US 11,987,929 B2
Textile materials containing dyed polyphenylene sulfide fibers and methods for producing the same
Shulong Li, Spartanburg, SC (US); Richard A. Mayernik, Simpsonville, SC (US); and William E. Baird, Jr., Inman, SC (US)
Assigned to MILLIKEN & COMPANY, Spartanburg, SC (US)
Filed by Milliken & Company, Spartanburg, SC (US)
Filed on Aug. 4, 2022, as Appl. No. 17/881,221.
Application 17/881,221 is a continuation of application No. 15/970,304, filed on May 3, 2018, abandoned.
Application 15/970,304 is a continuation in part of application No. 15/785,772, filed on Oct. 17, 2017, abandoned.
Claims priority of provisional application 62/418,731, filed on Nov. 7, 2016.
Prior Publication US 2022/0389652 A1, Dec. 8, 2022
Int. Cl. D06P 3/82 (2006.01); D01H 1/02 (2006.01); D01H 4/00 (2006.01); D02G 3/04 (2006.01); D03D 15/54 (2021.01); D04B 1/16 (2006.01); D04B 1/22 (2006.01); D06P 1/00 (2006.01); D06P 1/613 (2006.01); D06P 1/645 (2006.01); D06P 1/651 (2006.01); D06P 1/653 (2006.01); D06P 3/00 (2006.01); D06P 3/54 (2006.01); D06P 3/60 (2006.01); D06P 5/02 (2006.01)
CPC D06P 3/8204 (2013.01) [D02G 3/04 (2013.01); D03D 15/54 (2021.01); D04B 1/16 (2013.01); D04B 1/225 (2013.01); D06P 1/0032 (2013.01); D06P 1/6133 (2013.01); D06P 1/645 (2013.01); D06P 1/65118 (2013.01); D06P 1/65131 (2013.01); D06P 1/6536 (2013.01); D06P 3/004 (2013.01); D06P 3/54 (2013.01); D06P 3/6025 (2013.01); D06P 3/6033 (2013.01); D06P 5/02 (2013.01); D01H 1/02 (2013.01); D01H 4/00 (2013.01); D06M 2200/30 (2013.01); D06P 3/002 (2013.01); D06P 3/6041 (2013.01); D10B 2201/02 (2013.01); D10B 2201/24 (2013.01); D10B 2331/04 (2013.01); D10B 2331/301 (2013.01); D10B 2401/04 (2013.01); D10B 2501/04 (2013.01); D10B 2503/02 (2013.01); D10B 2505/08 (2013.01); D10B 2505/12 (2013.01)] 5 Claims
 
1. A method for dyeing textile materials containing polyphenylene sulfide fibers, the method comprising the steps of:
(a) providing a plurality of polyphenylene sulfide fibers and cellulosic fibers, wherein the polyphenylene sulfide fibers comprise polyphenylene sulfide having a percent crystallinity from about 20% to about 80%, a melt viscosity of about 1,000 poise or more when measured at 300° C. and an apparent shear rate of 400 s−1 in accordance with ASTM Test Method 3835;
(b) ring spinning the polyphenylene sulfide fibers and cellulosic fibers into a plurality of yarns comprising blended polyphenylene sulfide fibers and cellulosic fibers;
(c) forming the plurality of yarns into a textile material;
(d) providing a dye liquor comprising a liquid medium and a disperse dye selected from the group consisting of disperse dyes having a molar mass of about 350 g/mol or more, disperse dyes comprising a nitro group and mixtures thereof, wherein the disperse dye has a flash point of 300° C. or more, and wherein the dye liquor further comprises a volatile organic acid having a boiling point of about 100° C. to about 170° C. and a dye carrier selected from the group consisting of propylene glycol, ethylene glycol, dipropylene glycol, tripropylene glycol, diethylene glycol, triethylene glycol, benzoic acid, triethanolamine, polyethylene oxide, polyethylene glycol, copolymers of ethylene oxide and propylene oxide;
(e) applying the dye liquor to the textile material;
(f) treating the textile material from step (e) with a caustic solution comprising sodium bisulfite to remove or neutralize unfixed disperse dye on the textile material;
(g) heating the textile material under ambient atmosphere to a temperature sufficient to evaporate substantially all of the liquid medium from the textile material;
(h) heating the textile material under ambient atmosphere to a temperature of about 180° C. or more to fix the disperse dye to the polyphenylene sulfide fibers; and;
(i) treating the textile material with a phosphorus-based flame retardant.