Colorfast fabrics and garments of olefin block compositions

Abstract

Dyed fabric compositions have now been discovered that often have a balanced combination of desirable properties. The dyed fabric comprises one or more elastic fibers wherein the elastic fibers comprise the reaction product of at least one ethylene olefin block polymer and at least one crosslinking agent. Often the fabrics are characterized by a color change of greater than or equal to about 3.0 according to AATCC evaluation after a first wash by AATCC61-2003-2A.

1 . A dyed fabric comprising one or more elastic fibers wherein the elastic fibers comprise the reaction product of at least one ethylene olefin block polymer and at least one crosslinking agent and wherein said fabric is characterized by a color change of greater than or equal to about 3.0 according to AATCC evaluation after a first wash by AATCC61-2003-2A. 
     
     
         2 . The dyed fabric of  claim 1  wherein said fabric is characterized by a color change of greater than or equal to about 3.5 according to AATCC evaluation after a first wash by AATCC61-2003-2A. 
     
     
         3 . The dyed fabric of  claim 1  wherein said fabric is characterized by a color change of greater than or equal to about 4.0 according to AATCC evaluation after a first wash by AATCC61-2003-2A. 
     
     
         4 . The fabric of  claim 1  wherein the fabric is a woven fabric which is characterized by a stretch of at least about 10 percent measured according to ASTM D3107. 
     
     
         5 . The fabric of  claim 1  wherein, the ethylene olefin block polymer is an ethylene/α-olefin interpolymer characterized by one or more of the following characteristics prior to crosslinking:
 (a) has a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
     T   m >−2002.9+4538.5( d )−2422.2( d ) 2 , or 
   (b) has a Mw/Mn from about 1.7 to about 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
   Δ T>− 0.1299(Δ H )+62.81 for Δ H  greater than zero and up to 130 J/g, 
   ΔT≧48° C. for ΔH greater than 130 J/g, 
   wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF pea then the CRYSTAF temperature is 30° C.; or   (e) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when the ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
 Re>1481−1629(d); or 
   (d) has a molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and a melt index, density, and molar comonomer content (based on the whole polymer) within percent of that of the ethylene/α-olefin interpolymer; or   (e) is characterized by a storage modulus at 25° C., G′(25° C.), and a storage modulus at 100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) is from about 1:1 to about 10:1; or   (1) at least one molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1 and a molecular weight distribution, Mw/Mn, greater than about 1.3 or   (g) an average block index greater than zero and up to about 1.0 and a molecular weight distribution, Mw/Mn, greater than about 1.3.   
     
     
         6 . The fabric of  claim 1  wherein the fabric is a knit fabric which is characterized by a stretch of at least about 30 percent measured according to ASTM D2594. 
     
     
         7 . The fabric of  claim 1  wherein said elastic fibers comprise from about 2 to about 30 weight percent of the fabric. 
     
     
         8 . The fabric of  claim 1  wherein said fabric further comprises polyester, nylon, cellulose, cotton, flax, ramie, hemp, wool, silk, linen, bamboo, tencel, mohair, other natural fibers, and mixtures thereof. 
     
     
         9 . The fabric of  claim 8  wherein said polyester is microfiber polyester. 
     
     
         10 . The fabric of  claim 8  wherein the polyester comprises at least about 50 percent by weight of the fabric. 
     
     
         11 . The fabric of  claim 9  wherein the microfiber polyester comprises at least about 50 percent by weight of the fabric. 
     
     
         12 . The fabric of  claim 5  wherein the ethylene/α-olefin interpolymer is blended with another polymer. 
     
     
         13 . The fabric of  claim 5  wherein the ethylene/α-olefin interpolymer is characterized by a density of from about 0.865 to about 0.92 g/cm3 (ASTM D 792) and an uncrosslinked melt index of from about 0.1 to about 10 g/10 minutes. 
     
     
         14 . The fabric of  claim 1  wherein the fabric is a knit fabric and comprises a majority of the fibers that have a denier of from about 1 denier to about 180 denier. 
     
     
         15 . The dyed fabric of  claim 1  wherein said fabric is characterized by a color change of greater than or equal to about 2.5 according to AATCC evaluation after a second wash by AATCC61-2003-2A. 
     
     
         16 . The dyed fabric of  claim 1  wherein said fabric is characterized by a color change of greater than or equal to about 3.0 according to AATCC evaluation after a second wash by AATCC61-2003-2A. 
     
     
         17 . The dyed fabric of  claim 1  wherein said fabric is characterized by a color change of greater than or equal to about 3.5 according to AATCC evaluation after a second wash by AATCC61-2003-2A. 
     
     
         18 . A dyed fabric comprising one or more elastic fibers wherein the elastic fibers comprise the reaction product of at least one ethylene olefin block polymer and at least one crosslinking agent and wherein said fabric is characterized by a color strength after dying of greater than or equal to about 600 as measured with a spectrum photometer. 
     
     
         19 . The dyed fabric of  claim 18  wherein said fabric is characterized by a color strength after dying of greater than or equal to about 650 as measured with a spectrum photometer. 
     
     
         20 . The dyed fabric of  claim 18  wherein said fabric is characterized by a color strength after dying of greater than or equal to about 700 as measured with a spectrum photometer. 
     
     
         21 . The dyed fabric of  claim 18  wherein said fabric is characterized by a color strength after dying of greater than or equal to about 750 as measured with a spectrum photometer. 
     
     
         22 . The dyed fabric of  claim 18  wherein said fabric is characterized by a color strength after a first wash by AATCC61-2003-2A that is at least about 90 percent of the color strength after dying wherein each color strength is measured with a spectrum photometer. 
     
     
         23 . The dyed fabric of  claim 18  wherein said fabric is characterized by a color strength after a first wash by AATCC61-2003-2A that is at least about 95 percent of the color strength after dying wherein each color strength is measured with a spectrum photometer. 
     
     
         24 . The dyed fabric of  claim 18  wherein said fabric is characterized by a color strength after a first wash by AATCC61-2003-2A that is at least about 97 percent of the color strength after dying wherein each color strength is measured with a spectrum photometer. 
     
     
         25 . The dyed fabric of  claim 18  wherein said fabric is characterized by a color strength after a second wash by AATCC61-2003-2A that is at least about 90 percent of the color strength after dying wherein each color strength is measured with a spectrum photometer. 
     
     
         26 . The dyed fabric of  claim 18  wherein said fabric is characterized by a color strength after a second wash by AATCC61-2003-2A that is at least about 92.5 percent of the color strength after dying wherein each color strength is measured with a spectrum photometer. 
     
     
         27 . The dyed fabric of  claim 18  wherein said fabric is characterized by a color 25 strength after a second wash by AATCC61-2003-2A that is at least about 94 percent of the color strength after dying wherein each color strength is measured with a spectrum photometer. 
     
     
         28 . The fabric of  claim 18  wherein the fabric is a woven fabric and is characterized by a stretch of at least about 10 percent measured according to ASTM D3107. 
     
     
         29 . The fabric of  claim 18  wherein the ethylene olefin block polymer is an ethylene/α-olefin interpolymer characterized by one or more of the following characteristics prior to crosslinking:
 (a) has a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship,
     T   m >−2002.9+4538.5( d )−2422.2( d ) 2 , or 
   (b) has a Mw/Mn from about 1.7 to about 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
   Δ T>− 0.1299(Δ H )+62.81 for Δ H  greater than zero and up to 130 J/g, 
   ΔT≧48° C. for ΔH greater than 130 J/g, 
   wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C.; or   (c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when the ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
 Re>1481-1629(d); or 
   (d) has a molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer; or   (e) is characterized by a storage modulus at 25° C., G′(25° C.), and a storage modulus at 100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) is from about 1:1 to about 10:1 or   (f) at least one molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1 and a molecular weight distribution, Mw/Mn, greater than about 1.3 or   (g) an average block index greater than zero and up to about 1.0 and a molecular weight distribution, Mw/Mn, greater than about 1.3.   
     
     
         30 . The fabric of  claim 18  wherein said elastic fibers comprise from about 2 to about 30 weight percent of the fabric. 
     
     
         31 . The fabric of  claim 18  wherein said fabric further comprises polyester, nylon, or mixtures thereof. 
     
     
         32 . The fabric of  claim 18  wherein said polyester is microfiber polyester. 
     
     
         33 . The fabric of  claim 31  wherein the polyester comprises at least about 80 percent by weight of the fabric. 
     
     
         34 . The fabric of  claim 32  wherein the microfiber polyester comprises at least about 80 percent by weight of the fabric. 
     
     
         35 . The fabric of  claim 28  wherein the ethylene/α-olefin interpolymer is blended with another polymer. 
     
     
         36 . The fabric of  claim 28  wherein the ethylene/α-olefin interpolymer is characterized by a density of from about 0.865 to about 0.92 g/cm3 (ASTM D 792) and an uncrosslinked melt index of from about 0.1 to about 10 g/10 minutes. 
     
     
         37 . The fabric of  claim 18  wherein a majority of the fibers have a denier of from about 1 denier to about 180 denier. 
     
     
         38 . In a process of producing a dyed fabric wherein said fabric comprises one or more elastic fibers comprised of the reaction product of at least one ethylene olefin block polymer and at least one crosslinking agent, wherein said process comprises contacting said fabric and said dye at a temperature above room temperature and then drying said fabric wherein the improvement comprises contacting said fabric and said dye at a temperature of at least about 130° C. to produce a dyed fabric wherein the fabric exhibits a growth to stretch ratio of less than 0.5. 
     
     
         39 . The process of  claim 38  wherein said dyed fabric exhibits a growth to stretch ratio of less than 0.25. 
     
     
         40 . The process of  claim 38  wherein said dyed fabric is characterized by a color change of greater than or equal to about 3.0 according to AATCC evaluation after a first wash by AATCC61-2003-2A. 
     
     
         41 . The process of  claim 38  wherein said dyed fabric is characterized by a color strength alter a first wash by AATCC661-2003-2A that is at least about 90 percent of the color strength after dying wherein each color strength is measured with a spectrum photometer. 
     
     
         42 . The process of  claim 38  wherein said process is conducted in the substantial absence of penetration agents. 
     
     
         43 . The process of  claim 38  wherein said dyed fabric is characterized by a color strength after dying of greater than or equal to about 600 as measured with a spectrum photometer. 
     
     
         44 . The process of  claim 38  wherein said dyed fabric is characterized by a color strength after a first wash by AATCC61-2003-2A that is at least about 90 percent of the color strength after dying wherein each color strength is measured with a spectrum photometer. 
     
     
         45 . The process of  claim 38  wherein the ethylene olefin block polymer is an ethylene/α-olefin interpolymer characterized by one or more of the following characteristics prior to crosslinking:
 (a) has a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
     T   m >−2002.9+4538.5( d )−2422.2( d ) 2 , or 
   (b) has a Mw/Mn from about 1.7 to about 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
   Δ T>− 0.1299(Δ H )+62.81 for Δ H  greater than zero and up to 130 J/g, 
   ΔT≧48° C. for ΔH greater than 130 J/g, 
   wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30° C.; or   (c) is characterized by an elastic recovery Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter wherein the numerical values of Re and d satisfy the following relationship when the ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
 Re>1481−1629(d); or 
   (d) has a molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer; or   (e) is characterized by a storage modulus at 25° C., G′(25° C.), and a storage modulus at 100° C., G′(100° C.), wherein the ratio of G′(25° C.) to G′(100° C.) is from about 1:1 to about 10:1; or   (f) at least one molecular fraction which elutes between 40° C. and 130° C. when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1 and a molecular weight distribution, Mw/Mn, greater than about 1.3 or   (g) an average block index greater than zero and up to about 1.0 and a molecular weight distribution Mw/Mn, greater than about 1.3.   
     
     
         46 . The fabric of  claim 1  wherein the fabric is a woven fabric and comprises a majority of the fibers that have a denier of less than about 3000 denier. 
     
     
         47 . The fabric of  claim 18  wherein the fabric is a knit fabric and is characterized by a stretch of at least about 30 percent measured according to ASTM D2594.