tint/dye) the semi-finished product as intensely as do Disperse Dyes (which have been described previously herein).
- Suitable static dyes include, for example, water-insoluble azo, diphenylamine and anthraquinone compounds.
- acetate dyes, dispersed acetate dyes, dispersion dyes and dispersol dyes such as are disclosed in Colour Index, 3 rd edition, vol. 2, The Society of Dyers and Colourists, 1971, pp. 2479 and pp. 2187-2743, respectively all incorporated herein by reference.
- Preferred dispersed dyes include Dystar's Palanil Blue E-R150 (anthraquinone/Disperse Blue) and DIANIX Orange E-3RN (azo dye/CI Disperse Orange 25). It has been observed that phenol red and 4-phenylazophenol do not provide a desirable level of dying when the semi-finished product is thermoplastic polycarbonate, in the present process.
- Static dyes known as direct dyes and those referred to as acid dyes have been observed to provide a less than desirable level of tinting when the semi-finished product contains thermoplastic polycarbonate, in the practice of the present invention.
- acid dyes have been observed to be effective with nylon.
- non-migratory static dyes i.e., static dyes that have been chemically modified to minimize or eliminate their migration out of semi-finished products into which they have been incorporated.
- a particular class of non-migratory static dyes may be represented by the following formula III, R 5 -(polymeric constituent-Y) t III
- R 5 represents an organic dyestuff radical (or chromophore radical); the polymeric constituent is selected independently for each (t) from homopolymers, copolymers and block-copolymers of poly(C 2 -C 4 alkylene oxides), e.g., homopolymers of polyethylene oxide and polypropylene oxide, poly(ethylene oxide-propylene oxide) copolymers, and di- or higher block copolymers of ethylene oxide and propylene oxide; (t) may be an integer from 1 to 6; and (Y) is selected independently for each (t) from hydroxyl, primary amine,
- the polymeric constituent may have a molecular weight of from, for example, 44 to 1500.
- Dyestuff radicals from which (Y) may be selected include, but are not limited to, nitroso, nitro, azo (e.g., monoazo, diazo and triazo), diarylmethane, triarylmethane, xanthene, acridene, methine, thiazole, indamine, azine, oxazine and anthraquinone dyestuff radicals.
- Non-migratory static dyes represented by formula III are described in further detail in U.S. Pat. Nos.: 4,284,729; 4,640,690; and 4,812,141.
- Non-migratory static dyes have been found to be useful when dyeing semi-finished products by means of imbibition or diffusion in accordance with the method of the present invention (e.g., by dipping). When incorporated into the semi-finished product by means of imbibition, excess non-migratory static dye can be washed off of the semi-finished product, with a minimum of imbibed non-migratory static dye being leached from the semi-finished product.
- Non-migratory static dyes e.g., as represented by formula II
- Non-migratory static dyes have been found to be particularly useful in the method of the present invention when dyeing (e.g., by dipping) semi-finished products fabricated from thermoplastic polyurethane.
- Photochromic dyes that may be used in the present method include those known to the skilled artisan.
- Classes of suitable photochromic dyes include, but are not limited to: spiro(indoline)naphthoxazines and spiro(indoline)benoxazines (e.g., as described in U.S. Pat. No. 4,818,096); and chromenes, such as benzopyrans and naphthopyrans (e.g., as described in U.S. Pat. No.
- photochromic dyes include, for example, fulgides and fulgimides, such as 3-furyl and 3-thienyl fulgides and fulgimides (e.g., as described in U.S. Pat. No. 4,931,220). The pertinent disclosures of the cited patents with regard to photochromic dyes is incorporated herein by reference.
- Photochromic dyes or mixtures thereof may be used alone or in combination with one or more static dyes in the method of the present invention.
- the imbibition of photochromic dyes into the semi-finished products, such that contain thermoplastic polycarbonate articles results in a dyed semi-finished product that does not readily change color upon exposure to or shielding from UV light.
- the photochromic dyes become trapped in either an open or closed form within the thermoplastic polymer matrix.
- softer, more rubbery polymers such as polyurethanes are very suitable matrices for photochromic dyes to readily transition between the dark and light states.
- the amount of dye present in the dye bath may vary widely. Typically the dye is present in the dye bath in an amount sufficient to result in the formation of a dyed semi-finished product having a colored effect and/or a photochromic effect that is discernible to the naked eye, e.g., upon exposure to UV light in the case of photochromic dyes.
- the amount of dye that is actually present in the dye bath will depend on the solubility of the dye within the mixture of water, carrier and diol. The solubility of the dye within the bath will also be affected by the temperature of the bath. In those instances where the dye is not fully soluble in the bath, the dye bath is deemed to contain a saturated level of dye.
- the level of dye in the bath can be maintained at the saturation level during dyeing operations.
- the level (e.g., the saturation level) of dye in the bath can be determined periodically or continuously by, for example, thermogravimetric analysis or spectrophotometric analysis.
- the dye is present in the dye bath in an amount of less than or equal to 15 percent by weight, more typically less than or equal to 5 percent by weight, further typically less than equal to 1 percent by weight, and still further typically less than 0.5 percent by weight.
- the dye is also typically present in the dye bath in an amount of at least 0.001 percent by weight, preferably at least 0.005 percent by weight, and more preferably at least 0.01 percent by weight.
- the dye may be present in the bath in an amount ranging between any combination of these upper and lower values, inclusive of the values thereof.
- the dye may be present in the dye bath in an amount typically from 0.001 to 15 percent by weight, more typically from 0.005 to 5 percent by weight, further typically in an amount of from 0.01 to 1 percent by weight, and still further typically in an amount of from 0.01 to 0.5 percent by weight.
- the dye is present in the dye bath in an amount of 0.03 percent by weight. The percent weights being based on the total weight of the dye bath, in each case.
- the dye bath contains: 0.001 to 0.5 percent by weight of said dye; 65 to 75 percent by weight of water; 15 to 25 percent by weight of said carrier; and 1 to 15 percent by weight of said diol.
- the percent weights being based, in each case, on the total weight of the dye bath.
- Water is typically present in the dye bath in an amount of less than or equal to 85 percent by weight, preferably less than or equal to 80 percent by weight, and more preferably less than or equal to 75 percent by weight. Water is also typically present in the dye bath in an amount of at least 50 or 51 percent by weight, preferably at least 60 percent by weight, and more preferably at least 65 percent by weight. Water may be present in the bath in an amount ranging between any combination of these upper and lower values, inclusive of the values thereof. For example, water may be present in the dye bath in an amount typically from 50 (or 51) to 85 percent by weight, more typically from 60 to 87 percent by weight, and further typically in an amount of from 65 to 75 percent by weight. The percent weights being based on the total weight of the dye bath, in each case.
- the water used is preferably deionized water or distilled water.
- the dye bath further includes a surfactant (or emulsifier), which is different from each of the carrier and the diol.
- a surfactant or emulsifier
- Suitable surfactants in the present invention are readily dispersible upon being poured into water, and then form a milky emulsion upon agitation thereof.
- the surfactant may be selected from at least one of: anionic surfactants; amphoteric surfactants; and a non-ionic surfactant selected from at least one of poly(C 2 -C 4 alkoxylated) C 14 -C 18 unsaturated fatty acids, poly(C 2 -C 4 alkoxylated) phenol and poly(C 2 -C 4 alkoxylated) C 1 -C 9 alkyl substituted phenol.
- anionic surfactants that may be used in the present invention include, for example, amine salts or alkali salts of carboxylic, sulfamic or phosphoric acids, for example sodium lauryl sulfate, ammonium lauryl sulfate, lignosulfonic acid salts, ethylene diamine tetra acetic acid (EDTA) sodium salts and acid salts of amines such as laurylamine hydrochloride or poly(oxy-1,2-ethanediyl),alpha.-sulfo-omega-hydroxy ether with phenol 1-(methylphenyl)ethyl derivative ammonium salts
- amine salts or alkali salts of carboxylic, sulfamic or phosphoric acids for example sodium lauryl sulfate, ammonium lauryl sulfate, lignosulfonic acid salts, ethylene diamine tetra acetic acid (EDTA) sodium salts and acid salts of
- Amphoteric surfactants that may be present in the dye bath include, for example: lauryl sulfobetaine; dihydroxy ethylalkyl betaine; amido betaine based on coconut acids; disodium N-lauryl amino propionate; or the sodium salts of dicarboxylic acid coconut derivatives.
- poly(C 2 -C 4 alkoxylated) C 14 -C 18 unsaturated fatty acids include, ethoxylated, propoxylated and/or butoxylated tetradecenyl carboxylic acid.
- poly(C 2 -C 4 alkoxylated) phenols include ethoxylated, propoxylated and/or butoxylated phenol.
- poly(C 2 -C 4 alkoxylated) C 1 -C 9 alkyl substituted phenols include, octylphenoxypolyethyleneoxyethanol and poly(oxy-1,2-ethanediyl), alpha-phenyl-omega-hydroxy, styrenated.
- the optional surfactant may be used in an amount less than or equal to 5 percent by weight.
- the optional surfactant is present in the dye bath in an amount of 0.5 to 5 percent by weight, and more preferably in an amount of 1 to 4 percent by weight.
- the percent weights, in each case, being based on the weight of the dye bath.
- the dye bath may further optionally include a performance enhancing additive selected from at least one of UV stabilizers, optical brighteners, mold release agents, antistatic agents, thermal stabilizers, IR absorbers and antimicrobial agents (substances or compounds). Inclusion of one or more of these optional performance enhancing additives in the dye bath serves to improve the physical performance/properties of the dyed semi-finished product. In addition to the dye, the optional additives also diffuse, impregnate or otherwise are imbibed into the bulk of the semi-finished product while it is immersed in the dye bath. For example, including UV stabilizers in the dye bath results in a dyed semi-finished product having improved UV resistance.
- a performance enhancing additive selected from at least one of UV stabilizers, optical brighteners, mold release agents, antistatic agents, thermal stabilizers, IR absorbers and antimicrobial agents (substances or compounds). Inclusion of one or more of these optional performance enhancing additives in the dye bath serves to improve the physical performance/properties of the dyed semi-
- Mold release agents would be more advantageously included in the dye bath when the semi-finished product is selected from thermoplastic pellets, thermoplastic strands, or thermoplastic powders from which a finished product would later be prepared, as will be discussed further herein.
- the optional performance enhancing additives may be selected from those that are known for use in preparing thermoplastic molded articles.
- Classes of UV (ultraviolet) stabilizers (or absorbers) that may be used in the dye bath of the present invention include, but are not limited to salicylic acid UV absorbers, benzophenone UV absorbers, benzotriazole UV absorbers, cyanoacrylate UV absorbers, and mixtures thereof.
- benzotriazole UV absorbers include but are not limited to: 2-(2′-hydroxy-5′methylphenyl)-benzotriazole (commercially available as Tinuvine® P from Ciba, Tarrytown, N.Y.); 2-(3′-5′-di-tert-butyl-2′-hydroxyphenyl)-5-chlorobenzotriazole (commercially available as Tinuvin® 327 from Ciba); 2(2′-hydroxy-3′-5′-di-tert-amylphenyl)benzotriazole (commercially available as Tinuvin® 328 from Ciba); benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethyl ethyl)-4-hydroxy-, C 7-9 branched alkyl esters (commercially available as Tinuvin® 384 from Ciba); 2-(3′,5′-bis(1-methyl-1-phenylethyl)-2′-hydroxy
- UV stabilizer is 2-hydroxy-4-(N-octoxy) benzophenone (commercially available as Lowilite® 22 from Great Lakes Chemical Corp. of West Lafayette, Ind.).
- UV stabilizers that may be use in the present invention include, but are not limited to: p-methoxycinnamic acid 2-ethylhexyl ester stabilized with butylated hydroxy toluene (hereinafter “BHT”) (commercially available as Uvinul MC 80 from BASF of Mount Olive, N.J.); p-methoxycinnamic acid 2-ethylhexyl ester unstabilized (commercially available as Uvinul MC 80 N from BASF); 2-cyano-3,3-diphenylacrylic acid 2′-ethylhexyl ester (commercially available as Uvinul 539 T from BASF); 2-hydroxy-4-(N-octoxy) benzophenone (commercially available
- a further class of UV stabilizers that may be used in the method of the present invention include those modified with at least one poly(oxyalkylene) chain.
- Such poly(oxyalkylene) chain modified UV stabilizers are characterized in having low migratory properties once imbibed (or diffused) into the semi-finished product (e.g., they are not easily leached out of the semi-finished product into which they have been imbibed).
- the poly(oxyalkylene) chain may be a homopolymer, copolymer or block-copolymer formed from the reaction of C 2 -C 20 alkylene oxides (e.g., ethylene oxide, propylene oxide and butylene oxide).
- the poly(oxyalkylene) group may be terminated with a hydroxyl group, a C 1 -C 20 alkyl ether group, or a C 1 -C 20 ester group.
- Poly(oxyalkylene) chain modified UV stabilizers are described, for example, in further detail in U.S. Pat. No. 6,602,447 B2.
- Optical brighteners that may be included in the dye bath in the method of the present invention typically absorb a light wavelength of 450 nm or less and emit the light at a higher wavelength, such as a wavelength of 550 nm or less, preferably 525 nm or less. It is preferred that the emitted light be in the blue region of the visible spectrum (e.g., emitted light having a wavelength of at least about 400 nm and up to about 525 nm. Most preferably, the light emitted is no more than about 500 nm.
- Classes of optical brighteners that may be used in the present invention include, but are not limited to benzoxazole derivatives and stilbene derivatives.
- Examples of commercially available benzoxazole derivatives that may be used in the present invention include, but are not limited to:
- 2,2′-(2,5-thiophenediyl) bis [5-tert-butylbenzoxazole] (commercially available as Uvitex® OB from Ciba); benzoxazole derivatives such as Blankophor® KLA (from Bayer of Pittsburgh, Pa.); Hostalux® KCB (from Clariant of Muttenz, Switzerland); and Hostalux® KCU (from Clariant).
- An example of a commercially available stilbene derivative is 4,4′-bis(2-benzoxazolyl) stilbene (commercially available as Eastobrite® OB-1 from Eastman of Kingsport, Tenn.).
- Classes of mold release agents that may be included in the dye bath include, but are not limited to hydrocarbon-based mold release agents, fatty acid-based release agents, fatty acid amide-based mold release agents, alcohol-based mold release agents, fatty acid ester-based mold release agents, silicone-based mold release agents, and mixtures or combinations thereof.
- hydrocarbon-based mold release agents include, synthetic paraffins, polyethylene waxes and fluorocarbons.
- Fatty acid-based release agents that may be used include, for example, stearic acid and hydroxystearic acid.
- Fatty acid amide-based mold release agents that may be used include, for example, stearic acid amide, ethylenebisstearoamide and alkylenebis fatty acid amides.
- alcohol-based mold release agents examples include, stearyl alcohol, cetyl alcohol, and polyhydric alcohols such as polyglycols and polyglycerols.
- polyhydric alcohols such as polyglycols and polyglycerols.
- An example of a fatty acid ester-based mold release agent that may be included in the dye is butyl stearate.
- Antistatic agents that may be included in the dye bath in the method of the present invention include, but are not limited to non-ionic antistatic agents, such as those containing fluorocarbon groups, and silicone oils, such as BAYSILONE O1 A (commercially available from Bayer AG, Germany). Further examples of antistatic agents that may be used in the present invention include, distearylhydroxylamine, triphenyl amine, tri-n-octylphosphine oxide, triphenyl phosphine oxide, pyridine N-oxide and ethoxylated sorbitan monolaurate.
- Classes of thermal (or heat-resistant) stabilizers that may be included in the dye bath of the method of the present invention include, but are not limited to, phenol stabilizers, organic thioether stabilizers, organic phosphide stabilizers, hindered amine stabilizers, epoxy stabilizers and mixtures thereof.
- thermal stabilizers include, but are not limited to, 2,6-di-t-butyl-p-cresol, o-t-butyl-p-cresol, tetrakis-(methylene-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate)methane, ⁇ -naphtylamine, p-phenylenediamine, and thiodiethylene bis(3,5-di-tert-butyl)-4-hydroxyhydrocinnamate, which is commercially available from Ciba Specialty Chemical under the tradename IRGANOX 1035 thermal stabilizer.
- Infra red (IR) absorbers that may be used in the method of the invention include dyes that absorb in the IR region of the spectrum.
- Examples of commercially available IR absorbers include, CYASORB IR-99, IR-126 and IR-165, which are available from Glendale Protective Technologies, Inc., Lakeland, Fla.
- Antimicrobial agents that may be included in the dye bath in the method of the present invention include, for example, substances having antimicrobial activity towards microorganisms, such as pathogenic microorganisms.
- the term “antimicrobial agents” as used herein and in the claims is also inclusive of antiseptic, disinfectant and antifungal substances.
- the antimicrobial agents may also be used in a pre-activated form, e.g., in a form that does not become antimicrobially active until the occurrence of a triggering event, such as action of a microbe on the pre-activated substance.
- antimicrobial agents examples include, but are not limited to: quinolones, such as nalidixic acid, pipemidic acid, cinoxacin, ciprofloxacin, norfloxacin, ofloxacin, pefloxacin and enoxacin; aminoglycosides, such as gentamycin, kanamycin, amikacin, sisomycin, tobramycin and netilmicin; macrolides, such as erythromycin, clarithromycin and azithromycin; polypeptides, such as bacitracin, mupirocin, thyrothricin, gramicidin and tyrocidin; lincomycins, such as lincomycin and clindamycin; and antimycobacterial agents, such as rifampicin and fusidic acid.
- quinolones such as nalidixic acid, pipemidic acid, cinoxacin, ciprofloxacin, norfloxacin,
- antimicrobial agents that may be used in the dye bath include: 10,10′-oxybisphenoxy arsine; 2-n-octyl-4-isothiazolin-3-one; 2,4,4′-trichloro-2′-hydroxy diphenyl ether (also named 5-chloro-2-(2,4-dichlorophenoxy)phenol, and commonly referred to as Triclosan); N-butyl-1,2-benzisothiazolin-3-one; and N-(trichloromethylthio)phthalamide.
- 10,10′-oxybisphenoxy arsine 2-n-octyl-4-isothiazolin-3-one
- 2,4,4′-trichloro-2′-hydroxy diphenyl ether also named 5-chloro-2-(2,4-dichlorophenoxy)phenol, and commonly referred to as Triclosan
- N-butyl-1,2-benzisothiazolin-3-one and N-(trichloromethylthio)phthalamide.
- the performance enhancing additives if used are typically present in the dye bath in a positive amount totaling less than or equal to 15 percent by weight, preferably less than or equal to 5 percent by weight, and more preferably less than or equal to 1 percent by weight.
- the performance enhancing additives are also typically present in the dye bath in an amount totaling at least 0.001 percent by weight, preferably at least 0.005 percent by weight, and more preferably at least 0.01 percent by weight.
- the performance enhancing additives may be present in the bath in a total amount ranging between any combination of these upper and lower values, inclusive of the recited values thereof.
- the performance enhancing additives may be present in the dye bath in an amount typically totaling from 0.001 to 15 percent by weight, more typically from 0.005 to 5 percent by weight, and further typically in an amount of from 0.01 to 1 percent by weight.
- the percent weights being based on the total weight of the dye bath, in each case.
- the method of the present invention involves dyeing a semi-finished product.
- the semi-finished product in the context of the present invention is defined as an intermediate thermoplastic product selected from the group consisting of pellets, strands and powders calculated to be further processed (reshaped) to form a finished product. These terms are well known to the art skilled.
- thermoplastic material suitable for the inventive method is a thermoplastic material system that contains at least one member selected from the group consisting of (co)polyesters, (co)polycarbonates, polyesterpolycarbonate copolymers, acrylonitrile-butadiene-styrene (ABS) copolymers, polyamides, polyurethanes, polyalkyl(meth)acrylate (e.g., polymethylmethacrylate) and styrene copolymers (e.g., styrene acrylonitrile copolymers).
- the (co)polyesters, (co)polycarbonates, polyesterpolycarbonate copolymers may be aliphatic or aromatic polymers (e.g., containing residues of bisphenol A).
- thermoplastic means a polymer that has a softening or melting point, and is substantially free of a three dimensional crosslinked network resulting from the formation of covalent bonds between chemically reactive groups, e.g., active hydrogen groups and free isocyanate groups.
- the semi-finished product may contain additives that are known to the skilled artisan.
- additives include, but are not limited to: mold release agents; fillers; reinforcing agents in the form of fibers or flakes (e.g., metal flakes such as aluminum flakes); flame retardant agents; pigments; and opacifying agents, such as titanium dioxide; light-diffusing agents, such as polytetrafluoroethylene, zinc oxide, Paraloid EXL-5136 available from Rohm and Haas and crosslinked polymethylmethacrylate microspheres (such as n-licrospheres from Nagase America); UV-stabilizers; hydrolytic stabilizers; thermal stabilizers; and antimicrobial agents.
- the semi-finished product contains at least one of pigments, crosslinked polymethylmethacrylate microspheres, glass microspheres and metal flakes.
- the semi-finished product may be prepared by art-recognized methods, such as extrusion—for making strands, and chopping of strands to make pellets.
- Powders in the context of the invention may be prepared by solution spray drying or by precipitation of their polymeric solution or melt. The powders are sometimes characterized by the largest dimension of their particles that may range up to about 1000 microns.
- the semi-finished product is selected from powders, pellets and strands.
- Thermoplastic pellets and strands may be made by art-recognized methods, such as extrusion or melt-spinning.
- the thermoplastic pellets and/or strands are dyed, and then may be further processed.
- the dyed thermoplastic pellets and/or strands are melted (e.g., in an extruder) to form a molten dyed thermoplastic composition, and then the molten dyed thermoplastic composition is introduced (e.g., injected) into a mold.
- the contents of the mold are allowed to cool, the mold is opened, and a dyed shaped finished product is removed therefrom.
- This method of further processing dyed semi finished products is favorably differentiated from the direct incorporation methods described previously herein.
- the dye With dyed thermoplastic pellets and/or strands, the dye is already present within the thermoplastic polymer (rather than being added to the polymer separately), which allows for more control and reliability with regard to the desired and reproducible level of tinting.
- the semi-finished product to be tinted is immersed in the dye bath for a period of time and at temperature at least sufficient to facilitate at least some impregnation (diffusion or imbibition), of the dye into the bulk of the semi-finished product thus effecting dyeing (or tinting) thereof.
- the time and temperature employed typically depends on the composition of the semi-finished product. Immersion times are typically less than or equal to 8 hours, more typically less than or equal to 4 hours, and even more typically less than or equal to 1 hour. Immersion times are also typically at least 5 seconds, more typically at least 30 seconds, and even more typically at least 1 minute.
- the immersion time may range between any of these upper and lower values, inclusive of the recited values. In an embodiment of the present invention, the immersion time is typically from 5 seconds to 8 hours, more typically from 15 or 30 seconds to 4 hours, and further typically from 1 minute to 1 hour (e.g., 1 to 15 minutes).
- the temperature of the dye bath during immersion of the semi-finished product is typically at least room temperature (e.g., 25° C.) and less than the boiling and/or decomposition temperature of the dye bath.
- the dye bath is maintained at a temperature of 25° C. to 99° C., for example from 60° C. to 97° C. or from 70° C. to 95° C.
- the time and temperature of immersion will depend at least in part on the type of semi-finished product that is to be dyed. For example, with semi-finished products of thermoplastic aromatic polycarbonate, dyeing may be efficiently carried out at a temperature of 90 to 99° C., with an immersion time of typically less than 1 hour, and more typically in the range of 1 to 15 minutes.
- the tinted (or dyed) semi-finished product is then withdrawn from the dye bath.
- the dye bath may be prepared by mixing the dye, water, carrier, diol, optional surfactants and optional performance enhancing additives together in any order.
- the carrier and diol may be mixed together with the dye, and then this mixture is either added to water or water is added to it.
- the dye bath is formed by: (i) preparing a mixture of water, carrier and diol; (ii) introducing the dye into a filter; and (iii) passing the mixture over the dye and through the filter, thereby forming the dye bath.
- the dye bath, or at least a portion thereof, is then typically passed continuously through the filter.
- the mixture of water, carrier and diol may be heated, e.g., heated to a temperature of 25° C. to 99° C., or 60° C. to 97° C., or 70° C. to 95° C., and then the heated mixture is contacted with the dye in the filter.
- the filter into which the dye is added may be any suitable filter known to the skilled artisan.
- a preferred type of filter is a bag filter. Preparing and maintaining the dye bath in this manner, ensures that the level of dye in the bath is maintained substantially at a saturation level (as discussed previously herein).
- passing the dye bath continuously through the bag filter serves to remove particulate contaminants therefrom (e.g., unsolubilized dye particles), which could foul the dyed semi-finished products prepared by immersion in the dye bath.
- the dye bath is continuously introduced into and withdrawn from an immersion tank (or vessel).
- the immersion tank is part of a circuit which includes an inlet that is in fluid communication (via an inlet conduit) with a pump, which is in fluid communication with an outlet from the tank via an outlet conduit.
- the circuit may optionally include at least one filter, e.g., a bag filter as described previously herein, located inline with the inlet and/or outlet conduits.
- the inlet and outlet of the immersion tank are positioned below the liquid level of the dye bath within the tank.
- the immersion tank inlet may include a plate having a plurality of perforations (e.g., a diffuser or diffuser plate). Continuously introducing the dye bath into the immersion tank by passage through a plate having a plurality of perforations increases the level of turbulent mixing within the immersion tank, and improves the efficiency and uniformity of dyeing of semi-finished products immersed therein.
- the perforations in the diffuser plate may have any suitable shape, e.g., circular, ellipsoid, polygonal or combinations thereof.
- the perforations of the diffuser plate typically have diameters of from 0.79 mm to 12.70 mm, e.g., from 3.17 mm to 6.35 mm.
- the diffuser plate may have any suitable configuration, e.g., it may be flat, concave or convex.
- the scope of the method of the present invention is inclusive of additional steps whereby the composition of the dye bath is modified, e.g., such that an initial dye or dyes may be substituted with a subsequent dye or dyes.
- the dye and optional performance enhancing additives are separated from the other components of the dye bath (e.g., the water, carrier, diol and optional surfactants).
- Such a separation is environmentally favorable in that it allows for re-use of the non-dye components of the bath, for example with another dye or dyes, or with a fresh dye(s), or as a rinse composition for rinsing dyed semi-finished products removed from the dye bath.
- the dye separation method may be performed if the dye of the dye bath has been damaged, such as oxidized or otherwise denatured (e.g., due to over heating due to a temperature spike).
- the dye separation process may be performed by contacting the dye bath with particulate activated carbon, and then isolating a substantially dye-free liquid therefrom containing water, carrier, diol and optional surfactants in substantially the same relative proportions as prior to the separation step.
- the dye-free liquid may then be mixed with another dye(s) to form a different dye bath.
- the dye bath may be contacted with the activated carbon by passing the dye bath continuously through a bed or column containing activated carbon.
- the activated carbon typically retains substantially all of the dye of the dye bath, and preferably less than a minimal amount of the organic liquid components of the dye bath (e.g., carrier, diol and optional surfactants). However, there may be some evaporation of the organic liquid components, requiring adjustment of the dye-free liquid by means of subsequent additions of the evaporated components. It has been found that when the dye separation step is performed with a dye bath that contains dye, water, carrier and diol (in the absence of optional surfactants and optional performance enhancing additives), substantially none of the organic liquid components are retained on the activated carbon. This result is particularly surprising in that the use of activated carbon for the separation of organic compounds from aqueous compositions is known. As such, retention of both the dye and substantial amounts of the organic liquid components of the dye bath would be expected, but surprisingly is not observed in the present case.
- the organic liquid components of the dye bath e.g., carrier, diol and optional surfactants
- the method further involves a dye separation process that includes:
- the dye bath may be contacted with the particulate activated carbon by passing the dye bath through a bed or a column containing the particulate activated carbon.
- the dye-free liquid that is isolated in the dye separation process is substantially free of dye, e.g., containing an undetectable amount of dye as determined by means of spectrophotometric analysis.
- the particulate activated carbon typically has a 200 mesh particle size (e.g., a particle size of 0.075 mm).
- An example of a commercially available particulate activated carbon that may be used in the present invention is Filtrasorb 200 activated carbon from Calgon Carbon Corporation.
- the amount of activated carbon that is required to effect dye separation is dependent in part on the temperature of the dye bath. In general, the amount of activated carbon required to effect dye separation is: reduced as the temperature of the dye bath is reduce; and increased as the temperature of the dye bath is increased. In an embodiment of the present invention, the dye bath is contacted with the activated carbon at a temperature of 25° C.
- the dye(s) optionally added to the dye-free liquid may be selected from static dyes, photochromic dyes, and combinations thereof.
- the static dyes and photochromic dyes that may be added include those classes and examples described previously herein.
- the dye added to the dye-free liquid may be of the same type as the dye that was removed from the dye bath, in which case the further dye bath is a fresh or refreshed dye bath.
- the dye added to the dye-free liquid may be different than the dye that was removed from the dye bath, in which case the further dye bath is a new or different dye bath.
- the dye separation process may further include adding additional materials to the dye-free liquid and/or the further dye bath.
- additional materials include, for example, surfactants and/or performance enhancing additives, which may each be selected from those classes and examples as described previously herein.
- the dyed semi-finished product Upon removal from the dye bath, the dyed semi-finished product is typically rinsed to remove excess dye bath material there from.
- the rinsing step is typically achieved by contacting at least a portion of the surface of the dyed article with a rinse composition comprising water, and optionally a carrier represented by formula I, and/or a diol.
- the water of the rinse composition may be deionized or distilled water.
- the carrier and diol that may be present in the rinse composition are as described previously herein with reference to the dye bath, and may each be selected from those classes and examples as recited previously herein.
- the carrier is ethyleneglycol mono-butyl ether
- the diol is diethylene glycol.
- the rinse composition is composed of water, a carrier represented by formula I and a diol (as described previously herein with reference to diol (iv) of the dye bath).
- the rinse composition may be contacted with the surface of the dyed semi-finished product by means of, for example, immersion (dipping), spray application and/or curtain application. After contact with the surface of the dyed semi-finished product, the rinse composition may be recycled and used to rinse additional dyed articles. After a number of rinse cycles, dye will typically accumulate in the recycled rinse composition. Accumulated dye may be removed from the recycled rinse composition by contacting the recycled rinse composition with particulate activated carbon, as described previously herein with regard to the dye separation process.
- the rinse composition typically contains water in an amount typically from 50 (or 51) to 100 percent by weight, more typically from 60 to 87 percent by weight, and further typically in an amount of from 65 to 75 percent by weight. The percent weights being based on the total weight of the rinse composition, in each case.
- the amounts of carrier and/or diol that may be present in the rinse composition may be selected from those ranges and amounts as recited previously herein with regard to the dye bath.
- the carrier may be present in the rinse composition in an amount typically from 10 to 30 percent by weight, more typically from 15 to 25 percent by weight, and further typically in an amount of from 17 to 20 percent by weight.
- the percent weights being based on the total weight of the rinse composition, in each case.
- the diol may, for example, be present in the rinse composition in an amount of typically from 1 to 20 percent by weight, more typically from 5 to 15 percent by weight, and further typically in an amount of from 10 to 12 percent by weight. The percent weights being based on the total weight of the rinse composition, in each case.
- the dyed semi-finished product is typically dried prior to use in molding or shaping a finished article therefrom.
- the present invention is more particularly described in the following examples, which are intended to be illustrative only, since numerous modifications and variations therein will be apparent to those skilled in the art. Unless otherwise specified, all parts and percentages are by weight.
- the dye bath is prepared by mixing deionized water, carrier and diol together in a mixing tank, thus forming a liquid mixture.
- the liquid mixture is passed continuously at a temperature of 95° C. through a bag filter into which 50 grams of dye is placed.
- the heated mixture containing dye is cycled from the mixing tank through the bag filter and back to the mixing tank for a period of time sufficient to saturate the mixture of water, carrier and diol with dye, and thus form the dye bath.
- the amount of dye in the dye bath is about 0.1 percent by weight.
- the dye bath contains about 70 percent by weight (pbw) deionized water, 18 pbw ethyleneglycol mono-butyl ether (as carrier) and 12 pbw diethylene glycol (as diol), the percent weights being based on the total weight of deionized water, carrier and diol.
- This liquid mixture is passed through a bag filter into which 50 grams of dye is introduced.
Abstract
A method of dyeing a semi-finished product is disclosed. The method comprise: (a) providing a semi-finished product selected from the group consisting of powders, pellets and strands, that contain at least one thermoplastic polymer; (b) immersing said semi-finished product in a dye bath comprising, (i) at least one dye, (ii) water, (iii) at least one carrier represented by the following general formula I,
(I) R1[O(CH2)n]mOR2
(I) R1[O(CH2)n]mOR2
-
- where R1 and R2 independently one of the other denote H, C1-18-alkyl, benzyl, benzoyl or phenyl radicals which may be substituted in the aromatic ring by alkyl and/or halogen, n is 2 or 3 and m is 1 to 35, and
- (iv) a diol selected from at least one of linear or branched C2-C20 aliphatic diols, poly(C2-C4 alkylene glycol), cycloaliphatic diols having from 5 to 8 carbon atoms in the cyclic ring, monocyclic aromatic diols, bisphenols and hydrogenated bisphenols; (c) retaining said semi-finished product in said bath for a period of time sufficient to form a dyed semi-finished product; and (d) removing said dyed semi-finished product from said bath.
Description
- This application is a continuation-in-part of application Ser. No. 10/733,111, filed Dec. 11, 2003.
- The present invention relates to a method of dyeing a semi-finished product. The semi-finished product is immersed at least partially in a dye bath which includes one or more dyes, water, at least one carrier (e.g., ethyleneglycol butyl ether), and a diol (e.g., diethylene glycol).
- Colored semi-finished products can be prepared by means of incorporating (e.g., by means of compounding) pigments and/or dyes directly into the polymeric materials from which the products are prepared. Such direct incorporation methods result in the colorant being dispersed substantially throughout the semi-finished product. Direct incorporation methods are not particularly well suited for the preparation of semi-finished products that are only slightly colored or tinted (e.g., less than opaque), such as in the case of sunshade lenses. It is typically difficult to adequately and sufficiently disperse the small amounts of colorant required to prepare slightly colored or tinted semi-finished products, by means of direct incorporation methods.
- While master-batches of dye and resin can be used to better control the amount of dye incorporated during compounding and/or extrusion processes, the preparation of the master-batch requires additional steps. In addition, the resin of the master-batch will be exposed to at least two heat cycles (one during the preparation of the master-batch, and another during preparation of the dyed semi-finished product), which can result in a final semi-finished product having degraded physical properties.
- The preparation of colored semi-finished products by means of applying a dye composition to the surface of the semi-finished product is generally known. Such dyeing methods are more suited to the preparation of slightly colored or tinted semi-finished products, as only small and controlled amounts of colorant are incorporated into the surface thereof. The dye compositions may be aqueous or non-aqueous.
- In light of environmental concerns related to the use of organic solvents, more recently there has been increased emphasis towards the development of dyeing methods that make use of aqueous dye compositions. Methods of dyeing semi-finished products that make use of aqueous dye compositions typically suffer from disadvantages that include, for example, non-uniform and/or inadequate dyeing, and an inconsistent degree of dyeing between different batches of the same semi-finished product.
- It would be desirable to develop new methods of dyeing semi-finished products that make use of aqueous dye compositions, and that result in the formation of uniformly and sufficiently dyed products. In addition, it would be desirable that such new methods also provide consistent degrees of dyeing over time.
- A method of dyeing a semi-finished product is disclosed. The method comprise:
- (a) providing a semi-finished product selected from the group consisting of powders, pellets and strands, that contain at least one thermoplastic polymer;
- b) immersing said semi-finished product in a dye bath comprising,
- (i) at least one dye,
- (ii) water,
- (iii) at least one carrier represented by the following general formula I,
(I) R1[O(CH2)n]mOR2 - where R1 and R2 independently one of the other denote H, C1-18-alkyl, benzyl, benzoyl or phenyl radicals which may be substituted in the aromatic ring by alkyl and/or halogen, n is 2 or 3 and m is 1 to 35, and
- (iv) a diol selected from at least one of linear or branched C2-C20 aliphatic diols, poly(C2-C4 alkylene glycol), cycloaliphatic diols having from 5 to 8 carbon atoms in the cyclic ring, monocyclic aromatic diols, bisphenols and hydrogenated bisphenols;
- (c) retaining said semi-finished product in said bath for a period of time sufficient to form a dyed semi-finished product; and
- (d) removing said dyed semi-finished product from said bath.
- The dye bath used in the method of the present invention includes at least one carrier according to formula I, as described previously herein. Linear or branched alkyls from which R of formula I may be selected include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl and octadecyl, and structural isomers thereof (e.g., iso-propyl, i-butyl, t-butyl, etc.).
- With further reference to formula I, R may also be selected from benzyl, benzoyl and phenyl groups, each of which may independently and optionally be substituted with 1 to 5 groups selected from halo groups (e.g., chloro, bromo and fluoro), linear or branched C1-C9 alkyl groups (e.g., methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl and nonyl,), and aromatic groups (e.g., phenyl).
- In an embodiment of the present invention, regarding formula I, n is 2 and R is selected from n-butyl, i-butyl and t-butyl. In a particularly preferred embodiment of the present invention, n is 2, and R is n-butyl.
- The carrier is typically present in the dye bath in an amount of less than or equal to 30 percent by weight, preferably less than or equal to 25 percent by weight, and more preferably less than or equal to 20 percent by weight. The carrier is also typically present in the dye bath in an amount of at least 10 percent by weight, preferably at least 15 percent by weight, and more preferably at least 17 percent by weight. The carrier may be present in the bath in an amount ranging between any combination of these upper and lower values, inclusive of the values thereof. For example, the carrier may be present in the dye bath in an amount typically from 10 to 30 percent by weight, more typically from 15 to 25 percent by weight, and further typically in an amount of from 17 to 20 percent by weight. The percent weights being based on the total weight of the dye bath, in each case.
- The dye bath also further includes a diol selected from at least one of linear or branched C2-C20 aliphatic diols, poly(C2-C4 alkylene glycol), cycloaliphatic diols having from 5 to 8 carbon atoms in the cyclic ring, monocyclic aromatic diols, bisphenols and hydrogenated bisphenols. Examples of linear or branched C2-C20 aliphatic diols include, but are not limited to, ethylene glycol, propylene glycol, 1,3-propane diol, 1,2- and 2,3-butane diol, pentane diols, hexane diols, heptane diols, octane diols, nonane diols, decane diols, undecane diols, dodecane diols, tridecane diols, tetradecane diols, pentadecane diols, hexadecane diols, hetadecane diols, octadecane diols, nonadecane diols and icosane diols.
- Examples of poly(C2-C4)alkylene glycols from which the diol (iv) may be selected include, but are not limited to, di-, tri-, tetra-, penta- and higher ethylene glycols, di-, tri-, tetra-, penta- and higher propylene glycols, and di-, tri-, tetra-, penta- and higher butylene glycols. Cycloaliphatic diols having from 5 to 8 carbon atoms that may be used as diol (iv) include, but are not limited to, cyclopentane diol, cyclohexane diol, cyclohexane dimethanol, cycloheptane diol and cyclooctane diol. Examples of monocyclic aromatic diols that may be used as diol (iv) include but are not limited to, benzene diol, e.g., 1,2-dihydroxy benzene and 1,3-dihydroxy benzene; C1-C4 alkyl substituted benzene diol, e.g., 4-tert-butyl-benzene-1,2-diol, 4-methyl-benzene-1,2-diol, 3-tert-butyl-5-methyl-benzene-1,2-diol and 3,4,5,6-tetramethyl-benzene-1,2-diol; halo substituted benzene diol, e.g., 3,5-dichlorobenzene-1,2-diol, 3,4,5,6-tetrabromo-benzene-1,2-diol and 3,4,5-trichloro-benzene-1,2-diol; and C1-C4 alkyl and halo substituted benzene diol, e.g., 3-bromo-5-tert-butyl-benzene-1,2-diol, 3,6-dichloro-4-methyl-benzene-1,2-diol, 3,-bromo-4,5-dimethyl-benzene-1,2-diol and 3-chloro-4,6-di-tert-butyl-benzene-1,2-diol.
- Bisphenols and hydrogenated bisphenols that may be used as diol (iv) may be represented by the following general formula II,
In formula II: R1 and R2 are each selected independently from each other and independently for each p and q from C1-C4 alkyl (e.g., methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl and tert-butyl), chlorine and bromine; p and q are each independently an integer from 0 to 4; and —X— is a divalent linking group selected from —O—, —S—, —S(O2)—, —C(O)—, —CH2—, —CH═CH—, —C(CH3)2—, and —C(CH3)(C6H5)—; and
represents a benzene ring or a cyclohexane ring. An example of a bisphenol that may be used as diol (iv) is 4,4′-isopropylidenebisphenol (i.e., bisphenol A). An example of a hydrogenated bisphenol that may be used as diol (iv) is 4,4′-isopropylidenebiscyclohexanol. - In a preferred embodiment of the present invention, diol (iv) is a poly(C2-C4 alkylene glycol) selected from diethylene glycol, triethylene glycol, tetraethylene glycol, pentaethylene glycol and mixtures thereof. Particularly preferred diols are ethylene glycol and diethylene glycol.
- The diol is typically present in the dye bath in an amount of less than or equal to 20 percent by weight, preferably less than or equal to 15 percent by weight, and more preferably less than or equal to 12 percent by weight. The diol is also typically present in the dye bath in an amount of at least 1 percent by weight, preferably at least 5 percent by weight, and more preferably at least 10 percent by weight. The diol may be present in the bath in an amount ranging between any combination of these upper and lower values, inclusive of the values thereof. For example, the diol may be present in the dye bath in an amount typically from 1 to 20 percent by weight, more typically from 5 to 15 percent by weight, and further typically in an amount of from 10 to 12 percent by weight. The percent weights being based on the total weight of the dye bath, in each case.
- The dye that is present in the dye bath may be selected from static dyes, photochromic dyes and combinations thereof. As used herein and in the claims, the term “static dyes” means a dye that does not substantially change color upon exposure to (or being shielded from) ultraviolet (UV) light. The term “photochromic dyes” as used herein and the claims means dyes that reversibly change color upon exposure to UV light, as is known to the skilled artisan. Typically, upon exposure to a particular wavelength of UV light, a photochromic dye will be converted into an open or activated form which is colored (within a particular portion of the visible spectrum). Upon removal of the UV light source, the open/activated photochromic dye returns to a closed/inactivated from which is not colored, or which is at least less colored than the activated form.
- Static dyes that may be included in the dye bath include, for example, fabric dyes and disperse dyes as well as dyes that are known in the art as being suitable for tinting semi-finished products, such as thermoplastic polycarbonate articles. Examples of suitable disperse dyes include, but are not limited to, Disperse Blue #3, Disperse Blue #14, Disperse Yellow #3, Disperse Red #13 and Disperse Red #17. The classification and designation of the static dyes are recited herein in accordance with “The Colour Index”, 3rd edition published jointly by the Society of Dyes and Colors and the American Association of Textile Chemists and Colorists (1971), which is incorporated herein by reference. Dyestuffs can generally be used either as a sole dye constituent or as a component of a dye mixture depending upon the color desired. Thus, the term static dye as used herein includes mixtures of static dyes.
- The static dye class known as Direct Dyes is useful in the practice of the present invention. Direct Dye examples include, but are not limited to, Solvent Blue 35, Solvent Green 3 and Acridine Orange Base. However, it has been observed that Direct Dyes, typically do not color (tint/dye) the semi-finished product as intensely as do Disperse Dyes (which have been described previously herein).
- Further suitable static dyes include, for example, water-insoluble azo, diphenylamine and anthraquinone compounds. Especially suitable examples include acetate dyes, dispersed acetate dyes, dispersion dyes and dispersol dyes, such as are disclosed in Colour Index, 3rd edition, vol. 2, The Society of Dyers and Colourists, 1971, pp. 2479 and pp. 2187-2743, respectively all incorporated herein by reference. Preferred dispersed dyes include Dystar's Palanil Blue E-R150 (anthraquinone/Disperse Blue) and DIANIX Orange E-3RN (azo dye/CI Disperse Orange 25). It has been observed that phenol red and 4-phenylazophenol do not provide a desirable level of dying when the semi-finished product is thermoplastic polycarbonate, in the present process.
- Static dyes known as direct dyes and those referred to as acid dyes have been observed to provide a less than desirable level of tinting when the semi-finished product contains thermoplastic polycarbonate, in the practice of the present invention. However, acid dyes have been observed to be effective with nylon.
- Another class of suitable static dyes that may be used in the method of the present invention include non-migratory static dyes (i.e., static dyes that have been chemically modified to minimize or eliminate their migration out of semi-finished products into which they have been incorporated). A particular class of non-migratory static dyes may be represented by the following formula III,
R5-(polymeric constituent-Y)t III
In formula III: R5 represents an organic dyestuff radical (or chromophore radical); the polymeric constituent is selected independently for each (t) from homopolymers, copolymers and block-copolymers of poly(C2-C4 alkylene oxides), e.g., homopolymers of polyethylene oxide and polypropylene oxide, poly(ethylene oxide-propylene oxide) copolymers, and di- or higher block copolymers of ethylene oxide and propylene oxide; (t) may be an integer from 1 to 6; and (Y) is selected independently for each (t) from hydroxyl, primary amine, secondary amine and thiol groups. The polymeric constituent may have a molecular weight of from, for example, 44 to 1500. Dyestuff radicals from which (Y) may be selected include, but are not limited to, nitroso, nitro, azo (e.g., monoazo, diazo and triazo), diarylmethane, triarylmethane, xanthene, acridene, methine, thiazole, indamine, azine, oxazine and anthraquinone dyestuff radicals. Non-migratory static dyes represented by formula III are described in further detail in U.S. Pat. Nos.: 4,284,729; 4,640,690; and 4,812,141. - Non-migratory static dyes have been found to be useful when dyeing semi-finished products by means of imbibition or diffusion in accordance with the method of the present invention (e.g., by dipping). When incorporated into the semi-finished product by means of imbibition, excess non-migratory static dye can be washed off of the semi-finished product, with a minimum of imbibed non-migratory static dye being leached from the semi-finished product. Non-migratory static dyes (e.g., as represented by formula II) have been found to be particularly useful in the method of the present invention when dyeing (e.g., by dipping) semi-finished products fabricated from thermoplastic polyurethane.
- Photochromic dyes that may be used in the present method include those known to the skilled artisan. Classes of suitable photochromic dyes include, but are not limited to: spiro(indoline)naphthoxazines and spiro(indoline)benoxazines (e.g., as described in U.S. Pat. No. 4,818,096); and chromenes, such as benzopyrans and naphthopyrans (e.g., as described in U.S. Pat. No. 5,274,132), and benzopyrans having substituents at the 2-position of the pyran ring and an optionally substituted heterocyclic ring, such as a benzothieno or benzofurano ring fused to the benzene portion of the benzopyran (e.g., as described in U.S. Pat. No. 5,429,774). Further classes of photochromic dyes include, for example, fulgides and fulgimides, such as 3-furyl and 3-thienyl fulgides and fulgimides (e.g., as described in U.S. Pat. No. 4,931,220). The pertinent disclosures of the cited patents with regard to photochromic dyes is incorporated herein by reference.
- Photochromic dyes or mixtures thereof may be used alone or in combination with one or more static dyes in the method of the present invention. Typically, the imbibition of photochromic dyes into the semi-finished products, such that contain thermoplastic polycarbonate articles, results in a dyed semi-finished product that does not readily change color upon exposure to or shielding from UV light. While not intending to be bound by any theory, it is believed based on the information at hand, that the photochromic dyes become trapped in either an open or closed form within the thermoplastic polymer matrix. However, softer, more rubbery polymers such as polyurethanes are very suitable matrices for photochromic dyes to readily transition between the dark and light states.
- The amount of dye present in the dye bath may vary widely. Typically the dye is present in the dye bath in an amount sufficient to result in the formation of a dyed semi-finished product having a colored effect and/or a photochromic effect that is discernible to the naked eye, e.g., upon exposure to UV light in the case of photochromic dyes.
- The amount of dye that is actually present in the dye bath will depend on the solubility of the dye within the mixture of water, carrier and diol. The solubility of the dye within the bath will also be affected by the temperature of the bath. In those instances where the dye is not fully soluble in the bath, the dye bath is deemed to contain a saturated level of dye. By adding an amount of dye that is in excess of the saturation level of dye in the bath (e.g., to a bag filter through which the dye bath is continually passed) the level of dye in the bath can be maintained at the saturation level during dyeing operations. The level (e.g., the saturation level) of dye in the bath can be determined periodically or continuously by, for example, thermogravimetric analysis or spectrophotometric analysis.
- Typically the dye is present in the dye bath in an amount of less than or equal to 15 percent by weight, more typically less than or equal to 5 percent by weight, further typically less than equal to 1 percent by weight, and still further typically less than 0.5 percent by weight. The dye is also typically present in the dye bath in an amount of at least 0.001 percent by weight, preferably at least 0.005 percent by weight, and more preferably at least 0.01 percent by weight. The dye may be present in the bath in an amount ranging between any combination of these upper and lower values, inclusive of the values thereof. For example, the dye may be present in the dye bath in an amount typically from 0.001 to 15 percent by weight, more typically from 0.005 to 5 percent by weight, further typically in an amount of from 0.01 to 1 percent by weight, and still further typically in an amount of from 0.01 to 0.5 percent by weight. In an embodiment, the dye is present in the dye bath in an amount of 0.03 percent by weight. The percent weights being based on the total weight of the dye bath, in each case.
- In a preferred embodiment of the present invention, the dye bath contains: 0.001 to 0.5 percent by weight of said dye; 65 to 75 percent by weight of water; 15 to 25 percent by weight of said carrier; and 1 to 15 percent by weight of said diol. The percent weights being based, in each case, on the total weight of the dye bath.
- Water is typically present in the dye bath in an amount of less than or equal to 85 percent by weight, preferably less than or equal to 80 percent by weight, and more preferably less than or equal to 75 percent by weight. Water is also typically present in the dye bath in an amount of at least 50 or 51 percent by weight, preferably at least 60 percent by weight, and more preferably at least 65 percent by weight. Water may be present in the bath in an amount ranging between any combination of these upper and lower values, inclusive of the values thereof. For example, water may be present in the dye bath in an amount typically from 50 (or 51) to 85 percent by weight, more typically from 60 to 87 percent by weight, and further typically in an amount of from 65 to 75 percent by weight. The percent weights being based on the total weight of the dye bath, in each case. The water used is preferably deionized water or distilled water.
- In an embodiment of the present invention, the dye bath further includes a surfactant (or emulsifier), which is different from each of the carrier and the diol. Suitable surfactants in the present invention are readily dispersible upon being poured into water, and then form a milky emulsion upon agitation thereof. The surfactant may be selected from at least one of: anionic surfactants; amphoteric surfactants; and a non-ionic surfactant selected from at least one of poly(C2-C4 alkoxylated) C14-C18 unsaturated fatty acids, poly(C2-C4 alkoxylated) phenol and poly(C2-C4 alkoxylated) C1-C9 alkyl substituted phenol.
- Examples of anionic surfactants that may be used in the present invention include, for example, amine salts or alkali salts of carboxylic, sulfamic or phosphoric acids, for example sodium lauryl sulfate, ammonium lauryl sulfate, lignosulfonic acid salts, ethylene diamine tetra acetic acid (EDTA) sodium salts and acid salts of amines such as laurylamine hydrochloride or poly(oxy-1,2-ethanediyl),alpha.-sulfo-omega-hydroxy ether with phenol 1-(methylphenyl)ethyl derivative ammonium salts
- Amphoteric surfactants that may be present in the dye bath include, for example: lauryl sulfobetaine; dihydroxy ethylalkyl betaine; amido betaine based on coconut acids; disodium N-lauryl amino propionate; or the sodium salts of dicarboxylic acid coconut derivatives.
- Examples of poly(C2-C4 alkoxylated) C14-C18 unsaturated fatty acids include, ethoxylated, propoxylated and/or butoxylated tetradecenyl carboxylic acid. Examples of poly(C2-C4 alkoxylated) phenols include ethoxylated, propoxylated and/or butoxylated phenol. Examples of poly(C2-C4 alkoxylated) C1-C9alkyl substituted phenols, include, octylphenoxypolyethyleneoxyethanol and poly(oxy-1,2-ethanediyl), alpha-phenyl-omega-hydroxy, styrenated.
- The optional surfactant (emulsifier) may be used in an amount less than or equal to 5 percent by weight. Preferably the optional surfactant is present in the dye bath in an amount of 0.5 to 5 percent by weight, and more preferably in an amount of 1 to 4 percent by weight. The percent weights, in each case, being based on the weight of the dye bath.
- The dye bath may further optionally include a performance enhancing additive selected from at least one of UV stabilizers, optical brighteners, mold release agents, antistatic agents, thermal stabilizers, IR absorbers and antimicrobial agents (substances or compounds). Inclusion of one or more of these optional performance enhancing additives in the dye bath serves to improve the physical performance/properties of the dyed semi-finished product. In addition to the dye, the optional additives also diffuse, impregnate or otherwise are imbibed into the bulk of the semi-finished product while it is immersed in the dye bath. For example, including UV stabilizers in the dye bath results in a dyed semi-finished product having improved UV resistance. Mold release agents would be more advantageously included in the dye bath when the semi-finished product is selected from thermoplastic pellets, thermoplastic strands, or thermoplastic powders from which a finished product would later be prepared, as will be discussed further herein. The optional performance enhancing additives may be selected from those that are known for use in preparing thermoplastic molded articles.
- Classes of UV (ultraviolet) stabilizers (or absorbers) that may be used in the dye bath of the present invention include, but are not limited to salicylic acid UV absorbers, benzophenone UV absorbers, benzotriazole UV absorbers, cyanoacrylate UV absorbers, and mixtures thereof. More specific examples of benzotriazole UV absorbers include but are not limited to: 2-(2′-hydroxy-5′methylphenyl)-benzotriazole (commercially available as Tinuvine® P from Ciba, Tarrytown, N.Y.); 2-(3′-5′-di-tert-butyl-2′-hydroxyphenyl)-5-chlorobenzotriazole (commercially available as Tinuvin® 327 from Ciba); 2(2′-hydroxy-3′-5′-di-tert-amylphenyl)benzotriazole (commercially available as Tinuvin® 328 from Ciba); benzenepropanoic acid, 3-(2H-benzotriazol-2-yl)-5-(1,1-dimethyl ethyl)-4-hydroxy-, C7-9 branched alkyl esters (commercially available as Tinuvin® 384 from Ciba); 2-(3′,5′-bis(1-methyl-1-phenylethyl)-2′-hydroxyphenyl)benzotriazole (commercially available as Tinuvin® 900 from Ciba); 2-[2-hydroxy-3-dimethylbenzylphenyl-5-(1,1,3,3-tetramethylbutyl)]-2H-benzo triazole (commercially available as Tinuvin® 928); a mixture of poly (oxy-1,2-ethanediyl), α-[3-[3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxyphenyl]-1-oxopropyl]-omega-hydroxy and poly(oxy-1,2-ethanediyl), α-[3-[3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxyphenyl]-1-oxopropyl]-omega-[3-[3-(2H-benzotriazol-2-yl)-5-(1,1-dimethylethyl)-4-hydroxyphenyl]-1-oxopropyl]-(commercially available as Tinuvin® 1130 from Ciba); and 2-[4-[2-hydroxy-3-tridecyl oxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine and 2-[4-[2-hydroxy-3-dodecyl oxypropyl]oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine (commercially available as Tinuvin® 400 from Ciba). An example of a commercially available benzophenone UV stabilizer is 2-hydroxy-4-(N-octoxy) benzophenone (commercially available as Lowilite® 22 from Great Lakes Chemical Corp. of West Lafayette, Ind.). Further examples of commercially available UV stabilizers that may be use in the present invention include, but are not limited to: p-methoxycinnamic acid 2-ethylhexyl ester stabilized with butylated hydroxy toluene (hereinafter “BHT”) (commercially available as Uvinul MC 80 from BASF of Mount Olive, N.J.); p-methoxycinnamic acid 2-ethylhexyl ester unstabilized (commercially available as Uvinul MC 80 N from BASF); 2-cyano-3,3-diphenylacrylic acid 2′-ethylhexyl ester (commercially available as Uvinul 539 T from BASF); 2-hydroxy-4-(N-octoxy) benzophenone (commercially available as Cyasorb UV-501 from Cytec of West Paterson, N.J.); 2-(2′-hydroxy-3′-5′-di-t-amylphenyl) benzotriazole (commercially available as Cyasorb UV-2337 from Cytec); and 2-(2-hydroxy-5-t-octylphenyl) benzotriazole (commercially available as Cyasorb UV-5411 PA from Cytec).
- A further class of UV stabilizers that may be used in the method of the present invention include those modified with at least one poly(oxyalkylene) chain. Such poly(oxyalkylene) chain modified UV stabilizers are characterized in having low migratory properties once imbibed (or diffused) into the semi-finished product (e.g., they are not easily leached out of the semi-finished product into which they have been imbibed). The poly(oxyalkylene) chain may be a homopolymer, copolymer or block-copolymer formed from the reaction of C2-C20 alkylene oxides (e.g., ethylene oxide, propylene oxide and butylene oxide). The poly(oxyalkylene) group may be terminated with a hydroxyl group, a C1-C20 alkyl ether group, or a C1-C20 ester group. Poly(oxyalkylene) chain modified UV stabilizers are described, for example, in further detail in U.S. Pat. No. 6,602,447 B2.
- Optical brighteners that may be included in the dye bath in the method of the present invention typically absorb a light wavelength of 450 nm or less and emit the light at a higher wavelength, such as a wavelength of 550 nm or less, preferably 525 nm or less. It is preferred that the emitted light be in the blue region of the visible spectrum (e.g., emitted light having a wavelength of at least about 400 nm and up to about 525 nm. Most preferably, the light emitted is no more than about 500 nm.
- Classes of optical brighteners that may be used in the present invention include, but are not limited to benzoxazole derivatives and stilbene derivatives. Examples of commercially available benzoxazole derivatives that may be used in the present invention include, but are not limited to:
- 2,2′-(2,5-thiophenediyl) bis [5-tert-butylbenzoxazole] (commercially available as Uvitex® OB from Ciba); benzoxazole derivatives such as Blankophor® KLA (from Bayer of Pittsburgh, Pa.); Hostalux® KCB (from Clariant of Muttenz, Switzerland); and Hostalux® KCU (from Clariant). An example of a commercially available stilbene derivative is 4,4′-bis(2-benzoxazolyl) stilbene (commercially available as Eastobrite® OB-1 from Eastman of Kingsport, Tenn.). Further classes of optical brighteners that may be used in the present invention include, but are not limited to: derivatives of 4,4′-diminostilbene-2-2′-disulfonic acid; coumarin derivatives (e.g., 4-methyl-7-diethylaminocoumarin); and bis-(styryl) biphenyls.
- Classes of mold release agents that may be included in the dye bath include, but are not limited to hydrocarbon-based mold release agents, fatty acid-based release agents, fatty acid amide-based mold release agents, alcohol-based mold release agents, fatty acid ester-based mold release agents, silicone-based mold release agents, and mixtures or combinations thereof. Examples of hydrocarbon-based mold release agents include, synthetic paraffins, polyethylene waxes and fluorocarbons. Fatty acid-based release agents that may be used include, for example, stearic acid and hydroxystearic acid. Fatty acid amide-based mold release agents that may be used include, for example, stearic acid amide, ethylenebisstearoamide and alkylenebis fatty acid amides. Examples of alcohol-based mold release agents include, stearyl alcohol, cetyl alcohol, and polyhydric alcohols such as polyglycols and polyglycerols. An example of a fatty acid ester-based mold release agent that may be included in the dye is butyl stearate.
- Antistatic agents that may be included in the dye bath in the method of the present invention include, but are not limited to non-ionic antistatic agents, such as those containing fluorocarbon groups, and silicone oils, such as BAYSILONE O1 A (commercially available from Bayer AG, Germany). Further examples of antistatic agents that may be used in the present invention include, distearylhydroxylamine, triphenyl amine, tri-n-octylphosphine oxide, triphenyl phosphine oxide, pyridine N-oxide and ethoxylated sorbitan monolaurate.
- Classes of thermal (or heat-resistant) stabilizers that may be included in the dye bath of the method of the present invention include, but are not limited to, phenol stabilizers, organic thioether stabilizers, organic phosphide stabilizers, hindered amine stabilizers, epoxy stabilizers and mixtures thereof. Specific examples of thermal stabilizers include, but are not limited to, 2,6-di-t-butyl-p-cresol, o-t-butyl-p-cresol, tetrakis-(methylene-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate)methane, β-naphtylamine, p-phenylenediamine, and thiodiethylene bis(3,5-di-tert-butyl)-4-hydroxyhydrocinnamate, which is commercially available from Ciba Specialty Chemical under the tradename IRGANOX 1035 thermal stabilizer.
- Infra red (IR) absorbers that may be used in the method of the invention include dyes that absorb in the IR region of the spectrum. Examples of commercially available IR absorbers include, CYASORB IR-99, IR-126 and IR-165, which are available from Glendale Protective Technologies, Inc., Lakeland, Fla.
- Antimicrobial agents that may be included in the dye bath in the method of the present invention include, for example, substances having antimicrobial activity towards microorganisms, such as pathogenic microorganisms. The term “antimicrobial agents” as used herein and in the claims is also inclusive of antiseptic, disinfectant and antifungal substances. In addition, the antimicrobial agents may also be used in a pre-activated form, e.g., in a form that does not become antimicrobially active until the occurrence of a triggering event, such as action of a microbe on the pre-activated substance.
- Examples of antimicrobial agents that may be included in the dye bath include, but are not limited to: quinolones, such as nalidixic acid, pipemidic acid, cinoxacin, ciprofloxacin, norfloxacin, ofloxacin, pefloxacin and enoxacin; aminoglycosides, such as gentamycin, kanamycin, amikacin, sisomycin, tobramycin and netilmicin; macrolides, such as erythromycin, clarithromycin and azithromycin; polypeptides, such as bacitracin, mupirocin, thyrothricin, gramicidin and tyrocidin; lincomycins, such as lincomycin and clindamycin; and antimycobacterial agents, such as rifampicin and fusidic acid. Further examples of antimicrobial agents that may be used in the dye bath include: 10,10′-oxybisphenoxy arsine; 2-n-octyl-4-isothiazolin-3-one; 2,4,4′-trichloro-2′-hydroxy diphenyl ether (also named 5-chloro-2-(2,4-dichlorophenoxy)phenol, and commonly referred to as Triclosan); N-butyl-1,2-benzisothiazolin-3-one; and N-(trichloromethylthio)phthalamide.
- The performance enhancing additives if used are typically present in the dye bath in a positive amount totaling less than or equal to 15 percent by weight, preferably less than or equal to 5 percent by weight, and more preferably less than or equal to 1 percent by weight. The performance enhancing additives are also typically present in the dye bath in an amount totaling at least 0.001 percent by weight, preferably at least 0.005 percent by weight, and more preferably at least 0.01 percent by weight. The performance enhancing additives may be present in the bath in a total amount ranging between any combination of these upper and lower values, inclusive of the recited values thereof. For example, the performance enhancing additives may be present in the dye bath in an amount typically totaling from 0.001 to 15 percent by weight, more typically from 0.005 to 5 percent by weight, and further typically in an amount of from 0.01 to 1 percent by weight. The percent weights being based on the total weight of the dye bath, in each case.
- The method of the present invention involves dyeing a semi-finished product. The semi-finished product in the context of the present invention is defined as an intermediate thermoplastic product selected from the group consisting of pellets, strands and powders calculated to be further processed (reshaped) to form a finished product. These terms are well known to the art skilled. The thermoplastic material suitable for the inventive method is a thermoplastic material system that contains at least one member selected from the group consisting of (co)polyesters, (co)polycarbonates, polyesterpolycarbonate copolymers, acrylonitrile-butadiene-styrene (ABS) copolymers, polyamides, polyurethanes, polyalkyl(meth)acrylate (e.g., polymethylmethacrylate) and styrene copolymers (e.g., styrene acrylonitrile copolymers). The (co)polyesters, (co)polycarbonates, polyesterpolycarbonate copolymers may be aliphatic or aromatic polymers (e.g., containing residues of bisphenol A).
- As used herein and in the claims, the term “thermoplastic” means a polymer that has a softening or melting point, and is substantially free of a three dimensional crosslinked network resulting from the formation of covalent bonds between chemically reactive groups, e.g., active hydrogen groups and free isocyanate groups. Thermoplastic polymers that may be used in the present invention include those known to the skilled artisan, such as thermoplastic (co)polyesters, thermoplastic (co)polycarbonates, thermoplastic polyesterpolycarbonate copolymers, thermoplastic acrylonitrile-butadiene-styrene (ABS) copolymers, thermoplastic polyamides, thermoplastic polyurethanes, thermoplastic polyalkyl(meth)acrylate and thermoplastic styrene copolymers.
- The semi-finished product may contain additives that are known to the skilled artisan. Such additives include, but are not limited to: mold release agents; fillers; reinforcing agents in the form of fibers or flakes (e.g., metal flakes such as aluminum flakes); flame retardant agents; pigments; and opacifying agents, such as titanium dioxide; light-diffusing agents, such as polytetrafluoroethylene, zinc oxide, Paraloid EXL-5136 available from Rohm and Haas and crosslinked polymethylmethacrylate microspheres (such as n-licrospheres from Nagase America); UV-stabilizers; hydrolytic stabilizers; thermal stabilizers; and antimicrobial agents. In an embodiment, the semi-finished product contains at least one of pigments, crosslinked polymethylmethacrylate microspheres, glass microspheres and metal flakes.
- The semi-finished product may be prepared by art-recognized methods, such as extrusion—for making strands, and chopping of strands to make pellets. Powders in the context of the invention may be prepared by solution spray drying or by precipitation of their polymeric solution or melt. The powders are sometimes characterized by the largest dimension of their particles that may range up to about 1000 microns. In an embodiment of the present invention, the semi-finished product is selected from powders, pellets and strands. Thermoplastic pellets and strands may be made by art-recognized methods, such as extrusion or melt-spinning. The thermoplastic pellets and/or strands are dyed, and then may be further processed. In an embodiment of the present invention, the dyed thermoplastic pellets and/or strands are melted (e.g., in an extruder) to form a molten dyed thermoplastic composition, and then the molten dyed thermoplastic composition is introduced (e.g., injected) into a mold. The contents of the mold are allowed to cool, the mold is opened, and a dyed shaped finished product is removed therefrom.
- This method of further processing dyed semi finished products is favorably differentiated from the direct incorporation methods described previously herein. With dyed thermoplastic pellets and/or strands, the dye is already present within the thermoplastic polymer (rather than being added to the polymer separately), which allows for more control and reliability with regard to the desired and reproducible level of tinting.
- In the method of the present invention, the semi-finished product to be tinted is immersed in the dye bath for a period of time and at temperature at least sufficient to facilitate at least some impregnation (diffusion or imbibition), of the dye into the bulk of the semi-finished product thus effecting dyeing (or tinting) thereof. The time and temperature employed typically depends on the composition of the semi-finished product. Immersion times are typically less than or equal to 8 hours, more typically less than or equal to 4 hours, and even more typically less than or equal to 1 hour. Immersion times are also typically at least 5 seconds, more typically at least 30 seconds, and even more typically at least 1 minute. The immersion time may range between any of these upper and lower values, inclusive of the recited values. In an embodiment of the present invention, the immersion time is typically from 5 seconds to 8 hours, more typically from 15 or 30 seconds to 4 hours, and further typically from 1 minute to 1 hour (e.g., 1 to 15 minutes).
- The temperature of the dye bath during immersion of the semi-finished product is typically at least room temperature (e.g., 25° C.) and less than the boiling and/or decomposition temperature of the dye bath. Typically the dye bath is maintained at a temperature of 25° C. to 99° C., for example from 60° C. to 97° C. or from 70° C. to 95° C. As described previously herein, the time and temperature of immersion will depend at least in part on the type of semi-finished product that is to be dyed. For example, with semi-finished products of thermoplastic aromatic polycarbonate, dyeing may be efficiently carried out at a temperature of 90 to 99° C., with an immersion time of typically less than 1 hour, and more typically in the range of 1 to 15 minutes. The tinted (or dyed) semi-finished product is then withdrawn from the dye bath.
- The dye bath may be prepared by mixing the dye, water, carrier, diol, optional surfactants and optional performance enhancing additives together in any order. For example the carrier and diol may be mixed together with the dye, and then this mixture is either added to water or water is added to it. In an embodiment, the dye bath is formed by: (i) preparing a mixture of water, carrier and diol; (ii) introducing the dye into a filter; and (iii) passing the mixture over the dye and through the filter, thereby forming the dye bath. The dye bath, or at least a portion thereof, is then typically passed continuously through the filter. Optionally, the mixture of water, carrier and diol may be heated, e.g., heated to a temperature of 25° C. to 99° C., or 60° C. to 97° C., or 70° C. to 95° C., and then the heated mixture is contacted with the dye in the filter.
- The filter into which the dye is added, may be any suitable filter known to the skilled artisan. A preferred type of filter is a bag filter. Preparing and maintaining the dye bath in this manner, ensures that the level of dye in the bath is maintained substantially at a saturation level (as discussed previously herein). In addition, passing the dye bath continuously through the bag filter serves to remove particulate contaminants therefrom (e.g., unsolubilized dye particles), which could foul the dyed semi-finished products prepared by immersion in the dye bath.
- In a further embodiment, the dye bath is continuously introduced into and withdrawn from an immersion tank (or vessel). Typically, the immersion tank is part of a circuit which includes an inlet that is in fluid communication (via an inlet conduit) with a pump, which is in fluid communication with an outlet from the tank via an outlet conduit. The circuit may optionally include at least one filter, e.g., a bag filter as described previously herein, located inline with the inlet and/or outlet conduits. Preferably, the inlet and outlet of the immersion tank are positioned below the liquid level of the dye bath within the tank.
- The immersion tank inlet may include a plate having a plurality of perforations (e.g., a diffuser or diffuser plate). Continuously introducing the dye bath into the immersion tank by passage through a plate having a plurality of perforations increases the level of turbulent mixing within the immersion tank, and improves the efficiency and uniformity of dyeing of semi-finished products immersed therein. The perforations in the diffuser plate may have any suitable shape, e.g., circular, ellipsoid, polygonal or combinations thereof. The perforations of the diffuser plate typically have diameters of from 0.79 mm to 12.70 mm, e.g., from 3.17 mm to 6.35 mm. The diffuser plate may have any suitable configuration, e.g., it may be flat, concave or convex.
- The scope of the method of the present invention is inclusive of additional steps whereby the composition of the dye bath is modified, e.g., such that an initial dye or dyes may be substituted with a subsequent dye or dyes. In an embodiment of the present invention, the dye and optional performance enhancing additives are separated from the other components of the dye bath (e.g., the water, carrier, diol and optional surfactants). Such a separation, is environmentally favorable in that it allows for re-use of the non-dye components of the bath, for example with another dye or dyes, or with a fresh dye(s), or as a rinse composition for rinsing dyed semi-finished products removed from the dye bath. In addition, the dye separation method may be performed if the dye of the dye bath has been damaged, such as oxidized or otherwise denatured (e.g., due to over heating due to a temperature spike).
- The dye separation process may be performed by contacting the dye bath with particulate activated carbon, and then isolating a substantially dye-free liquid therefrom containing water, carrier, diol and optional surfactants in substantially the same relative proportions as prior to the separation step. The dye-free liquid may then be mixed with another dye(s) to form a different dye bath. The dye bath may be contacted with the activated carbon by passing the dye bath continuously through a bed or column containing activated carbon.
- The activated carbon typically retains substantially all of the dye of the dye bath, and preferably less than a minimal amount of the organic liquid components of the dye bath (e.g., carrier, diol and optional surfactants). However, there may be some evaporation of the organic liquid components, requiring adjustment of the dye-free liquid by means of subsequent additions of the evaporated components. It has been found that when the dye separation step is performed with a dye bath that contains dye, water, carrier and diol (in the absence of optional surfactants and optional performance enhancing additives), substantially none of the organic liquid components are retained on the activated carbon. This result is particularly surprising in that the use of activated carbon for the separation of organic compounds from aqueous compositions is known. As such, retention of both the dye and substantial amounts of the organic liquid components of the dye bath would be expected, but surprisingly is not observed in the present case.
- In an embodiment of the present invention, the method further involves a dye separation process that includes:
-
- (i) contacting the dye bath with particulate activated carbon to form a mixture of the dye bath and particulate activated carbon;
- (ii) isolating, from the mixture, a dye-free liquid comprising water, carrier and diol; and
- (iii) optionally adding at least one dye to the dye-free liquid, thereby forming a further dye bath.
- As discussed previously herein, the dye bath may be contacted with the particulate activated carbon by passing the dye bath through a bed or a column containing the particulate activated carbon. The dye-free liquid that is isolated in the dye separation process is substantially free of dye, e.g., containing an undetectable amount of dye as determined by means of spectrophotometric analysis. The particulate activated carbon typically has a 200 mesh particle size (e.g., a particle size of 0.075 mm). An example of a commercially available particulate activated carbon that may be used in the present invention is Filtrasorb 200 activated carbon from Calgon Carbon Corporation.
- The amount of activated carbon that is required to effect dye separation is dependent in part on the temperature of the dye bath. In general, the amount of activated carbon required to effect dye separation is: reduced as the temperature of the dye bath is reduce; and increased as the temperature of the dye bath is increased. In an embodiment of the present invention, the dye bath is contacted with the activated carbon at a temperature of 25° C.
- The dye(s) optionally added to the dye-free liquid may be selected from static dyes, photochromic dyes, and combinations thereof. The static dyes and photochromic dyes that may be added include those classes and examples described previously herein. The dye added to the dye-free liquid may be of the same type as the dye that was removed from the dye bath, in which case the further dye bath is a fresh or refreshed dye bath. Alternatively, the dye added to the dye-free liquid may be different than the dye that was removed from the dye bath, in which case the further dye bath is a new or different dye bath.
- The dye separation process may further include adding additional materials to the dye-free liquid and/or the further dye bath. Such other additional materials include, for example, surfactants and/or performance enhancing additives, which may each be selected from those classes and examples as described previously herein.
- Upon removal from the dye bath, the dyed semi-finished product is typically rinsed to remove excess dye bath material there from. The rinsing step is typically achieved by contacting at least a portion of the surface of the dyed article with a rinse composition comprising water, and optionally a carrier represented by formula I, and/or a diol. The water of the rinse composition may be deionized or distilled water. The carrier and diol that may be present in the rinse composition are as described previously herein with reference to the dye bath, and may each be selected from those classes and examples as recited previously herein. For example, in an embodiment, the carrier is ethyleneglycol mono-butyl ether, and the diol is diethylene glycol. Preferably, the rinse composition is composed of water, a carrier represented by formula I and a diol (as described previously herein with reference to diol (iv) of the dye bath).
- The rinse composition may be contacted with the surface of the dyed semi-finished product by means of, for example, immersion (dipping), spray application and/or curtain application. After contact with the surface of the dyed semi-finished product, the rinse composition may be recycled and used to rinse additional dyed articles. After a number of rinse cycles, dye will typically accumulate in the recycled rinse composition. Accumulated dye may be removed from the recycled rinse composition by contacting the recycled rinse composition with particulate activated carbon, as described previously herein with regard to the dye separation process.
- The rinse composition typically contains water in an amount typically from 50 (or 51) to 100 percent by weight, more typically from 60 to 87 percent by weight, and further typically in an amount of from 65 to 75 percent by weight. The percent weights being based on the total weight of the rinse composition, in each case.
- If present, the amounts of carrier and/or diol that may be present in the rinse composition may be selected from those ranges and amounts as recited previously herein with regard to the dye bath. For example, the carrier may be present in the rinse composition in an amount typically from 10 to 30 percent by weight, more typically from 15 to 25 percent by weight, and further typically in an amount of from 17 to 20 percent by weight. The percent weights being based on the total weight of the rinse composition, in each case. The diol may, for example, be present in the rinse composition in an amount of typically from 1 to 20 percent by weight, more typically from 5 to 15 percent by weight, and further typically in an amount of from 10 to 12 percent by weight. The percent weights being based on the total weight of the rinse composition, in each case.
- After rinsing, the dyed semi-finished product is typically dried prior to use in molding or shaping a finished article therefrom. The present invention is more particularly described in the following examples, which are intended to be illustrative only, since numerous modifications and variations therein will be apparent to those skilled in the art. Unless otherwise specified, all parts and percentages are by weight.
- In the following examples, the dye bath is prepared by mixing deionized water, carrier and diol together in a mixing tank, thus forming a liquid mixture. The liquid mixture is passed continuously at a temperature of 95° C. through a bag filter into which 50 grams of dye is placed. The heated mixture containing dye is cycled from the mixing tank through the bag filter and back to the mixing tank for a period of time sufficient to saturate the mixture of water, carrier and diol with dye, and thus form the dye bath.
- In the following examples, the amount of dye in the dye bath is about 0.1 percent by weight. The dye bath contains about 70 percent by weight (pbw) deionized water, 18 pbw ethyleneglycol mono-butyl ether (as carrier) and 12 pbw diethylene glycol (as diol), the percent weights being based on the total weight of deionized water, carrier and diol. This liquid mixture is passed through a bag filter into which 50 grams of dye is introduced.
- Clear polycarbonate pellets (Makrolon 3208 from Bayer MaterialScience LLC) were tinted using Macrolex Red G, Blue 3R, or Yellow 3R dyes obtained from LanXess Corporation. The pellets (1.4 kg) were placed in a wire mesh basket having sufficient mesh size to allowing the coloring solution to surround the pellets while the pellets were retained in the basket. The basket, containing the pellets, was then immersed in the coloring solution at 95° C. After 5 minutes, the pellets were rinsed with dye-free coloring solution to remove excess dye from the pellet surfaces and finally the pellets were rinsed with deionized water. After thorough drying in a convection oven, the pellets were molded into speciments having dimensions of 5 cm×7.5 cm×0.25 cm.
Value Control Blue 3R Red G Yellow 3R L 95.8 32.1 55.0 92.4 a −0.16 26.3 76.0 −14.6 b 1.32 −67.5 35.5 85.0 YI 4.1 −665 112 89 % T 90.3 2.3 24.4 84.0 % haze 1.9 0.5 0.4 0.4 - The present invention has been described with reference to specific details of particular embodiments thereof. It is not intended that such details be regarded as limitations upon the scope of the invention except insofar as and to the extent that they are included in the accompanying claims.
Claims (21)
1. A method of dyeing a semi-finished product selected from the group consisting of strand, pellet and powder comprising:
(a) providing a semi-finished product comprising at least one thermoplastic polymer;
(b) immersing said semi-finished product in a dye bath comprising,
(I) R1[O(CH2)n]mOR2
(i) at least one dye,
(ii) water,
(iii) at least one carrier represented by the following general formula I,
(I) R1[O(CH2)n]mOR2
where R1 and R2 independently one of the other denote H, C1-18-alkyl, benzyl, benzoyl or phenyl radicals which may be substituted in the aromatic ring by alkyl and/or halogen, n is 2 or 3 and m is 1 to 35, and
(iv) a diol selected from at least one of linear or branched C2-C20 aliphatic diols, poly(C2-C4 alkylene glycol), cycloaliphatic diols having from 5 to 8 carbon atoms in the cyclic ring, monocyclic aromatic diols, bisphenols and hydrogenated bisphenols;
(c) retaining said portion of said semi-finished product in said bath for a period of time at least sufficient to form a dyed semi-finished product; and
(d) removing said dyed semi-finished product from said bath.
2. The method of claim 1 wherein said thermoplastic polymer is at least one member selected from the group consisting of (co)polyesters, (co)polycarbonates, polyesterpolycarbonate copolymers, acrylonitrile-butadiene-styrene copolymers, polyamides, polyurethanes, polyalkyl(meth)acrylate and styrene copolymers.
3. The method of claim 1 wherein said dye bath comprises,
0.001 to 0.5 percent by weight of said dye,
65 to 75 percent by weight of water,
15 to 25 percent by weight of said carrier, and
1 to 15 percent by weight of said diol,
the percent weights being based on the total weight of said dye bath in each case.
4. The method of claim 1 wherein said dye bath is maintained at a temperature of 25 to 99° C.
5. The method of claim 1 wherein R is selected from linear or branched C1-C18 alkyl, and n is 2.
6. The method of claim 5 wherein R is selected from n-butyl, i-butyl and t-butyl.
7. The method of claim 1 wherein said dye bath further comprises a surfactant selected from at least one of: anionic surfactants; amphoteric surfactants; and a non-ionic surfactant selected from at least one of poly(C2-C4 alkoxylated) C14-C18 unsaturated fatty acids, poly(C2-C4 alkoxylated) phenol and poly(C2-C4 alkoxylated) C1-C9 alkyl substituted phenol.
8. The method of claim 7 wherein said surfactant is present in an amount of from 1 to 15 percent by weight, based on the total weight of the dye bath.
9. The method of claim 1 wherein said diol is a poly(C2-C4 alkylene glycol) selected from diethylene glycol, triethylene glycol, tetraethylene glycol, pentaethylene glycol and mixtures thereof.
10. The method of claim 9 wherein said diol is diethylene glycol.
11. The method of claim 1 wherein said dye is selected from static dyes, photochromic dyes and combinations thereof.
12. The method of claim 11 wherein said dye is a water-insoluble static dye selected from the group consisting of azo dyes, diphenylamine dyes and anthraquinone dyes.
13. The method of claim 11 wherein said dye is a static dye, and said static dye is selected from the group consisting of disperse dyes, non-migratory static dyes and combinations thereof.
14. The method of claim 11 wherein said photochromic dye is selected from at least one of spiro(indoline)naphthoxazines, spiro(indoline)benoxazines, benzopyrans, naphthopyrans, organo-metal dithizonates, fulgides and fulgimides.
15. The method of claim 1 wherein said dye bath further comprises at least one of, UV stabilizers, optical brighteners, mold release agents, antistatic agents, thermal stabilizers, IR absorbers and antimicrobial agents.
16. The method of claim 1 wherein said semi-finished product further contains at least one member selected from the group consisting of pigments, crosslinked polymethylmethacrylate microspheres, glass microspheres and metal flakes.
17. The method of claim 1 wherein said thermoplastic polycarbonate is aromatic polycarbonate.
18. The semi-finished product prepared by the method of claim 1 .
19. The strand prepared by the method of claim 1 .
20. The pellet prepared by the method of claim 1 .
21. The powder prepared by the method of claim 1.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US11/633,797 US20070079453A1 (en) | 2003-12-11 | 2006-12-05 | Method of dyeing a semi-finished product |
TW096143807A TW200902793A (en) | 2006-12-05 | 2007-11-20 | Method of dyeing a semi-finished product |
PCT/US2007/024802 WO2008070056A2 (en) | 2006-12-05 | 2007-12-04 | Method of dyeing a semi-finished product |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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US10/733,111 US7175675B2 (en) | 2003-12-11 | 2003-12-11 | Method of dyeing a plastic article |
PCT/US2004/040544 WO2005061780A1 (en) | 2003-12-11 | 2004-12-06 | Method of dyeing a plastic article |
WOPCT/US04/40544 | 2004-12-06 | ||
US11/633,797 US20070079453A1 (en) | 2003-12-11 | 2006-12-05 | Method of dyeing a semi-finished product |
Related Parent Applications (1)
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US10/733,111 Continuation-In-Part US7175675B2 (en) | 2003-12-11 | 2003-12-11 | Method of dyeing a plastic article |
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US20070079453A1 true US20070079453A1 (en) | 2007-04-12 |
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US11/633,797 Abandoned US20070079453A1 (en) | 2003-12-11 | 2006-12-05 | Method of dyeing a semi-finished product |
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US (1) | US20070079453A1 (en) |
TW (1) | TW200902793A (en) |
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EP2050866A3 (en) * | 2007-10-09 | 2013-12-04 | Bayer MaterialScience LLC | Method of tinting a plastic article |
WO2014135656A3 (en) * | 2013-03-06 | 2014-11-27 | Essilor International (Compagnie Générale d'Optique) | Arylene carriers for enhanced polycarbonate tinting |
WO2015124639A1 (en) * | 2014-02-19 | 2015-08-27 | Dyemansion Gmbh | Method for treating surfaces of plastic objects |
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CN113026382A (en) * | 2021-02-22 | 2021-06-25 | 苏州图延模具有限公司 | Coloring technology for CNC (computer numerical control) machining of PMMA (polymethyl methacrylate) transparent part |
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US7175675B2 (en) * | 2003-12-11 | 2007-02-13 | Bayer Materialscience Llc | Method of dyeing a plastic article |
EP1739119A1 (en) * | 2005-06-29 | 2007-01-03 | Bayer MaterialScience AG | Process for the treatment of plastic profiles |
-
2006
- 2006-12-05 US US11/633,797 patent/US20070079453A1/en not_active Abandoned
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US5015523A (en) * | 1983-07-29 | 1991-05-14 | Seiko Epson Corporation | Coated synthetic resin lens |
US6367930B1 (en) * | 1999-12-30 | 2002-04-09 | Bayer Corporation | Process for preparing a photochromic lens |
US20030182738A1 (en) * | 2002-03-26 | 2003-10-02 | Pyles Robert A. | Process for making dyed articles |
Cited By (7)
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US20040082694A1 (en) * | 2001-02-21 | 2004-04-29 | Kenzo Kubo | Polyphenylene sulfide member and its manufacturing method |
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EP2050866A3 (en) * | 2007-10-09 | 2013-12-04 | Bayer MaterialScience LLC | Method of tinting a plastic article |
WO2014135656A3 (en) * | 2013-03-06 | 2014-11-27 | Essilor International (Compagnie Générale d'Optique) | Arylene carriers for enhanced polycarbonate tinting |
US20160010276A1 (en) * | 2013-03-06 | 2016-01-14 | Essilor International (Compagnie Generale D'optique) | Arylene Carriers for Enhanced Polycarbonate Tinting |
WO2015124639A1 (en) * | 2014-02-19 | 2015-08-27 | Dyemansion Gmbh | Method for treating surfaces of plastic objects |
EP3978555A1 (en) * | 2014-02-19 | 2022-04-06 | DyeMansion GmbH | Method for treating surfaces of plastic items |
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WO2008070056A3 (en) | 2008-07-31 |
TW200902793A (en) | 2009-01-16 |
WO2008070056A2 (en) | 2008-06-12 |
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