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High-Quality Disperse Dyes for Vibrant Textile Coloring Solutions1
Pigment DyeDyestuffDisperse Dyes
Suzhou Trillion Shine Import & Export Co., Ltd.
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Product Description Product IntroductionDisperse dyes Disperse dyes are a class of dyes with relatively small molecules and no water-soluble groups in their structure, belonging to non-ionic dyes. During dyeing, they must rely on dispersants to uniformly disperse the dye in the dye liquor to color fibers such as polyester. ### Structure Disperse dyes have small molecules and lack water-soluble groups in their structure. They achieve uniform dispersion in the dye liquor with the aid of dispersants for dyeing. These dyes can color polyester fibers, acetate fibers, and polyamide fibers, making them specialized dyes for polyester. Disperse dyes can be broadly categorized into disperse orange, disperse blue, disperse yellow, and disperse red. By blending different disperse dyes in specific proportions, colors such as disperse black, disperse green, and disperse violet can be obtained. During commercial processing, disperse dyes must be ground to a particle size of around 1 micron to form a stable colloidal suspension in water. Dispersants and wetting agents are added during sand milling. The post-processing of disperse dyes typically includes sand milling, blending, spray drying, and packaging. Various auxiliaries are used in post-processing, such as lignin, MF, anti-settling agents (SOS), anti-dust agents, dispersant NNO, and Glauber's salt for adjusting strength. Disperse dyes are the most important and major category in the dye industry. They lack strong water-soluble groups and remain in a dispersed state during dyeing. Their particle size must be around 1 μm. After synthesizing the raw dye, post-processing-including crystal stabilization and grinding with dispersants-is required to produce the commercial product. These dyes are primarily used for printing and dyeing polyester and its blended fabrics but can also dye synthetic fibers like acetate, nylon, polypropylene, polyvinyl chloride, and acrylic. ### Development History Disperse dyes are slightly water-soluble and achieve high dispersion in water with the aid of dispersants. They lack water-soluble groups, have low molecular weight, and contain polar groups (e.g., hydroxyl, amino, hydroxyalkylamino, cyanoalkylamino), yet remain non-ionic. Post-processing demands are high, often requiring grinding with dispersants to achieve stable, highly dispersed particles. Disperse dye suspensions are uniform and stable. First produced in 1922 by Badische Anilin- & Soda-Fabrik (BASF) in Germany, they were initially used for acetate fibers. After the emergence of polyester fibers in the 1950s, they rapidly developed into a major product in the dye industry. ### Classification by Molecular Structure Disperse dyes can be divided into three types: 1. **Azo-type**: Full color range (yellow, orange, red, purple, blue). Simple synthesis and low cost. 2. **Anthraquinone-type**: Red, purple, and blue hues. 3. **Heterocyclic-type**: Recently developed, offering bright colors. Anthraquinone and heterocyclic types have complex production processes and higher costs. ### Classification by Thermal Performance 1. **Low-temperature (E-type)**: Low sublimation fastness, good leveling, suitable for exhaust dyeing. 2. **High-temperature (S-type)**: High sublimation fastness, poor leveling, suitable for thermosol dyeing. 3. **Medium-temperature (SE-type)**: Intermediate properties. ### Properties Disperse dyes have simple structures and extremely low water solubility. To ensure dispersion, particles must be ground below 2 μm, and large amounts of dispersants are added to stabilize the suspension. Operation Method Due to the strong hydrophobicity, high crystallinity and alignment, small fiber microvoids, and difficulty in wetting and swelling of polyester fibers, it is challenging to achieve dye penetration into the fibers in single-molecule form for polyester dyeing using conventional methods. Therefore, more specialized dyeing techniques are required. The primary methods employed include the carrier method, high-temperature and high-pressure method, and high-temperature thermosol method. These approaches utilize different conditions to swell the fibers, enlarging the gaps between fiber molecules, while incorporating auxiliaries to enhance the diffusion rate of dye molecules. This enables the dye molecules to continuously diffuse into the swollen and expanded fiber voids, where they are fixed to the fibers through intermolecular forces and hydrogen bonds, completing the polyester dyeing process. Since disperse dyes exhibit extremely low solubility in water, they must be combined with dispersing agents in the dye solution. To prevent hydrolysis of both the disperse dyes and polyester under high temperature and alkaline conditions, dyeing is typically conducted under weakly acidic conditions. **Carrier Dyeing Method** The carrier dyeing method is performed under atmospheric pressure with heating. It relies on chemicals that exhibit direct affinity for both the dye and the fiber. During dyeing, these chemicals penetrate the polyester fibers, carrying dye molecules along with them. Such chemicals are termed carriers or dye carriers. The principle behind carrier dyeing lies in the strong intermolecular attraction between the benzene rings in polyester and the aromatic nuclei in dye molecules. Polyester can adsorb simple hydrocarbons, phenols, and similar compounds, which then act as carriers. The interaction between the carrier and polyester relaxes the molecular structure of the fiber, increasing its void volume and facilitating dye penetration. Additionally, the carrier itself can form direct attractive forces with both the fiber and dye molecules, aiding in dye dissolution, transporting dye monomers to the fiber surface, increasing dye concentration on the fiber surface, and reducing surface tension. This accelerates the movement of dye molecules into the fiber voids, enhancing diffusion rates and promoting dye-fiber bonding to complete the dyeing process. After dyeing, alkali washing is used to completely remove the carrier. Common carriers include o-phenylphenol, biphenyl, and methyl salicylate. However, due to their toxicity and harmful effects on humans, their use has significantly declined and is only briefly introduced here. **High-Temperature and High-Pressure Dyeing Method** This method is conducted under high-temperature, high-pressure, and moist heat conditions. Dye uptake is very slow below 100°C, and even at boiling temperatures, the dyeing rate and percentage remain low. Therefore, pressure must be applied (up to 2 atm or 2.02×10x10x10x10x10 Pa), allowing the dye bath temperature to rise to 120-130°C. At these elevated temperatures, the intensified segmental motion of fiber molecules generates more and larger transient voids, accelerating dye diffusion and increasing the rate of dye penetration into the fibers until exhaustion is achieved. High-temperature and high-pressure dyeing with disperse dyes is a crucial method, particularly suitable for low-sublimation-fastness and low-molecular-weight dyes. This approach ensures excellent leveling, vibrant colors, good hand feel, and high fabric penetration, making it ideal for small-batch, multi-variety production. It is commonly used for dyeing polyester-cotton blended fabrics. This method can be performed using high-temperature and high-pressure jiggers or jet/overflow dyeing machines, especially for deep shades. The dyeing pH is typically maintained at 5-6, adjusted with acetic acid or ammonium dihydrogen phosphate. To ensure dye bath stability, dispersing agents and high-temperature leveling agents are added during dyeing. **Example of Overflow Dyeing Machine Process:** *Dyeing Recipe:* Disperse dye: X% High-temperature leveling agent: 0.2-1.0 g/L Dispersing agent: 0.5-1.0 g/L Acetic acid (98%): 0.5-1.0 g/L *Reduction Clearing:* Caustic soda: 2.0 g/L Hydrosulfite: 4.0 g/L *Process Flow:* Grey fabric sewing → Pretreatment → Dyeing → Reduction clearing → Hot wash → Rinse → Dewatering and opening → Heat setting. Dyeing typically starts at 60-70°C, gradually rising to 130°C over approximately 1 hour, followed by thorough rinsing. For medium to dark shades, reduction clearing is performed to ensure colorfastness. **Thermosol Dyeing Method** Thermosol dyeing of polyester/cotton fabrics resembles conventional pad dyeing. After padding with the dye liquor, the fabric is dried and subjected to thermosol treatment at around 200°C. Under this high temperature, the dye deposited on the fabric diffuses into the fibers in single-molecule form, completing polyester dyeing within a very short time. For polyester-cotton blends, thermosol treatment facilitates the transfer of dye from cotton to polyester via vapor-phase or contact mechanisms. Thermosol dyeing is the primary method for polyester-cotton blends, predominantly using continuous pad-dry-thermosol production for high efficiency, especially in large-scale operations. However, it requires significant equipment space and imposes limitations on dye selection, with lower dye utilization compared to high-temperature and high-pressure dyeing. **Example of Thermosol Dyeing Process (45×45 count, light blue, 65/35 polyester/cotton fine fabric):** *Dyeing Recipe:* Disperse Blue 2BLN: 1.5 g/L Wetting agent JFC: 1 mL/L Dispersing agent: 1 g/L 3% Sodium alginate paste: 5-10 g/L pH adjusted to 5-6 with acetic acid or ammonium dihydrogen phosphate. *Process Flow:* Pad dyeing (double dip and nip, 65% pickup, room temperature) → Pre-drying (80-120°C) → Thermosol (180-210°C, 2-1 min) → Cotton topping. During thermosol dyeing, precautions must be taken to prevent dye migration during pre-drying and curing. The thermosol stage is critical for transferring disperse dyes from cotton to polyester. The appropriate temperature and time should be selected based on the dye's thermal stability (sublimation fastness). In practice, dye transfer is incomplete, leaving residual dye on the cotton, which may require post-dyeing reduction clearing or soaping. If cotton topping follows thermosol dyeing, post-treatment can be performed afterward.Main Applications The primary use of disperse dyes is to dye synthetic fibers such as polyester fiber (polyester), acetate fiber (diacetate, triacetate), and polyamide fiber (nylon), with limited application on polyacrylonitrile (acrylic). Chemical fiber textile products processed with disperse dyes exhibit vibrant colors, excellent wash fastness, and a wide range of uses. Since disperse dyes are insoluble in water, they have no dyeing capability for natural fibers like cotton, hemp, wool, or silk, and hardly adhere to viscose fiber. Therefore, blended synthetic fiber products usually require the combined use of disperse dyes and other suitable dyes.Development Prospects Disperse dyes have seen new advancements in application: (1) Multicomponent disperse dyes, typically consisting of two (sometimes three or four) disperse dyes mixed in specific proportions, exhibit enhanced dye uptake due to synergistic effects during use. (2) Transfer printing involves formulating disperse dyes into printing inks, applying them to fabrics, and then fixing the colors through high-temperature pressing. This process, also known as non-aqueous printing, offers advantages such as energy savings, time efficiency, and convenience. (3) The combined use of disperse dyes and reactive dyes enables one-bath, one-step dyeing of polyester-cotton, polyester-viscose, and other blended textiles, simplifying the printing and dyeing process while improving quality. Color Sample of Disperse Dyestuffs Part of our CustomersCompany IntroductionSuzhou Trillion Shine Import & Export Co.,Ltd (Trillion Shine) is a leading Chinese supplier of disperse dyestuff and also provides services for sourcing all related products from China since 2003. Relying on Chinese complete industry Chain and enjoying price advantages, we provide customers with premium products, reasonable prices,and on-time services. Trillion Shine has a professional technique team who has been in this industry for more than 22 years, consists of advanced mechanics, engineers and professors. Powerful technical capabilities extend our core competence to analysis of customer's demand and provide customer with satisfying service. Trillion Shine has already established business relations with customers from South America, North America, Europe, Middle East, Southeast Asia and South Asia, obtained the customer affirmation and faith. The good faith manner,the premium quality product, the exquisite service and the customer first principle are Trillion Shine's service objective. Trillion Shine sincerely wish to establish stable business relationship with customers all over the world, please feel free to contact with us.
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