Formaldehyde-free binder compositions for simultaneous warp sizing and coloration of filament yarns

Abstract

An aqueous dispersion has an addition polymer (B) formed in situ on a sulfopolyester (A). The sulfopolyester (A) is formed as a polycondensation product of first and second reaction mixtures. The first reaction mixture includes at least about 70 mol. % of terephthalic acid or an ester thereof, and about 4-20 mol. % of a difunctional ester forming sulfomonomer containing at least one metal sulfonate group attached to an aromatic nucleus, wherein the functional groups are selected from the group consisting of hydroxyls, carboxyls and alkyl esters. The second reaction mixture includes at least two different glycols, at least about 20 mol. % of the second reaction mixture being ethylene glycol. The addition polymer (B) is formed in situ on the sulfopolyester (B) by polymerizing styrene monomer.

1 . A method of coloring and sizing a yarn comprising: forming an aqueous dispersion by a process comprising: forming a sulfopolyester by conducting polycondensation of: (1) a first reaction mixture comprising: (a) at least about 70 mol. % of terephthalic acid or an ester thereof, and (b) about 4-20 mol. % of a difunctional ester forming sulfomonomer containing at least one metal sulfonate group attached to an aromatic nucleus, wherein the functional groups are selected from the group consisting of hydroxyls, carboxyls and alkyl esters; and (2) a second reaction mixture comprising at least two different glycols, at least about 20 mol. % of the second reaction mixture being ethylene glycol; and conducting in situ polymerization of styrene monomer in the presence of the sulfopolyester; diluting the aqueous dispersion with water; adding colorant to the aqueous dispersion; coating the aqueous dispersion on the yarn after diluting with water and adding colorant; and drying the yarn.  
     
     
         2 . A method according to  claim 1 , wherein substantially no formaldehyde is added.  
     
     
         3 . A method according to  claim 2 , wherein the yarn is a polyester.  
     
     
         4 . A coloration and sizing mixture comprising: an aqueous dispersion formed by a process comprising: forming a sulfopolyester by conducting polycondensation of: (1) a first reaction mixture comprising: (a) at least about 70 mol. % of terephthalic acid or an ester thereof, and (b) about 4-20 mol. % of a difunctional ester forming sulfomonomer containing at least one metal sulfonate group attached to an aromatic nucleus, wherein the functional groups are selected from the group consisting of hydroxyls, carboxyls and alkyl esters; and (2) a second reaction mixture comprising at least two different glycols, at least about 20 mol. % of the second reaction mixture being ethylene glycol; and conducting in situ polymerization of styrene monomer in the presence of the sulfopolyester; and colorant.  
     
     
         5 . A coloration and sizing mixture according to  claim 4 , further comprising at least one auxiliaries selected from the group consisting of an antimigrant, a defoamer, an antistat, a lubricant, a dispersant and a biocide.  
     
     
         6 . A yarn produced by a process comprising: diluting an aqueous dispersion with water, the aqueous dispersion being produced by a process comprising: forming a sulfopolyester by conducting polycondensation of: (1) a first reaction mixture comprising: (a) at least about 70 mol. % of terephthalic acid or an ester thereof, and (b) about 4-20 mol. % of a difunctional ester forming sulfomonomer containing at least one metal sulfonate group attached to an aromatic nucleus, wherein the functional groups are selected from the group consisting of hydroxyls, carboxyls and alkyl esters; and (2) a second reaction mixture comprising at least two different glycols, at least about 20 mol. % of the second reaction mixture being ethylene glycol; and conducting in situ polymerization of styrene monomer in the presence of the sulfopolyester; adding colorant to the aqueous dispersion; coating the aqueous dispersion on the yarn after diluting with water and adding colorant; and drying the yarn.  
     
     
         7 . A yarn according to  claim 6 , wherein the yarn is a polyester.