Commercially Adaptable Coloration Processes for Generic Polypropylene Fiber

Abstract

Polypropylene (PP) fibers belong to the newest generation of large-scale, manufactured chemical fibers, having the fourth largest volume in production after polyesters, polyamides and acrylics [1, 2]. PP is one of the most successful commodity fibers, reaching a world production capacity of four million tons a year. Due to its low density (0.9 gm/cc), high crystallinity, high stiffness and excellent chemical/bacterial resistance, isotactic PP is widely used in many industrial applications such as nonwovens, industrial ropes, packaging materials, furnishing products, etc. PP fiber has potential, high-volume applications in the carpet, textile, apparel and industrial textile markets. Due to its thermoplastic nature, PP fiber is manufactured using conventional melt spinning. Subsequent multistage drawing imparts tensile strength and enhances mechanical properties required for industrial applications. Synthesis of PP polymer involves stereoregular polymerization of propylene gas using Ziegler-Natta catalysts [3]. Only isotactic polypropylene is useful for fiber applications among the three stereoisomers. Since only a simple monomer, i.e., propylene gas, is involved in the synthesis of PP, this fiber is relatively inexpensive to produce as compared to other high volume textile fibers such as polyesters, acrylics and nylons. The major products of PP fibrous materials are monofilaments, multifilament yarns, staple fibers and yarns, nonwoven textiles (spunbond, meltblown), tapes, split filament, ropes, carpet backing, etc. Crystallinity of isotactic PP is about 70%, and the molecular weight of fiber grade PP is in the range of 80,000 to 300,000 gm/mole. Since the advent of stereo-regular isotactic polypropylene (PP), the fiber has been used in many industrial applications, as well as in carpets and apparel, due to its high degree of crystallinity, good handle, strength and a high enough melting point for normal use. The potential commercial importance of unmodified polypropylene (PP) fiber in the carpet and textile industries has led to research to develop an aqueous dyeing process for the highly-hydrophobic fiber, consistent with the established coloration processes in use for other high-volume fibers (cotton, nylon, polyester and acrylic). Despite substantial research conducted around the globe, a commercially viable and sustainable aqueous dyeing process of PP based on demand-activated manufacturing has not been realized. PP offers the advantages of exceptionally low price, good strength and aesthetic properties, along with many other desirable characteristics of a textile/carpet fiber, thus creating the