U.S. patent application number 13/884701 was filed with the patent office on 2014-02-06 for aqueous dispersion of dye, stain-blocker, and fluorochemical and its use in the manufacture of carpet.
This patent application is currently assigned to Toray Opelontex Co., Ltd.. The applicant listed for this patent is Sundar Mohan Rao. Invention is credited to Sundar Mohan Rao.
Application Number | 20140033451 13/884701 |
Document ID | / |
Family ID | 45975118 |
Filed Date | 2014-02-06 |
United States Patent
Application |
20140033451 |
Kind Code |
A1 |
Rao; Sundar Mohan |
February 6, 2014 |
AQUEOUS DISPERSION OF DYE, STAIN-BLOCKER, AND FLUOROCHEMICAL AND
ITS USE IN THE MANUFACTURE OF CARPET
Abstract
Disclosed is composition comprising an aqueous dispersion
containing a dye, a stain blocker component, and an anti-soil
component. The composition provides uniform dyeing, and superior
stain blocking and anti-soil characteristics to fibers, carpets,
and fabrics by adjusting the conductivity and pH of the dispersion.
Alternatively, the composition can comprise an aqueous dispersion
containing a dye, a stain blocker component, and a retarder for
slowing down the rate of dye reaction. Also disclosed is a method
of applying the compositions and dispersions to fibers, carpets,
and fabrics.
Inventors: |
Rao; Sundar Mohan;
(Chattanooga, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rao; Sundar Mohan |
Chattanooga |
TN |
US |
|
|
Assignee: |
Toray Opelontex Co., Ltd.
Tokyo
JP
|
Family ID: |
45975118 |
Appl. No.: |
13/884701 |
Filed: |
November 9, 2011 |
PCT Filed: |
November 9, 2011 |
PCT NO: |
PCT/US11/59997 |
371 Date: |
June 20, 2013 |
Current U.S.
Class: |
8/490 ;
8/615 |
Current CPC
Class: |
D01F 1/10 20130101; D01F
6/70 20130101; D06P 5/04 20130101; D01F 1/103 20130101 |
Class at
Publication: |
8/490 ;
8/615 |
International
Class: |
D06P 5/04 20060101
D06P005/04 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 19, 2010 |
JP |
2010-234355 |
Claims
1. A composition comprising an aqueous dispersion of a dye, an
anti-soil component, and a stain blocker, wherein said aqueous
dispersion has a conductivity between about 2000 to about 9000
micromhos and a pH between about 1.5 to about 5.
2. The composition of claim 1, wherein said anti-soil component
comprises a fluorochemical.
3. The composition of claim 2, wherein said fluorochemical has less
than or equal to six fluorinated carbons.
4. The composition of claim 1, further comprising a metal salt.
5. The composition of claim 1, further comprising a retarder.
6. The composition of claim 4, wherein said metal salt is selected
from the group consisting of: sodium sulfate, magnesium sulfate,
potassium sulfate, calcium sulfate, manganese sulfate, iron
sulfate, copper sulfate, zinc sulfate, aluminum sulfate, sodium
nitrate, magnesium nitrate, potassium nitrate, calcium nitrate,
manganese nitrate, iron nitrate, copper nitrate, zinc nitrate,
aluminum nitrate, sodium chloride, potassium chloride, calcium
chloride, magnesium chloride, manganese chloride, copper chloride,
iron chloride, sodium phosphate, potassium phosphate, calcium
phosphate, manganese phosphate, iron phosphate, copper phosphate,
zinc phosphate, aluminum phosphate, sodium bicarbonate, sodium
carbonate, calcium bicarbonate, calcium carbonate, potassium
bicarbonate, and potassium carbonate.
7. The composition of claim 6, wherein said metal salt is magnesium
sulfate.
8. The composition of claim 4, wherein said metal salt is present
between about 1 gram of metal/Liter to about 16 gram of metal/Liter
of said aqueous solution.
9. The composition of claim 1, wherein said conductivity is between
about 4000 to about 7000 micromhos.
10. The composition of claim 1, wherein said pH is between about
1.5 to about 4.
11. The composition of claim 8, wherein said metal salt is present
between about 1 gram of metal/L to about 6 gram of metal/L of said
aqueous solution.
12. The composition of claim 9, further comprising a retarder.
13. The composition of claim 1, further comprising an additive that
performs a function selected from the group consisting of: aid in
dye penetration, aid in anti-soil penetration, aid in stain blocker
penetration, protect the carpet from long term exposure to the
elements, and keep the dye, stain blocker, and anti-soil components
in suspension.
14. The composition of claim 13, wherein said additive is selected
from the group consisting of: dye auxiliaries, sequestrants, pH
control agents, surfactants, fluoro-surfactants, nano materials,
odor control agents, antimicrobial agents, fragrance agents, bleach
resist agents, softeners, and UV stabilizers.
15. A method of applying a composition to a fiber comprising: (a)
providing an aqueous dispersion comprising a dye, an anti-soil
component, and a stain blocker, wherein said aqueous dispersion has
a conductivity between about 2000 to about 9000 micromhos and a pH
between about 1.5 to about 5; (b) contacting said fiber with said
aqueous dispersion at temperature between about 20.degree. C. to
about 40.degree. C.; (c) steaming said fiber for at least 60
seconds; (d) rinsing said fiber with water; and (e) drying said
fiber.
16. The method of claim 15, wherein said anti-soil component
comprises a fluorochemical.
17. The method of claim 15, wherein said aqueous dispersion further
comprises a metal salt.
18. The method of claim 15, wherein said aqueous dispersion further
comprises a retarder.
19. The method of claim 17, wherein said metal salt is selected
from the group consisting of: sodium sulfate, magnesium sulfate,
potassium sulfate, calcium sulfate, manganese sulfate, iron
sulfate, copper sulfate, zinc sulfate, aluminum sulfate, sodium
nitrate, magnesium nitrate, potassium nitrate, calcium nitrate,
manganese nitrate, iron nitrate, copper nitrate, zinc nitrate,
aluminum nitrate, sodium chloride, potassium chloride, calcium
chloride, magnesium chloride, manganese chloride, copper chloride,
iron chloride, sodium phosphate, potassium phosphate, calcium
phosphate, manganese phosphate, iron phosphate, copper phosphate,
zinc phosphate, aluminum phosphate, sodium bicarbonate, sodium
carbonate, calcium bicarbonate, calcium carbonate, potassium
bicarbonate, and potassium carbonate.
20. The method of claim 19, wherein said metal salt is magnesium
sulfate.
21. The method of claim 17, wherein said metal salt is present
between about 2 gram/Liter to about 16 gram/Liter of said aqueous
solution.
22. The method claim 21, wherein said metal salt is present between
about 2 gram/Liter to about 6 gram/Liter of said aqueous
solution.
23. The method of claim 15, wherein said aqueous dispersion has a
conductivity between about 4000 to about 7000 micromhos.
24. The method of claim 15, wherein said aqueous dispersion has a
pH between about 1.5 to about 4.
25. The method of claim 15, wherein said aqueous dispersion further
comprises an additive selected from the group consisting of: dye
auxiliaries, surfactants, fluoro-surfactants, nano materials, odor
control agents, antimicrobial agents, fragrance agents, bleach
resist agents, softeners, and UV stabilizers.
26. The method of claim 15, wherein said aqueous dispersion
temperature is between about 24.degree. C. to about 28.degree.
C.
27. The method of claim 15, wherein said steaming said fiber is
between about 2 minutes to about 3 minutes.
28. The method of claim 15, further comprising pre-steaming said
fiber prior to contacting said fiber with said aqueous
solution.
29. The method of claim 15, wherein said steaming is performed at a
temperature of about 100.degree. C.
30. The method of claim 15, wherein said drying is performed at a
temperature between about 130.degree. C. to about 135.degree.
C.
31. The method of claim 15, wherein said at least one fiber is a
polyamide fiber.
32. The method of claim 31, wherein said polyamide fiber is
selected from the group consisting of: nylon 6,6, nylon 6, nylon
4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends
thereof.
33. The method of claim 15, wherein said fiber is formed into a
carpet or fabric either before or after contacting said fiber with
said aqueous dispersion.
34. The method of claim 15, further comprising steam heat setting
said fiber at a temperature of about 100.degree. C. prior to
contacting said fiber with said aqueous dispersion.
35. The method of claim 15, further comprising dry heat setting
said fiber at a temperature between about 130.degree.
C.-135.degree. C. prior to contacting said fiber with said aqueous
dispersion.
36. The method of claim 15, wherein said contacting is done by a
process selected from the group consisting of: bathing, exhaustion,
foaming, spraying, and nip-rolling, skein dyeing, beck dyeing,
space dyeing
37. The method of claim 15, further comprising removing water from
the fiber prior to drying said fiber.
38. A method of applying a composition to a fiber comprising: (a)
providing an aqueous dispersion comprising a dye and a stain
blocker, wherein said aqueous dispersion has a conductivity between
about 2000 to about 9000 micromhos and a pH between about 1.5 to
about 5; (b) contacting said fiber with said aqueous dispersion at
temperature between about 20.degree. C. to about 40.degree. C.; (c)
steaming said fiber for at least 60 seconds; (d) rinsing said fiber
with water; and (f) drying said fiber.
39. The method of claim 38, wherein said method further comprises
applying an anti-soil component after contacting said fiber with
said aqueous dispersion solution.
40. The method of claim 38, wherein said anti-soil component
comprises a fluorochemical.
41. The method of claim 40, wherein said anti-soil is applied by a
method selected from the group consisting of: spraying or
foaming.
42. The method of claim 38, further comprising removing water from
the fiber prior to drying said fiber.
43. The method of claim 38, further comprising steam heat setting
said fiber at a temperature of about 100.degree. C. prior to
contacting said fiber with said aqueous dispersion.
44. The method of claim 38, further comprising dry heat setting
said fiber at a temperature between about 130.degree. C. to about
135.degree. C. prior to contacting said fiber with said aqueous
dispersion.
45. The method of claim 38, wherein said at least one fiber is a
polyamide fiber.
46. The method of claim 45, wherein said polyamide fiber is
selected from the group consisting of: nylon 6,6, nylon 6, nylon
4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends
thereof.
47. The method of claim 38, wherein said fiber is formed into a
carpet or fabric either before or after contacting said fiber with
said aqueous dispersion.
48. A composition comprising an aqueous dispersion of a dye, a
stain blocker, and a retarder, where the retarder reduces the rate
of dyeing.
49. The composition of claim 48, further comprising an anti-soil
component.
50. The composition of claim 48, where the retarder adjusts the
conductivity of the aqueous dispersion from about 2000 to about
9000 micromhos.
51. A carpet fiber comprising a dye, an anti-soil component, and a
stain block, wherein said stain block penetrates farther into said
fiber than said stain block applied separately from a dyeing step.
Description
FIELD OF THE INVENTION
[0001] This disclosure relates to the carpet industry in general
and to the application of carpet dyeing and finishing chemistry in
particular. The disclosed aqueous dispersion of dye, stain-blocker,
and fluorochemical and application thereof relates especially to
the treatment of carpet fiber to maintain carpet appearance after
extended use. The aqueous dispersion and processes disclosed herein
provide superior appearance retention via stain and soil protection
while using far less water and energy than processes of the prior
art. The aqueous dispersion and processes are applicable to various
fibers, including nylon 6,6 and copolymers and blends thereof.
BACKGROUND OF THE TECHNOLOGY
[0002] The carpet industry today uses large quantities of fresh
water in the course of dyeing and treating carpets. However, fresh
water is becoming increasingly valuable for other uses, and that
the continued growth of such water usage is unacceptable. Means of
reducing water consumption are now being sought actively as part of
a sustainably "green" philosophy, so that the carpet industry may
continue to thrive.
[0003] While various processes are in use in the carpet industry
for the dyeing and finishing of carpets, some large scale and some
small, most of the residential broad loom carpet made today is dyed
and finished on a continuous dye range. The is done mainly in one
of two ways: (1) a two stage process, where the carpet is steamed
and dyed first, steamed, rinsed, and excess water extracted, then
stain-blocker (SB) is applied, the carpet is again steamed and
washed, and then fluorochemical (FC) is applied in the form of a
foam or liquid spray and the carpet is finally dried. (See e.g.
U.S. Pat. Nos. 5,853,814; 5,948,480 and W02000/000691). (2) A
co-application process, where the carpet is steamed and dyed first,
steam again, rinsed, and extracted, and then a blend of SB and FC
is applied together at high wet pick-up (e.g. 300-400%), after
which the carpet and chemicals are exposed once again to steam to
fix the treatment, followed by drying. (See e.g. U.S. Pat. Nos.
6,197,378 and 5,520,962). Both of the continuous range-dye
processes in use today have been found to be quite efficient
compared to prior technologies, delivering excellent product
quality at lower cost and with far less water pollution per unit of
production.
SUMMARY OF THE INVENTION
[0004] Unfortunately, large volumes of water and steam are still
being employed in the continuous range-dye processes currently used
to finish carpets. In either case, carpet finishing treatment
processes of the prior art have required multiple steps because of
reagent incompatibility, especially with respect to pH limitations.
Specifically, dyes react too quickly and therefore react with poor
uniformity at low pH, while stain and soil resist chemistry require
low pH to be effectively applied. (See U.S. Pat. No. 5,948,480 for
an explanation of the difficulties of combining stain blocker and
fluorochemicals). Therefore, there is still a need for an aqueous
stain-blocker/fluorochemical solution and application process that
consumes less water than traditional two-stage and co-application
processes. There is also a need for an efficient process of dyeing
and finishing carpets to further reduce the consumption of
water.
[0005] The invention disclosed herein provides a stable aqueous
dispersion of dye, stain-blocker, and fluorochemical that can be
applied as a composition to fibers for carpets and fabrics. Such
solution overcomes the problem of dyes reacting too quickly at low
pH, by adjusting the conductivity of the solution to a level where
the dyes can react at a pace that provides uniform color
throughout. Further, the composition pH can remain relatively low
for stain and soil resist chemistry to be effectively applied. Also
disclosed are processes for applying the aqueous dispersion and
carpets and fabrics made with the fibers treated with the
composition and aqueous dispersion.
[0006] In one aspect, a composition comprising an aqueous
dispersion of a dye, an anti-soil component, and a stain blocker
component is disclosed. The aqueous dispersion has a conductivity
between about 2000 to about 9000 micromhos, and a pH between about
1.5 to about 5. The anti-stain component can comprise a
fluorochemical. Further, the aqueous dispersion can comprise a
metal salt and/or a retarder.
[0007] In another aspect, a method of applying the composition to a
fiber is disclosed. Such method comprises: (a) providing an aqueous
dispersion comprising a dye, an anti-soil component, and a stain
blocker, wherein said aqueous dispersion has a conductivity between
about 2000 to about 9000 micromhos and a pH between about 1.5 to
about 5; (b) contacting said fiber with said aqueous dispersion at
temperature between about 20.degree. C. to about 40.degree. C.; (c)
steaming said fiber for at least 60 seconds; (d) rinsing said fiber
with water; and (e) drying said fiber. Optionally, water can be
removed from the fiber prior to drying. The fiber can be
manufactured into a carpet or fabric. Alternatively, a pre-treated
fiber can be manufactured into a carpet or fabric, and then the
carpet or fabric treated with the composition as disclosed above.
The fiber can be any type, including natural staple, synthetic
staple, or synthetic continuous filament. The contacting can be
done using known processes, such as bathing, exhaustion, foaming,
spraying, and nip-rolling, and can also be implemented as part of
various dyeing processes such as skein dyeing, beck dyeing, piece
dyeing, and space dyeing.
[0008] In a further aspect, a composition comprising an aqueous
dispersion of a dye, stain blocker, and a retarder is disclosed.
The retarder reacts with dye sites and competes for the fiber
surface along with the dye, thus reducing the rate of dyeing and
creating more level dyeing. The composition can further comprise an
anti-soil component to make a four-part composition.
[0009] In yet another aspect, a method of applying a composition to
a fiber is disclosed.
[0010] Such method comprises: (a) providing an aqueous dispersion
comprising a dye and a stain blocker, wherein said aqueous
dispersion has a conductivity between about 2000 to about 9000
micromhos and a pH between about 1.5 to about 5; (b) contacting
said fiber with said aqueous dispersion at temperature between
about 20.degree. C. to about 40.degree. C.; (c) steaming said fiber
for at least 60 seconds; (d) rinsing said fiber with water; and (e)
drying said fiber. Optionally, the water can be removed from the
fiber prior to drying. This method can be used with fibers that are
already treated with an anti-soil component, that have inherent
anti-soil properties, or will be post-treated with an anti-soil
component after contacting with the aqueous dispersion.
[0011] In yet a further aspect, a carpet fiber comprising a dye, an
anti-soil component, and a stain block is disclosed. The stain
block penetrates farther into said fiber than the stain block
applied separately from a dyeing step.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 depicts a known process of applying a dye, stain
blocker, and anti-soil component in three separate steps.
[0013] FIG. 2 depicts on aspect of the disclosed method of applying
a composition comprising dye, stain blocker, and anti-soil
components.
DEFINITIONS
[0014] While mostly familiar to those versed in the art, the
following definitions are provided in the interest of clarity.
[0015] OWF (On weight of fiber): The amount of chemistry that was
applied as a % of weight of fiber.
[0016] WPU (Wet pick-up): The amount of water and solvent that was
applied on carpet before drying off the carpet, expressed as a % of
weight of fiber.
DETAILED DESCRIPTION OF THE INVENTION
[0017] A composition comprising an aqueous dispersion of a dye, an
anti-stain component, and a stain blocker is disclosed. The aqueous
dispersion is buffered to a pH of between about 1.5 to about 5,
including about 2 to about 4, and about 3 to about 5. The
conductivity of the aqueous dispersion is also adjusted from about
2000 to about 9000 micromhos, including from about 4000 to about
9000 micromhos, from about 2000 to about 7000 micromhos, and from
about 4000 to about 7000 micromhos.
[0018] The disclosed composition can use a variety of stain
blockers, such as syntans, sulfonated novolacs, or sulfonated
aromatic aldehyde condensation products (SACs). Stain blockers are
usually made by reacting formaldehyde, phenol, polymethacrylic
acid, maleic anyhydride, and sulfonic acid depending on specific
chemistry. Similarly, a variety of anti-soil components can be used
in the composition, including fluorochemical and non-fluorochemical
based. The fluorochemicals can be anionic or cationic or contain
extenders (See e.g. U.S. Pat. No. 5,756,407 herein incorporated by
reference in its entirety).
[0019] Examples of stain blockers include: formaldehyde polymers or
copolymers, such as CEASESTAIN and STAINAWAY (from American
Emulsions Company, Inc., Dalton, Ga.); MESITOL (from Bayer
Corporation, Rock Hill, N.C.); ERIONAL (from Ciba Corporation,
Greensboro, N.C.); STAINKLEER (from Dyetech, Inc., Dalton, Ga.);
LANOSTAIN (from Lenmar Chemical Corporation, Dalton, Ga.); and
SR-300; SR-400; and SR-500 (from DuPont, Wilmington Del.); polymers
of methacrylic acid such as the SCOTCHGUARD FX series (from 3M
Company, St. Paul Minn.); and sulfonated fatty acids from Rockland
React-Rite, Inc.; stain resist chemistries from ArrowStar LLC,
Dalton, Ga.; and Tri-Tex, from Canada.
[0020] Examples of fluorochemical anti-soil components include:
fluorochemical emulsions, such as AMGUARD (from American Emulsions
Company); SOFTECH (from Dyetech); LANAPOL (from Lenmar Chemical
Corporation); SOCTCHGUARD FC (from 3M); NK GUARD (from Nicca USA,
Inc., Fountain Head, N.C.); UNIDYNE (from Diakin America, Inc.,
Decatur Ala.); and ZONYL 555, N-130, N-119, and CAPSTONE RCP
(Dupont). Formulated chemistries from Daikin, Solvay, ArrowStar,
and Omnova can also be used. Further, fluorochemical compositions
based on C-8, C-6, C-4, and C-3 fluorocarbon chains can be
used.
[0021] The aqueous dispersion or composition can optionally contain
a metal salt in a range from about 1 gram of metal/Liter to about
16 gram of metal/Liter of aqueous solution, including from about 1
gram of metal/Liter to about 6 gram of metal/Liter of said aqueous
solution. Examples of metal salts include: sodium sulfate,
magnesium sulfate, potassium sulfate, calcium sulfate, manganese
sulfate, iron sulfate, copper sulfate, zinc sulfate, aluminum
sulfate, sodium nitrate, magnesium nitrate, potassium nitrate,
calcium nitrate, manganese nitrate, iron nitrate, copper nitrate,
zinc nitrate, aluminum nitrate, sodium chloride, potassium
chloride, calcium chloride, magnesium chloride, manganese chloride,
copper chloride, iron chloride, sodium phosphate, potassium
phosphate, calcium phosphate, manganese phosphate, iron phosphate,
copper phosphate, zinc phosphate, aluminum phosphate, sodium
bicarbonate, sodium carbonate, calcium bicarbonate, calcium
carbonate, potassium bicarbonate, and potassium carbonate.
[0022] Further, a retarder can be used in the aqueous dispersion or
composition in a range from about 0.25% to about 4% by weight
aqueous solution, including 0.5% to about 2% by weight of aqueous
solution. An example retarder is DOWFAX 2A4 or DOWFAX 2A1. The
retarder competes for the fiber surface along with the dye, thus
reducing the rate of dyeing and creating more level dyeing.
Alternatively, an aqueous dispersion comprising a dye, stain
blocker, and retarder is disclosed. Such compositions can be used
with fibers that are already treated with an anti-soil component,
that have inherent anti-soil properties, or will be post-treated
with an anti-soil component after contacting with the aqueous
dispersion. The retarder can adjust the conductivity of the aqueous
dispersion from about 2000 to about 9000 micromhos, including from
about 4000 to about 9000 micromhos, from about 2000 to about 7000
micromhos, and from about 4000 to about 7000 micromhos.
[0023] The disclosed compositions can also contain additives to aid
in dye penetration, anti-soil penetration, stain blocker
penetration, as well as additives to protect the carpet from long
term exposure to the elements and additives to keep the three
components in suspension. Such additives include: dye auxiliaries,
sequestrants, pH control agents, surfactants, fluoro-surfactants,
nano materials, odor control agents, antimicrobial agents,
fragrance agents, bleach resist agents, softeners, and UV
stabilizers.
[0024] By adjusting the conductivity of the aqueous dispersion, the
rate of dye reaction is retarded so that uniformity can be
obtained. In a typical 2 step process dye application is at 5-6 pH,
and the conductivity is not high (i.e. 265 micromhos). When fiber
is exposed to dye and stain blocker components that are mixed
together at lower pH dispersion, per this disclosure, they would
normally be expected to create an environment wherein dye will
strike very fast and result in non level dyeing. Surprisingly this
was not found to be the case. The higher conductivity however,
enables stain protection via stain blocker penetration of the fiber
adequately. Further, the higher conductivity of the disclosed
compositions allows for a relatively higher pH solution than would
typically be used for the individual components. The higher pH also
slows down the rate of dyeing, while the higher conductivity at the
higher pH facilitates the effective application of anti-soil and
stain blocker. Thus, it has been found that the pH and conductivity
can be adjusted to achieve an optimum balance between dye, stain
blocker, and anti-soil application.
[0025] Also disclosed is a method of applying the disclosed
compositions comprising the aqueous dispersion of the dye,
anti-soil component, and stain blocker to a fiber. The process
comprises contacting the fiber with the aqueous dispersion at a
temperature between about 20.degree. C. to about 40.degree. C.,
including between about 24.degree. C. to about 28.degree. C. After
contacting, the fiber is steamed for at least 60 seconds, including
from about 2 to about 3 minutes, followed by rinsing and drying the
fiber. Water can be removed from the fiber prior to drying using
conventional methods, such as suction, nip-rolling, centrifuge, and
convection. The steaming cycle to fix dye and stain blocker will be
at a steam temperature close to 100.degree. C. and the drying can
be performed at a temperature between about 130-135.degree. C. It
should be noted that the temperatures will be dependent on the line
speed, and specific type of equipment used. Optionally, the fiber
can be pre-heated or steamed prior to contacting the fiber with the
aqueous solution.
[0026] The fiber can be any type, including natural staple,
synthetic staple, or synthetic filament. Natural staple fibers
include wool. Synthetic fibers include polyamide, polyester, and
polyolefin. Examples of polyamides include: nylon 6,6, nylon 6,
nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and
blends thereof. Polyamide copolymers can also include
5-sulfosiophthalic acid, methylpentamethylenediamine, and
isophthalic acid moieties.
[0027] The fiber can be manufactured into various articles,
including carpets and fabrics either before or after contacting
said fiber with the aqueous solution. In other words, the disclosed
processes can be applied to the fiber prior to forming the article
or after forming the article. The process can further comprise,
prior to contacting the fiber with the aqueous dispersion, steam
heat setting the fiber at a temperature between about 118.degree.
C. to 145.degree. C. or optionally a dry heat set at a temperature
between about 145.degree. C. to 205.degree. C. The optional dry
heat set provides additional stain resistance.
[0028] The stain blockers have a range of molecular size and it is
theorized that the stain blocker during the steam fixation step
migrates to the interior. The extent of migration depends on the
steaming conditions and the molecular size of the stain blocker.
The durability of stain resistance to detergent washing, for
example, will depend on how much of the stain blocker is left on
the surface verses how much has penetrated the surface. The steam
fixing step after dyeing is usually longer and using this step for
steam fixing will more effectively drive the stain blocker into the
fiber and provide more durability compared to traditional steam
fixing post-stain blocker application. By suitable design of
molecular sizes, one can ensure more of the stain blocker stays on
the surface and less penetrates the surface. Such modification of
molecular sizes and types of stain blockers to further enhance the
tri-application process is contemplated by this disclosure. For
example, one of skill in the art can design a mixture of molecular
sizes for the stain blocker, that will ensure some larger molecules
stay on the surface and smaller molecules penetrate, thereby
offering not only improved initial stain resistance but also
durability of stain resistance. Additionally, the longer steam
fixing step provides for more durability of anti-soil chemistries,
since anti-soil components are typically non-water soluable.
[0029] Further disclosed is a method of applying a composition to a
fiber, where the composition comprises an aqueous dispersion
comprising a dye and a stain blocker.
[0030] The aqueous dispersion is kept at a conductivity between
about 2000 to about 9000 micromhos, including from about 4000 to
about 9000 micromhos, and about 4000 to about 7000 micromhos; and a
pH from about 1.5 to about 5, including about 2 to about 4 and
about 3 to about 5. As with the previously disclosed method, the
fiber is contacted with the aqueous solution, followed by steaming,
rinsing, drying, and optionally removing the water prior to drying.
Further, an anti-soil component, as discussed above, can be applied
after contacting the fiber with the aqueous solution. The anti-soil
component can be applied using numerous methods, such as spraying
or foaming. Also, as discussed above, the fiber can be manufactured
into an article before or after contacting the fiber with the
aqueous solution.
[0031] This method is especially applicable to those fibers that
have inherent anti-soil characteristics or in processes where the
specific anti-soil is most effectively applied by foaming of
spraying. Further, in some applications, the application of an
anti-soil component, such as a fluorochemical, may not be necessary
or desired. Such applications include non-allergen fabrics and
certain eco-friendly fabrics.
[0032] The disclosed processes effectively eliminates several steps
from the known fiber, carpet, and fabric treatment processes,
including multiple rinsing, washing, and steaming steps. The
process is surprisingly effective in that intermediately low pH
levels have been found effective for application of certain stain
resist chemistries when applied in the presence of acid dyes, while
certain combinations of stain and soil resist chemistry were found
to be surprisingly effective in moderating acid dye rate, so that
dyed fabrics were surprisingly uniform.
[0033] FIG. 1 depicts a known process of applying a dye, stain
blocker, and anti-soil component in three separate steps to a
carpet. The carpet is fed to pre-steamer 5, where it is pre-steamed
prior to entering the dyer 10. After dyeing, the carpet is fed to
main steamer 15, rinsed 20, and water is extracted in the extractor
25. Stain-block is applied in a flex-nip applicator 30, followed by
post-steaming 35. The carpet is then washed 40 and the water
extracted 45. Finally, anti-soil is applied via a spray applicator
50 and the carpet dried 55.
[0034] FIG. 2 depicts one aspect of the disclosed process as
applied to a carpet. The carpet is fed to a pre-steamer 105, where
it is pre-steamed prior to applying the disclosed composition 110.
After applying the dye, anti-soil, and stain blocker, the carpet is
fed to a main steamer 115, rinsed 120, and the water is extracted
in the extractor 125. Finally, the carpet is dried 130. Because the
anti-soil component and stain blocker go through a much longer
steam fixing cycle than known processes, the surface texture of the
carpet fiber will differ and the stain blocker penetrates deeper
into the carpet fiber.
[0035] The disclosed compositions and methods are beneficial to
almost any fabric treatment process where dyes, stain blockers, and
anti-soil components are employed, especially where dye and stain
resist can be placed in competition with one another for amine ends
(i.e. acid dye sites) in the dye bath. Articles to which the
disclosed compositions and methods are applicable include: textile
fabrics, rugs, carpets, furniture coverings, automotive upholstery,
draperies, and various other soft surfaces to which dyes and stain
blocking chemistries are both applied.
EXAMPLES
[0036] The following are examples of nylon carpets treated with
various aspects of the disclosed compositions compared to standard
treatments with separate components. Selection of alternative
anti-soil components, dyes, stain blockers, fibers, and textiles
having different surface chemistries will necessitate minor
adjustments to the variables herein described.
Test Methods
[0037] Stain Rating Method using AATCC 175 referenced and described
in U.S. Pat. Nos. 5,853,814 and 5,948,480. Stain Rating is on a
scale of 1 to 10, with 1 being the lowest stain resistance and 10
being the highest.
[0038] Shampoo test (wash durability) using WAQE test method
referenced and described in U.S. Pat. Nos. 5,853,814 and
5,948,480.
[0039] Conductivity measurement: Conductivity measurements were
taken with a Myron L Co. Ultrameter II model 6 Psi. Samples
including two Myron L KCI conductivity standards (700 and 7000
micromhos) were heated to approximately 25.degree. C. in a
laboratory oven. The conductivity instrument cell was rinsed 3
times with sample solution before taking sample measurements. Three
replications of each sample was measured and recorded when the
temperature range was at 24.9-25.2.degree. C.
Example 1
[0040] A control carpet sample was prepared as follows: Two 995
denier nylon 6,6 yarns (Fiber 995-476AS, a mild dull, medium acid
dyeable, fiber with wavy trilobal cross section available from
INVISTA) were twisted to 6 twists-per-inch and heat set via a
Superba heat set process at a temperature of 265.degree. F. with
residence time of 28 seconds and tufted into 1/8'' gage, 9/16''
pile height carpet with a weight of 45-46 ounces/square yard. The
carpet was then dyed using the dye mixture below to a wool beige
color. Stain blocker and anti-soil were not added. The control
carpet had an initial stain rating of 1, a stain rating of 1 after
1 WAQE wash and a stain rating of 1 after 3 WAQE washes.
[0041] Sample carpets were prepared similar to above, except that a
Suessen heat set at 195.degree. C., instead of Superba heat set,
was performed on the yarn for 60 seconds residence time.
[0042] A tri-component composition was prepared as follows: A
mixture of dyes (Yellow 3G, Red 2B, and Blue 4R to obtain a wool
beige color), stain blocker (s-801 from INVISTA) at 4%, and
anti-soil (Capstone RCP fluorochemical) at a concentration that
imparts a final fluorine OWF between 150-250 ppm was prepared at
room temperature. Also added to the mixture was a 40% wt/wt aqueous
magnesium salt mixture (10 grams of metal/liter) to adjust the pH
to about 2.1.
[0043] Table 1 below shows the results of applying dye, stain
blocker (SB), and anti-soil using the traditional method (Sample
1), and two aspects of the disclosed process using the
tri-component composition described above. (Samples 2 and 3). The
composition was applied at 80.degree. F.
TABLE-US-00001 TABLE 1 Initial SB and Stain Sample Description
level Anti-soil Rating 1 WAQE 3 WAQE 1 Dye, SB, and S-801 at
Capstone 10 10 10 anti-soil applied 4%, 2.1 pH RCP at separately
150 ppm OWF 2 Dye and SB S-801 at Capstone 10 10 9.5 applied
together, 4%, pH 2.1 RCP at anti-soil applied in 150 ppm subsequent
step OWF 3 Tri-component S-801 at Capstone 10 10 10 application as
4%, pH 2.1 RCP at described above. 150 ppm OWF
[0044] As shown above, the aspects of the disclosed process yield
excellent stain test results. It should also be noted that similar
tests without the magnesium sulfate and at pH of 3.5 yielded
similar results. Further, the dye uniformity and dye depth was
good, which is counter-intuitive, since the dyes should react
quickly with the acid dye sites at the 2.1 pH resulting in
non-uniform color.
Example 2
[0045] Sample carpets were prepared as discussed above, except that
the yarn was heat set in a Superba heat setting machine at
265.degree. F. , with a residence time of 28 seconds. The carpet
was treated on a range continuous dyer as described in Table 2
below. The dye was the wool beige color described above. The
carpets were tested for stain resistance. The tri-component
composition was prepared as above without the salt, with the
variations disclosed in Table 2. The stain blocker in all cases was
S-801 at 4.0% and 2.1 pH, unless otherwise stated. Samples 8 and 9
used MgSO.sub.4 in the concentrations disclosed above.
TABLE-US-00002 TABLE 2 Initial Stain 1 3 Conductivity Sample
Description Anti-soil Rating WAQE WAQE (micromhos) 1 Standard
separate Capstone 10 9 7.5 265 process RCP at 250 ppm OWF 2 Dye +
SB applied Capstone 9.5 7.5 7 4806 together RCP at 250 ppm OWF 3
Dye + SB applied Capstone 9 7 5.5 4721 together with RCP at DOWFAX
2A1 at 250 ppm 0.5% OWF 4 Dye + SB applied Capstone 9 7.5 6 4903
together with RCP at DOWFAX 2A1 at 1% 250 ppm OWF 5 Dye + SB
applied Capstone 7 5 4 3302 together with RCP at DOWFAX 2A1 at 1%
250 ppm applied at 4 pH OWF 6 Tri-component with Capstone 4 3 2
2740 DOWFAX 2A1 at RCP at 1.0% at 4 pH 250 ppm OWF 7 Tri-component
with Capstone 8 7 7 4556 DOWFAX 2A1 at RCP at 1.0% at 4 pH and 250
ppm MgSO.sub.4. OWF 8 Tri-component with Capstone 8 7 6 6560 DOWFAX
2A1 at RCP at 1.0% at 2 pH and 250 ppm MgSO.sub.4. OWF
[0046] As shown above in Samples 2-6, lower conductivities (i.e.
below 4000) affect the stain rating when applying the dye and stain
blocker separate from the anti-soil component. However, a
conductivity value around 2000 could be used with darker colors,
since they are not as sensitive to staining as the lighter colors.
With the tri-component application, the higher conductivity sample
(Sample 8) performed equally well to the medium conductivity sample
(Sample 7). With darker colors, a conductivity level of 2000 would
be acceptable for the reasons stated above.
[0047] The invention has been described above with reference to the
various aspects of the disclosed composition, treated fibers,
carpets, fabrics, and methods of making the same. Obvious
modifications and alterations will occur to others upon reading and
understanding the proceeding detailed description. It is intended
that the invention be construed as including all such modifications
and alterations insofar as they come within the scope of the
claims.
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