U.S. patent number 3,918,901 [Application Number 05/349,771] was granted by the patent office on 1975-11-11 for method for coloring fibrous material composed of phenolic resins.
This patent grant is currently assigned to Kaneko Ltd.. Invention is credited to Norio Endo, Syunya Ida.
United States Patent |
3,918,901 |
Ida , et al. |
November 11, 1975 |
**Please see images for:
( Certificate of Correction ) ** |
Method for coloring fibrous material composed of phenolic
resins
Abstract
A method for coloring fibers or fibrous structures composed of
phenolic resins, which comprises coloring the fibers or fibrous
structures using a dye liquor which contains as a dyeing assistant
at least one amide compound of the general formula ##EQU1## wherein
R, R' and R" are the same or different and each represent a
hydrogen atom, an alkyl group, a phenyl group, a benzyl group or a
phenetyl group, but R, R' and R" do not represent hydrogen atoms at
the same time.
Inventors: |
Ida; Syunya (Nara,
JA), Endo; Norio (Osaka, JA) |
Assignee: |
Kaneko Ltd. (Tokyo,
JA)
|
Family
ID: |
26377063 |
Appl.
No.: |
05/349,771 |
Filed: |
April 10, 1973 |
Foreign Application Priority Data
|
|
|
|
|
Apr 14, 1972 [JA] |
|
|
47-37897 |
Jun 19, 1972 [JA] |
|
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47-61622 |
|
Current U.S.
Class: |
8/535; 8/576;
8/582; 8/607; 8/617; 8/623; 8/635; 8/922; 8/552; 8/577; 8/586;
8/611; 8/618; 8/625; 8/920; 8/929 |
Current CPC
Class: |
D06P
1/90 (20130101); D06P 1/65106 (20130101); D06P
3/00 (20130101); D06P 1/67341 (20130101); D06P
1/928 (20130101); D06P 1/6495 (20130101); D06P
1/922 (20130101); D06P 1/6735 (20130101); Y10S
8/922 (20130101); Y10S 8/92 (20130101); Y10S
8/929 (20130101) |
Current International
Class: |
D06P
1/44 (20060101); D06P 3/00 (20060101); D06P
1/673 (20060101); D06P 1/649 (20060101); D06P
1/651 (20060101); D06P 1/92 (20060101); D06P
1/64 (20060101); D06P 1/00 (20060101); D06P
005/06 () |
Field of
Search: |
;8/4,169,172
;264/176F |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Bentley; Stephen C.
Assistant Examiner: Nelson; P. A.
Attorney, Agent or Firm: Sherman & Shalloway
Claims
What we claim is:
1. A method for coloring fibers or fibrous structures composed of
phenolic resins, which comprises coloring said fibers or fibrous
structures using a dye liquor which contains as a dyeing assistant
at least one amide compound of formula ##EQU6## wherein R, R' and
R" are the same or different and each represent a hydrogen atom, an
alkyl group, a phenyl group, a benzyl group or a phenetyl group,
but R, R' and R" do not represent hydrogen atoms at the same
time.
2. The method of claim 1 wherein the amount of the amide compound
is 3 to 50% by weight based on the total weight of the dye
liquor.
3. The method of claim 1 wherein said amide compound is selected
from compounds of formula (I) wherein R, R' and R" are the same or
different and each represents a hydrogen atom, an alkyl group
having 1 to 3 carbon atoms, a phenyl group and a benzyl group and
R, R' and R" do not represent hydrogen atoms at the same time.
4. The method of claim 3 wherein said amide compound is selected
from the group consisting of N,N-dimethyl formamide, N,N-dimethyl
acetamide, N,N-diethyl formamide, N,N-diethyl acetamide,
N,N-diphenyl formamide, N,N-diphenyl acetamide, methyl benzamide,
benzanilide, benzamide, acetanilide, ethyl benzamide and propyl
benzamide.
5. The method of claim 1 wherein said dye liquor contains at least
one metal sulfate
6. The method of claim 5 wherein the amount of said metal sulfate
is 3 to 35% by weight based on the total weight of the dye liquor
and the amount of amide compound is 3 to 10% by weight based on the
total amount of the dye liquor.
7. The method of claim 5 wherein said dye liquor is a printing
paste containing a dye.
8. The method of claim 5 wherein said metal sulfate is selected
from the group consisting of sodium sulfate, potassium sulfate,
beryllium sulfate, magnesium sulfate, aluminum sulfate, potassium
alum, chromium sulfate, chromium alum, ferrous sulfate, ferric
sulfate, ferrous ammonium sulfate, cobalt sulfate and nickel
sulfate.
9. The method of claim 1 wherein said dye liquor is in the form of
solution containing a dye.
10. The method of claim 9 wherein said dye is a disperse dye, azoic
dye, cationic dye or vat dye.
11. The method of claim 1 wherein dyeing is carried out by dip
dyeing, pad dyeing or printing method.
12. The method of claim 11 wherein said dip dyeing is carried out
at a bath temperature of 80.degree. to 140.degree.C.
13. The method of claim 11 wherein said pad dyeing is carried out
by padding a paste-like dye liquor on the phenolic fibers of
fibrous structures, and then steaming them for 10 to 60 minutes at
110.degree. to 140.degree.C.
14. The method of claim 7 wherein dyeing is carried out by printing
method by applying said paste-like dye liquor to the phenolic
fibers or fibrous structures, and then steaming them at 110.degree.
to 140.degree.C. for 10 to 50 minutes.
15. The method of claim 1 wherein said dye liquor further contains
at least one oxygen-containing compound selected from the group
consisting of alkanols having 3 to 5 carbon atoms, benzyl alcohol,
tetrahydrofurfuryl alcohol, dioxane, dialkyl ketones having 3 to 5
carbon atoms, cyclohexane and lower alkyl esters of formic acid and
acetic acid.
16. The method of claim 15 wherein the amount of said
oxygen-containing compound is 3 to 35% by weight based on the total
weight of the dye liquor, and the amount of said amide compound is
3 to 10% by weight based on the total amount of the dye liquor.
17. The method of claim 1 wherein said dye liquor further contains
both (i) at least one metal sulfate and (ii) at least one
oxygen-containing compound selected from the group consisting of
alkanols having 3 to 5 carbon atoms, benzyl alcohol,
tetrahydrofurfuryl alcohol, dioxane, dialkyl ketones having 3 to 5
carbon atoms, cyclohexanone and lower alkyl esters of formic acid
and acetic acid.
18. The method of claim 17 wherein the total amount of said metal
sulfate and the oxygen-containing compound is 3 to 35% by weight
based on the total weight of the dye liquor, and the amount of said
amide compound is 3 to 10% by weight based on the total amount of
the dye liquor.
19. The method for coloring fibers or fibrous structures composed
of phenolic resins, which comprises coloring said fibers of firbous
structures using a dye liquor which contains, as a dye assistant,
N,N-dimethyl formamide and benzyl alochol.
20. The method of claim 15 wherein said dye liquor is a printing
paste containing dye.
21. The method of claim 17 wherein said dye liquor is a printing
paste containing a dye.
22. The method of claim 20 wherein dyeing is carried out by
printing method by applying said paste-like dye liquor to the
phenolic fibers or fibrous structures, and then steaming them at
110.degree. to 140.degree.C. for 10 to 60 minutes.
23. The method of claim 21 wherein dyeing is carried out by
printing method by applying said paste-like dye liquor to the
phenolic fibers or fibrous structures, and then steaming them at
110.degree. to 140.degree.C. for 10 to 60 minutes.
Description
This invention relates to a method for coloring fibers or fibrous
structures prepared from phenolic resins. More specifically, this
invention relates to a method for uniformly coloring phenolic
fibers or their structures in deep colors with fastness
characteristics.
As is well known, fibers composed of phenolic resins (to be
referred to simply as phenolic fibers) have poor affinity with dyes
and extremely low dyeability for a variety of reasons such as their
compact fibrous structure, the lack of dye-affinitive groups, or
their high negative surface potential. It is very difficult
therefore to color phenolic fibers uniformly in deep fast
colors.
Other fibers having a compact fibrous structure and no
dye-affinitive groups, such as polyester fibers or polypropylene
fibers, are colored at a temperature as high as 110.degree. to
130.degree.C. using dyes having a small molecular volume, or using
a dye liquor containing a carrier material (swelling agent) such as
ortho-phenylphenol, chlorobenzene, a salicylic acid ester or a
benzoic acid ester in order to give satisfactory dyeings.
In contrast, the phenolic fibers can scarcely be colored
substantially even at 110.degree. to 130.degree.C. using a carrier
material such as those mentioned above, and it has been difficult
to provide colored phenolic fibers which are useful for practical
applications.
Certain kinds for such difficultly-dyeable synthetic fibers have
previously been colored, for example, by a method wherein a
substance having dye-affinitive groups, such as a polymer having a
free amino group, is incorporated in a spinning solution, and
fibers obtained by spinning this solution are dyed by conventional
methods, a method wherein a pigment is incorporated in a spinning
solution beforehand, and the spinning solution is spun to form
colored fibers, or a method wherein a pigment is fixed to the
surface of the fibers by a binder to color the fibers.
However, when such methods are used for coloring phenolic fibers,
the results are poor. For example, when a reagent (for example,
hydrazine) having a functional group capable of being bound to a
dye or an organic or inorganic pigment is added to a molten
prepolymer of the phenol type, and the mixture is spun and then
cured, the tenacity of the phenolic fibers after curing is markedly
reduced, or the desirable non-combustibility of phenolic fibers is
impaired. On the other hand, when the phenolic fibers are colored
by fixing a pigment to their surfaces using a binder, the resulting
colored fibers prove infeasible because of poor fastness
characteristics or harsh finish. In addition, many binders that can
be applied for this purpose impart combustibility to the phenolic
fibers, and thus hamper their most desirable property (i.e.,
non-combustibility).
Accordingly, the conventional methods for coloring synthetic fibers
have not proved satisfactory for dyeing phenolic fibers, and the
development of a dyeing method for the phenolic fibers which can
gain commercial acceptance with good results has been strongly
desired.
A primary object of this invention is to provide an improved method
for coloring fibers composed of phenolic resins and structures
formed from these fibers (to be referred to generically as phenolic
fibrous materials).
A secondary object of this invention is to provide a method for
uniformly coloring phenolic fibrous material in deep fast
colors.
Another object of this invention is to provide a method for
coloring phenolic fibrous materials that can be utilized
industrially.
Other objects and advantages of this invention will become apparent
from the following description.
According to this invention, there is provided a method for
coloring fibers or fibrous structures composed of phenolic resins,
which comprises dyeing the fibers or fibrous structures using a dye
bath containing as a dyeing assistant at least one amide compound
expressed by the following general formula ##EQU2## wherein R, R'
and R" are the same or different and each represent a hydrogen
atom, an alkyl group, a phenyl group, a benzyl group or a phenetyl
group, but R, R' and R" do not represent hydrogen atoms at the same
time. The term "coloring(or dyeing)", used in the present
specification and claims, denotes coloring in a broad sense, and
therefore, includes (a) the dip dyeing whereby a fibrous material
is dyed as dipped in a dye solution, (b) the pad dyeing whereby a
dye solution is padded on a fibrous material, and then the fibrous
material is heated, and (c) the printing whereby a printing paste
is applied to a fibrous material, and the material is then heated
to color the printed portions.
Accordingly, the dye liquor used in accordance with the process of
this invention may be in the form of a solution containing a dye
(especially in the case of dip dyeing) or a paste containing a dye
(pad dyeing and printing).
A typical composition of such a dye liquor is illustrated as
follows although the invention is not limited thereto.
______________________________________ Composition of the dye
liquor for dip dyeing and pad dyeing
______________________________________ Dye in an amount
corresponding to about 0.01 to about 30% by weight of the material
to be dyed Amide compound of formula (I) above in the amount to be
indicated below Viscosity Absent or present in a small regulator
amount Water the remainder Composition of the dye liquor for
printing ______________________________________ Dye in an amount
corresponding to about 5 to about 50% of the total weight of the
dye liquor Paste* in an amount corresponding to about 0.1 to about
10% of the total weight of the dye liquor Amide compound of formula
(I) above in the amount to be indicated below Water remainder
______________________________________ *Examples of the printing
paste include sodium alginate, tragacanth rubber, starch
hydroxyethyl cellulose, carboxymethyl cellulose, methyl cellulose,
carboxy methyl starch, gelatin, dextrin, British gum, polyviny
alcohol, kerosene, and 1,1,1-trichloroethane.
The term "fibers composed of phenolic resins (phenolic fibers)", as
referred to in the present specification and claims, denotes
uncured fibers formed by melt spinning, or wet spinning, etc. of a
prepolymer of the novolak or resol type prepared from a phenol
(e.g., phenol, cresol, xylenol, ethylphenol, phenylphenol,
amylphenol, bisphenol A, or resorcinol) and an aldehyde
(Formaldehyde, acetaldehyde, para-formaldehyde, hexamethylene
tetramine, furfural, glutaraldehyde, or glyoxal), or the cured
products thereof obtained by curing such uncured fibers with a
curing agent such as an aldehyde in the presence of an alkaline or
acidic catalyst.
Since the phenolic fibers can be produced by any known method, we
will not describe it here.
The phenolic fibers to be dyed by the method of this invention may
be composed of a phenolic resin alone, or a blend of a major
proportion of the phenolic resin with a minor proportion
(generally, 1-40% by weight) of another fiber-forming polymer. In
order, however, not to impair the incombustibility of the phenolic
resin, the amount of the fiber-forming polymer should be as small
as possible, preferably up to 30 % by weight, when the blend is
used, or the phenolic fibers should be composed solely of the
phenolic resin.
Specific examples of the fiber-forming polymer that can be used
include polyamide resins such as nylon 6, nylon 11, nylon 12, nylon
66, nylon 610, nylon 611, nylon 612, and blends of two or more of
these with each other; polyester resins such as polyethylene
terephthalate, polyesters derived from the same constituent
elements as polyethylene terephthalate with part of ethylene glycol
replaced by other known glycols, polyesters derived from the same
constituent elements as polyethylene terephthalate with the
terephthalic acid replaced by ortho- or metaphthalic acids, other
known aliphatic dicarboxylic acids or blends of two or more of
these with each other; polyester ethers such as polyethylene
hydroxybenzoate, and polyolefin resins such as polyethylene,
polypropylene, and ethylene-propylene copolymer, or blends of two
or more of these with each other.
The term "fibrous structures composed of phenolic resins", used in
the present specification and claims, denotes a fibrous product
such as a web, yarn, woven fabric, knitted fabric, non-woven
fabric, carpet, batt or laminated cloth composed of the phenolic
fibers alone or a composite of the phenolic fibers and other
natural, semi-synthetic or synthetic fibers.
Most of the dyes that are usually used in the dyeing of natural,
semi-synthetic or synthetic fibrous materials can be used in
accordance with the method of this invention for dyeing the
phenolic fibrous materials. For example, there are used, vat dyes,
azoic dyes, cationic dyes, disperse dyes, metal-containing dyes,
acid dyes, direct dyes, reactive dyes, and chrome dyes. Of these,
the azoic dyes, cationic dyes, disperse dyes and vat dyes have good
dyeability with regard to the phenolic fibers, and can be
conveniently used in the present invention. Typical examples of
these dyes are as follows:
1. Cationic dyes
Cationic dyes of the azo, diphenylmethane, triphenylmethane,
xanthene, acridine, quinoline, methine, thiazole, azine, thiazine,
and oxazine types. Specific examples are Sumiacryl Orange G (C.I.
Basic Orange 21), Sumiacryl Brilliant Red BB, Sumiacryl Red 6B
(C.I. Basic Violet 7), Sumiacryl Brown 3G (C.I. Basic Orange 30),
Sumiacryl Blue GG (C. I. Basic Blue 22), Diacryl Brilliant Pink R
(C.I. Basic Red 35), Diacryl Blue 2RL (C.I. Basic Blue 59), Diacryl
Green 2BL (C.I. Basic Green 77), and Diacryl Violet BRL (C.I. Basic
Violet 26).
2. Disperse dyes
Disperse dyes of the azo, anthraquinone, nitro, aminoquinone and
methine types. Specific examples are Dianix Fast Orange R-FS,
Dianix Fast Red B-FS, Dianix Red Brown R-FS, Kayalon Polyester
Violet BNF (C.I. Disperse Violet 30), Kayalon Polyester Pink BSF
(C.I. Disperse Red 55), Sumikalon Red FB (C.I. Disperse Red 60),
Sumikalon Blue R (C.I. Disperse Blue 71), and Sumikalon Dark Blue
RB (C.I. Disperse Blue 55).
3. Azoic dyes
As the azoic diazo component, there are C.I. Azoic Diazo Component
41, C.I. Azoic Diazo Component 48, C.I. Azoic Diazo Component 118,
C.I. Azoic Diazo Component 124, C.I. Azoic Diazo Component 125,
etc. As the azoic coupling component, there are C.I. Azoic Coupling
Component 8, C.I. Azoic Coupling Component 11, C.I. Azoic Coupling
Component 17, C.I. Azoic Coupling Component 35, etc. C.I. Azoic Red
79, C.I. Azoic Red 81, C.I. Azoic Blue 30, C.I. Azoic Green 1, and
C.I. Azoic Brown 15 are also used.
4. Vat dyes
Vat dyes of the antraquinone and indigozoyl types. Specific
examples are Caledon Orange Brown 2G (C.I. Vat Orange 14), Caledon
Red B (C.I. Vat Red 41), Mikethrene Violet FFBN (C.I. Vat Violet
13), Nihonthrene Dark Blue BO (C.I. Vat Blue 20), Caledon Olive OMW
(C.I. Vat Green 26), and Indanthrene Black Brown RV (C.I. Vat Brown
56).
The alkyl group represented by R, R' and R" in the general formula
(I) expressing the amide compound to be incorporated in the dye
liquor may be a straight-chain or branched chain alkyl group.
Preferably, it is a lower alkyl group, especially an alkyl group of
1 to 3 carbon atoms, that is a methyl, ethyl, n-propyl or i-propyl
group.
Examples of the amide compound include acetamide, acetomethyl
amide, acetoethyl amide, acetopropyl amide, form-methyl amide,
formethyl amide, formpropyl amide, formanilide, acetanilide,
N,N-dimethyl formamide, N,N'-diethyl formanilide, N,N-dipropyl
formamide, N,N-diphenyl formamide, N,N-dimethyl acetamide,
N,N-diethylacetamide, N,N-dipropyl acetamide, N,N-diphenyl
acetamide, benzamide, methylbenzamide, ethylbenzamide,
propionbenzamide, N,N-dimethylpropionylamide, N,N-diethylpropionyl
amide, N,N-diphenylpropionyl amide, N,N-dimethylbenzamide,
N,N-diethylbenzamide, N,N'-dipropylbenzamide,
N,N-diphenylbenzamide, propionamide, phenyl anilide, propionyl
anilide, butylamide, and butylanilide. These amide compounds may be
used alone or in admixture of two or more. Of these compounds,
N,N'.THETA. dimethylformamide, N,N'-dimethylacetamide, N,N-diethyl
formamide, N,N-diethylacetamide, N,N-diphenyl formamide,
N,N-diphenyl acetamide, methylbenzamide, benzamide, benzanilide,
acetanilide, ethylbenzamide, and propyl benzamide are preferred.
Especially useful amide compounds are N,N-diethylformamide,
N,N-dimethylacetamide and N,N-diethylacetamide.
The suitable concentration of the amide compound is generally from
3.0 to 50.0% based on the total weight of the dye liquor although
it may differ depending upon the type, form and amount of the
phenolic fibrous material to be colored. Preferably, the
concentration is 15.0 to 40.0% by weight. Within this concentration
range, the amide compound does not cause a deterioration in the
physical properties of the phenolic fibrous material, nor does it
pose any difficulty in dyeing operation. If the concentration of
the amide compound exceeds 50%, the diffusion of the compound into
the inner structure of the fibers is prevented because of its
extremely great ability to dissolve the dye, which in turn causes a
reduction in dyeability. Even if the dye is temporarily fixed to
the material, it tends to be dissolved, and the resulting dyeings
have only poor fastness characteristics. Furthermore, the amide
compound has a strong action of swelling the phenolic fibers, and
reduces the tenacity of the fibers. If, on the other hand, the
concentration of the amide compound is less than 3 % by weight, the
addition of the amide compound does not produce an improved dyeing
effect.
The procedure for dyeing the phenolic fibrous material in
accordance with the method of this invention does not differ from
the conventional methods. Thus, the fibrous material can be dyed by
the conventional dyeing method using a dye liquor containing a dye
in the concentration described above and if desired, using a size
such as tragacanth rubber or dextrin and a conventional
additive.
In a preferred embodiment of the method of this invention, the
suitable dyeing temperature (temperature of the dye bath) is
80.degree. to 140.degree.C., more preferably 100.degree. to
130.degree.C. when dip dyeing from an aqueous solution of a dye. If
the temperature is below 80.degree.C., the swelling action of the
phenol fibers is not sufficiently exhibited, and it becomes
difficult to dye them uniformly in deep colors. On the other hand,
if the temperature is higher than 140.degree.C., swelling occurs
excessively to cause a reduction in the tenacity of the phenolic
fibers or result in the decomposition of the amide compound.
When the pad dyeing process or printing process is utilized, a
solution or paste-like matter (printing paste) containing a dye and
the amide compound is padded on the material to be dyed or printed
thereon, and then the material is treated with steam. The
temperature of the steam is not critical, but preferably
110.degree. to 140.degree.C., more preferably 120.degree. to
130.degree.C. The steaming time is generally 10 minutes to 60
minutes.
The fibrous material so dyed is then washed, and dried. When a
disperse dye is used, the dyed material is washed by a conventional
method with an aqueous solution held at 60.degree.-80.degree.C.
containing hydrosulfite (0.5 to 2 g/l), soda ash (0.3-1 g/l) and a
nonionic surfactant (0.5-2 g/l) for about 20 to 30 minutes. When
the material is colored with other dyes, the dyed material is
desirably washed with an aqueous solution held at
60.degree.-80.degree.C. containing a nonionic surfactant (0.5 to
2g/l) for about 20 to 30 minutes. Since the amide compound
generally tends to remain on the dyed fibers as a result of
adsorption to it, it is essential to wash the material sufficiently
free of the amide compound. The amide compound is somewhat
flammable, and toxic to the skin, which results in a reduction in
the commercial value of the fibrous product.
The action of the amide compound on the phenolic fibers is not a
mere swelling action of a conventional carrier substance used in
the dyeing of synthetic fibers such as phenol, dichlorobenzene,
cresol or ethylene glycol, but also is an action of neutralizing
negative charge on the surface of the fibers, causing the dye to be
adsorbed to the fibers, and rendering it readily diffusible. Thus,
in conjunction with its swelling action, this neutralizing action
gives rise to an increased solubility of a dye or paste to give it
an effect of dyeing the material in deep fast colors. This is clear
from the fact that when a phenolic fibrous material is treated with
a dye bath containing a swelling agent such as phenol,
dichlorobenzene or cresol, it is not at all dyed. Furthermore, as
is well known, phenolic fibrous materials are difficult to dye
uniformly. However, in the present invention, the use of the amide
compound can lead to the removal of this defect, and give a uniform
dyeing.
In the conventional carrier dyeing of synthetic fibers, a surface
active agent is usually added in order to better the dispersibility
of the carrier and cause it to be adsorbed uniformly to the fibers.
According to the present invention, the use of such a surfactant
can be omitted, and even in the absence of the surfactant, it is
possible to dissolve and disperse a dye or paste uniformly by the
amide compound and promote the penetrability of the dye to provide
a dyeing of uniform deep color.
Furthermore, the adsorption and diffusion of the dye can be
promoted by the neutralization of negative charge on the surfaces
of the phenolic fibers which is caused by the action of the amide
compound. These derivatives cannot be expected from the
conventional technique of dyeing the phenolic fibers.
The improvement of the dyeability of the phenolic fibrous material
by the action of the amide compound of formula (I) is very
remarkable, and the method so improved is commercially acceptable
as such. The only difficultly with the amide compound is that the
dyed material must be thoroughly washed in order to remove the
amide compound completely from it.
We have however found that this difficulty can be overcome by
incorporating, together with the amide compound, (i) at least one
water-soluble metal sulfate, or (ii) at least one oxygen-containing
compound selected from the group consisting of alkanols having 3 to
5 carbon atoms, benzyl alcohol, tetrahydrofurfuryl alcohol,
dioxane, dialkyl ketones having 3 to 5 carbon atoms, cyclohexanone
and lower alkyl esters of formic acid and acetic acid, or both (i)
and (ii), in the dye liquor.
When the amide compound and the oxygen-containing compound is
present in the dye liquor, a number of remarkable commercial
advantages can be expected. For example, the diffusion of the dye
into the phenolic fibrous material and its dyeability are
remarkably improved by the synergistic effect of the amide compound
and the oxygen-containing compound, even if the concentration of
the amide compound is low. Also, there is a greatly reduced
tendency of the amide compound to be adsorbed to the surfaces of
the phenolic fibers. Therefore, by ordinary washing, the amide
compound can be completely removed.
Thus, according to another aspect of this invention, there is
provided a method for dyeing fibers composed of phenolic resins or
their fibrous structures which comprises dyeing said fibers or
fibrous structures using a dye liquor containing as a dyeing
assistant (A) at least one amide compound expressed by the general
formula ##EQU3## wherein R, R' and R" are the same or different and
each represent a hydrogen atom, an alkyl group, a phenyl group, a
benzyl group, or phenetyl group, but R, R' and R" do not represent
hydrogen atoms at the same time, and (B) (i) at least one
water-soluble metal sulfate, or (ii) at least one oxygen-containing
compound selected from the group consisting of alkanols having 3 to
5 carbon atoms, benzyl alcohol, tetrahydrofurfuryl alcohol,
dioxane, dialkyl ketones having 3 to 5 carbon atoms, cyclohexanone
and lower alkyl esters of formic acid and acetic acid, or both (i)
and (ii).
Any metal sulfates that are water-soluble can be used as component
(B) (i) described above, and its selection will be obvious to those
skilled in the art. Examples of the metal sulfates are sodium
sulfate, potassium sulfate, beryllium sulfate, magnesium sulfate,
aluminum sulfate, potassium alum (potassium aluminum sulfate),
chromium sulfate, chlorium alum, ferrous sulfate, ferric sulfate,
ferrous ammonium sulface, cobalt sulfate, and nickel sulfate.
Sodium sulfate, potassium sulfate and potassium alum are especially
preferred. These metal sulfates can be used either alone or in
admixture of two or more.
The metal sulfate can be incorporated in a concentration of 3.0 to
35.0 %, preferably 10.0 to 30.0%, based on the total weight of the
dye bath. If the concentration of the metal sulfate is in excess of
30.0%, it becomes difficult to dissolve in the dry liquor. If it is
less than 3.0%, the addition of the sulfate cannot be expected to
produce a dyeing effect, and moreover, the amide compound becomes
easier to adsorb to the surface of the phenolic fibers, in which
case the removal of the amide compound by washing is
time-consuming.
The alkanols having 3 to 5 carbon atoms to be used together with
the amide compound may, for example, be n-propanol, iso-propanol,
n-butanol, iso-butanol, sec-butanol, tert-butanol, n-amyl alcohol,
and sec.-amyl alcohol. Examples of the dialkyl ketones having 3 to
5 carbon atoms are acetone, methyl ethyl ketone, and diethyl
ketone. Examples of the lower alkyl esters of formic acid and
acetic acid are methyl formate, ethyl formate, propyl formate,
butyl formate, methyl acetate, ethyl acetate, propyl acetate, and
butyl acetate. Especially, n-propanol, n-butanol, benzyl alcohol,
dioxane and cyclohexanone are preferred.
The oxygen-containing compounds may be used alone or in admixture
of two or more. Preferably, the oxygen-containing compound is
miscible with the dye liquor. Thus, water-miscible
oxygen-containing compounds are conveniently used in the present
invention.
The oxygen-containing compound can be incorporated in the same
concentration as the metal sulfate, that is, in a concentration of
3.0 to 35.0 % by weight based on the total weight of the dye
liquor. Preferably, it is used in a concentration of 5.0 to 35.0 %
by weight based on the total weight of the dye liquor. If the
concentration of the oxygen-containing compound is lower than 3.0%
by weight, sufficient effects obtainable by its addition cannot be
expected. On the contrary, if it is higher than 30.0% by weight,
the solubility of the dye becomes exceedingly high, and the
diffusion of the dye into the fibers is prevented. This results in
a reduction in dyeability, and even if the fibers can be
temporarily dyed, the dye tends to bleed out. Furthermore, the
swelling action of the oxygen-containing compound becomes strong,
and causes a reduction of the tenacity of the fibers.
The metal sulfate and the oxygen-containing compound can be used
separately or in combination. When both of them are used at the
same time, the total amount of these compounds is 3.0 to 35.0% by
weight.
The greatest advantage of this embodiment is that the amount of the
amide compound which is difficult to remove by washing from the
phenolic fibrous material can be remarkably reduced. In this
embodiment of the invention, sufficiently improved dyeing effects
can be obtained even if the amide compound is present in an amount
as low as 3.0 to 10.0% by weight based on the total weight of the
dye liquor, although this amount is not critical. Preferably, the
concentration of the amide compound is 5.0 to 10.0% by weight.
In this embodiment wherein the metal sulfate or the
oxygen-containing compound or both are used together with the amide
compound, phenolic fibers can be colored in the same way as in the
case of using the amide compound alone in the dye liquor, that is,
by any of the dip dyeing, pad dyeing or printing process.
The action of the metal sulfate or the oxygen-containing compound
is not clear. But it is presumed that it is not a mere swelling
action of a conventional carrier substance, but serves to increase
the solubility of the dye and promote the diffusion of the dye. In
conjunction with the action of neutralizing negative charge on the
surfaces of the fibers which is exhibited by the amide compound,
these additional compounds can produce an effect of uniformly
coloring the phenolic fibers in deep fast colors. However, the
invention is in no way restricted by this presumption.
The amount of the amide compound can be markedly reduced by the
addition of the metal sulfate and/or the oxygen-containing
compound. Also, the adsorption of the amide compound to the fibers
can be prevented by these additional compounds, to render it easy
to remove the amide compound by washing.
According to the method of this invention, the phenolic fiberous
materials heretofore considered difficult to dye can be colored
uniformly in deep colors, and the dyeings have marked fastness
characteristics. Furthermore, this method does not result in
impairing the desirable incombustibility of the phenolic
fibers.
The method of this invention is very advantageous commercially,
because no additional step of dyeing is required.
The following Examples will illustrate the present invention
further. Unless otherwise specified, all percentages are by
weight.
The dye exhaustion shown in the Examples was determined by the
following equation. ##EQU4## wherein A is the concentration in g/l
of the dye in the dye solution before dyeing and B is the
concentration in g/l of the dye after dyeing.
The dyeability (K/S) was determined by the Kubelka-Munk equation
shown below. ##EQU5## where R is the reflectance of the sample
dyeing.
The fastness to laundering was measured in accordance with
JIS-L-1045, the fastness to rubbing in accordance with JIS-L-1048,
and the fastness to light in accordance with JIS-L-1044.
The carbonized length was measured in accordance with the vertical
method (JIS-L-1004) whereby the test cloth was maintained
perpendicular and flames were caused to come in contact with the
test cloth using a Bunsen burner for 12 seconds, and then the
length of the carbonized portion of the test cloth was
measured.
The presence of the amide compound remaining in the dyeing was
examined by infrared absorption spectrum.
EXAMPLE 1
A plain weave fabric made up of single yarns of phenolic filaments
obtained by melt-spinning a novolak type phenolic resin and
thereafter curing with formaldehyde was dyed with the following dye
solution.
______________________________________ Artisil Violet 2RP (Color
Index Number Disperse 1) 25% (o.w.f.) N,N'-diethylacetamide 30%
(based on dye bath weight) Amount of dye solution: 100-fold the
weight of material dyed. ______________________________________
The fabric was dipped in the dye bath, and the dyeing was started
at 40.degree.C., the temperature being raised to 130.degree.C.
during a period of 30 minutes, where the dyeing was carried out for
60 minutes. The fabric was then washed with water and thereafter
treated for 20 minutes at 80.degree.C. with a reducing wash liquid
consisting of 1 gram per liter of hydrosulfate, 1 gram per liter of
soda ash, 1 gram per liter of Noigen HC (a nonionic surfactant
produced by Daiichi Kogyo Seiyaku Co., Japan) and water, followed
by water-washing and drying. The so obtained dyed fabric was dyed
to a deep shade of purple. The dye exhaustion was 69.8%.
Next, dyeings were carried out under identical conditions as
hereinabove indicated, using dye baths prepared in same manner,
except that the content of N,N-diethylacetamide was varied as
indicated in Table 1. The results obtained are shown in Table
1.
Table 1 ______________________________________ No. Content of amide
type compound Dye exhaus- tion (%)
______________________________________ 1 N,N'-diethylacetamide 0 %
0 2 " 3 % 0 3 " 5 % 10.0 4 " 10 % 12.8 5 " 15 % 40.8 6 " 20 % 60.8
7 " 25 % 69.8 8 " 30 % 67.2 9 " 40 % 36.5 10 " 50 % 10.1 11 " 60 %
3.1 ______________________________________
As is apparent from the foregoing results, dyed products dyed
evenly to a deep shade were obtained when the content of the
N,N'-diethylacetamide was above 5 %. On the other hand, when the
amount added was less than 5 % or in excess of 50 %, a marked
decline in the rate of dye exhaustion was demonstrated.
Further, the ratings of colorfastness to light, laundering and
crocking were respectively Classes 4, 4 and 5.
EXAMPLE 2 A top consisting of the same phenolic filaments as in
Example 1 was dyed with the following dye solution.
______________________________________ Terasil Navy Blue - GRL
(disperse dye produced by Ciba Company) 15 % (based on weight of
material dyed) N,N'-dimethylacetamide 25 % (based on the dye bath
weight) Amount of dye solution: 20-fold the weight of material
dyed. ______________________________________
The top was dipped in the dye bath, and the dyeing was started at
30.degree.C., after which the temperature was raised to
120.degree.C. during a period of 30 minutes, where the dyeing was
carried out for 90 minutes followed by water-washing. The top was
then treated for 20 minutes at 80.degree.C. with a reducing wash
liquid consisting of 1 gram per liter of hydrosulfite, 0.5 gram per
liter of soda ash, 1 gram per liter of a nonionic surfactant and
water, after which the top was water-washed and dried. The so
obtained dyed product was dyed to a deep shade of blue, and the dye
exhaustion was 90.5 %.
The foregoing experiment was repeated for comparison of the
instance when the N,N'-dimethylacetamide was not added and the
instance where phenol, benzyl alcohol or metadichlorobenzene was
added instead of N,N'-dimethylacetamide. The results obtained are
shown in Table 2.
Table 2 ______________________________________ Dye exhaus- No.
Additve (%) tion (%) ______________________________________ 1
N,N'-dimethylacetamide 25 % 90.5 2 not added 0 % 0 3 phenol 20 %
2.0 4 benzyl alcohol 20 % 3.1 5 metadichlorobenzene 20 % 0
______________________________________
As can be seen from the foregoing results, a dyed product dyed
evenly to a deep shade was obtained when N,N'-dimethylacetamide was
added, but in the case where the N,N'-dimethylacetamide was not
added dyeing was not possible. Further, even though a carrier such
as phenol, benzyl alcohol or metadichlorobenzene was added, the dye
uptake was either nil or small. From this results, it can be seen
that the effect of the amide type compound, as used in the present
invention, is not that merely of a carrier.
Further, the ratings of colorfastness to light, laundering and
crocking were respectively Classes 4, 4 and 5.
EXAMPLE 3
A knit fabric made up the phenolic filaments of Example 1 was dyed
in a dye bath of the following composition.
______________________________________ Terasil Brilliant Pink 2Gl
(disperse dye produced by Ciba Company) 30 % (o.w.f.)
N,N'-dimethylformamide 27 % (based on the dye bath weight) Amount
of dye solution: 60-fold the weight of fabric dyed.
______________________________________
The fabric was dipped in the dye bath, and the dyeing was started
at 40.degree.C., after which the temperature was raised up to
100.degree.C. during a period of 30 minutes, where the dyeing was
continued for 60 minutes. The fabric was then water-washed and
thereafter treated for 20 minutes at 80.degree.C. in a reducing
wash bath consisting of 1 gram per liter of hydrosulfite, 1 gram
per liter of soda ash, 1 gram per liter of a nonionic surfactant
and water, followed by water-washing and drying. The so obtained
dyed fabric was dyed to a red shade.
The experiment was carried out by operating in the same manner as
described above but without adding N,N'-dimethylformamide or adding
formaldehyde instead of N,N'-dimethylformamide. The results
obtained are shown in Table 3.
Table 3 ______________________________________ Dye exhaus- No.
Additive (%) tion (%) ______________________________________ 1
N,N'-dimethylformamide 27 % 69.8 2 not added 0 % 0 3 formaldehyde
10 % 0 4 " 20 % 2.0 5 " 30 % 2.5
______________________________________
As is apparent from the foregoing results, the material to be dyed
could be dyed evenly to a deep shade when the
N,N'-dimethylformamide was added but could not be dyed at all when
it was not added. On the other hand, when formaldehyde was used
instead of N,N'-dimethylformamide, either the material was not dyed
at all or only slightly dyed at the several concentrations in which
the formaldehyde was used.
EXAMPLE 4
A curtain material made up of the same phenolic yarn as that of
Example 1 was dyed in a dye solution of the following
composition.
______________________________________ Sumiacryl Blue E-6G
(cationic dye produced by Sumitomo Chemical Co.) 15 % (o.w.f.)
Acetanilide 20 % (based on the dye bath weight) Amount of dye
solution: 50-fold the weight of material dyed.
______________________________________
After starting the dyeing at 40.degree.C., the temperature was
raised up to 125.degree.C. during a period of 30 minutes, and then
the dyeing was continued for 60 minutes at this temperature. The
dyed material was then water-washed and thereafter washed for 20
minutes at 80.degree.C. in a wash liquid consisting of an aqueous
solution of 1 gram per liter of a nonionic surfactant. This was
followed by water-washing and drying the material. The so obtained
dyed fabric was dyed a blue shade.
The experiment was carried out by operating in the same manner as
described above but using instead of the acetanilide either
N,N'-diphenylformamide, N,N'-diphenylacetamide, methylbenzamide,
N,N'-diethylformamide or N,N'-dimethylbenzamide. The results
obtained are shown in Table 4.
Table 4 ______________________________________ No. Additive (%) Dye
exhaustion (%) ______________________________________ 1 acetanilide
20 87.5 2 N,N'-diphenylformamide 20 86.0 3 N,N'-diphenylacetamide
20 79.6 4 methylbenzamide 20 82.1 5 N,N'-diethylformamide 20 72.5 6
N,N'-dimethylbenzamide 20 81.5 7 not added 0 0
______________________________________
As is apparent from the foregoing results, it was possible to
accomplish the dyeing to a deep shade and moreover evenly when
either acetanilide, N,N'-diphenylformamide, N,N'-diphenylacetamide,
methylbenzamide, N,N'-diethylformamide or N,N'-dimethylbenzamide
was added.
EXAMPLE 5
A 2-ply weaving yarn consisting of the phenolic filaments of
Example 1 was dyed with a dye solution of the following
composition.
______________________________________ TD Black B2S (diazo
component produced by Daito Chemical Co., 20 % (based on weight
Japan) of material dyed) TD 1200 - 2S (coupling component 30 %
(based on weight produced by Daito Chemical Co.) of material dyed)
Benzamilide 30 % (based on weight of dye bath) Amount of dye
solution: 20-fold the weight of material dyed.
______________________________________
After starting the dyeing at 30.degree.C., the temperature was
raised to 115.degree.C. during a period of 20 minutes, at which
temperature the dyeing was continued for 90 minutes and followed by
washing the dyed yarn in water and then in hot water. The yarn was
then developed by diazotizing for 30 minutes at 100.degree.C. in a
diazotizing coupling bath consisting of 10 % (based on weight of
material dyed) of sulfuric acid and 9 % (based on weight of
material dyed) of sodium nitrite, after which the yarn was
water-washed and dried. The so obtained dyed product was dyed to a
deep shade of black.
The foregoing procedure was repeated except that either benzamide,
methyl benzamide, ethyl benzamide, propyl benzamide,
N,N'-diethylbenzamide, N,N'-dipropylbenzamide was added instead of
benzanilide, with the results shown in Table 5.
Table 5 ______________________________________ No. Additive (%) Dye
exhaustion (%) ______________________________________ 1 benzanilide
30 76.5 2 benzamide 30 68.9 3 methylbenzamide 30 72.8 4
ethylbenzamide 30 69.5 5 propylbenzamide 30 43.8 6
N,N'-diethylbenzamide 30 60.5 7 N,N'-dipropylbenzamide 52.1 8 not
added 0 0 ______________________________________
As can be seen from the foregoing results, the yarn was dyed to a
deep shade when either benzanilide, benzamide, methylbenzamide,
ethylbenzamide, propylbenzamide, N,N'-diethylbenzamide or
N,N'-dipropylbenzamide was added.
EXAMPLE 6
A tweed made up of 2-ply yarn of the phenolic filaments of Example
1 was dyed with a dye bath of the following composition.
______________________________________ Foron Black S-2BL (disperse
dye produced by Sandoz Company) 17 % (o.w.f.) Acetoethylamide 22 %
(based on weight of dye bath) Amount of dye bath: 150-fold the
weight of material dyed. ______________________________________
After starting the dyeing at 20.degree.C., the temperature was
raised up to 100.degree.C. during a period of 60 minutes followed
by washing the dyed material in water. The dyed fabric was then
submitted to a reductive washing for 20 minutes at 80.degree.C. in
a reduction wash bath consisting of 1 gram per liter of
hydrosulfite, 0.5 gram per liter of soda ash, 1 gram per liter of
Noigen HC (nonionic surfactant) and water followed by water-washing
and drying. The so obtained dyed fabric was dyed to deep shade of
black tinged with blue.
The foregoing experiment was repeated except that either
acetopropylamide or acetonilide was added instead of the
acetoethylamide. The results obtained are shown in Table 6.
Table 6 ______________________________________ No. Additive (%) Dye
exhaustion (%) ______________________________________ 1 not added 0
2 acetoethylamide 22 75.6 3 acetopropylamide 20 68.5 4 acetoanilide
20 70.1 ______________________________________
As is apparent from the foregoing results, the fabric was dyed to a
deep shade as well as evenly when either acetoethylamide,
acetopropylamide or acetoanilide was added.
EXAMPLE 7
A twill fabric made up 2-ply yarn of the phenolic filaments of
Example 1 was printed with a printing paste of the following
composition and thereafter submitted to a steaming treatment.
______________________________________ Dianix Black 2GSE (disperse
dye produced by Mitsubishi Chemical Co.) 300 grams
N,N'-dimethylacetamide 200 grams Duckalgine (sodium alginate size
produced by Kamogawa Chemical Co., 50 grams Japan) Water 450 grams
Viscosity 5200 centipoises
______________________________________
After carrying out the printing of the printing paste by means of
the screen printing technique, the fabric was immediately steamed
for 30 minutes at 130.degree.C. and then water-washed. This was
followed by washing the fabric for 20 minutes at 80.degree.C. in an
aqueous solution of 1 gram per liter of a nonionic surfactant,
after which it was washed with water and dried.
By way of comparison, the experiment was repeated but without
adding the N,N'-dimethylacetamide. The results obtained are shown
in Table 7.
Table 7 ______________________________________ No. Additives (%)
Dye exhaustion (%) ______________________________________ 1 not
added 0 2 N,N'-dimethylacetamide 61.5
______________________________________
As is apparent from the foregoing results, a printed product dyed
to a deep shade was obtained when the N,N'-dimethylacetamide was
added but was not dyed at all when it was not added.
EXAMPLE 8
A plain weave fabric comprising fibers obtained by melt-spinning a
novolak type phenolic resin and thereafter curing with formaldehyde
was dyed with a dye solution of the following composition.
______________________________________ Sumikalon Violet R (C.I.
Disperse Violet 22) 20 % (o.w.f.) N,N'-dimethylformamide added in
an amount as previously indicated. (based on weight of dye bath)
Sodium sulfate added in amounts indicated in Table 8. Amount of dye
solution: 50-fold the weight of material dyed.
______________________________________
The material to be dyed was dipped in the dye bath, and its dyeing
was started at a temperature of 40.degree.C., after which the
temperature was raised up to 130.degree.C. during a period of 30
minutes, at which temperature the dyeing was continued for 60
minutes. The material was then waterwashed and thereafter submitted
to a reductive washing for 20 minutes at 80.degree.C. in a
reduction wash liquid consisting of 1 gram per liter of
hydrosulfite, 1 gram per liter of said ash, 1 gram per liter of
"Noigen" HC and water followed by water-washing and drying. The
results obtained are shown in Table 8.
Table 8
__________________________________________________________________________
Additive Dye Length of Residual No. N,N'- sodium exhaustion
carboni- N,N'-dimethyl- dimethyl- sulfate zation formamide
formamide (%) (%) (cm)
__________________________________________________________________________
1 10 0 10.2 16.2 no 2 10 3 35.6 16.2 no 3 10 10 44.8 16.0 no 4 10
20 52.2 16.3 no 5 10 30 54.9 16.2 no 6 10 50 11.8 16.2 no 7 0 30 0
16.0 no 8 2 30 5.8 16.0 no 9 20 30 58.7 19.1 yes 10 20 0 53.5 20.0
yes 11 not added 0 15.8 no 12 not dyed -- 13.2 no
__________________________________________________________________________
As is apparent from the results of the dye exhaustion measurements
shown in Table 8, the dye exhaustion is exceedingly small when
sodium sulfate is not added to the dye solution containing 10 % of
N,N'-dimethylformamide but becomes increasingly greater as the
sodium sulfate is added in increasingly greater amounts of 3 %, 10
%, 20 % and 30 %.
However, the addition of the sodium sulfate in an amount of 50 % is
not to be desired, for difficulty is experienced in its dissolution
and moreover the rate of dye exhaustion drops. Thus, even in the
case of a 10 % N,N'-dimethylformamide solution, dyeing effects
equal to the case where a 20 % N,N'-dimethylformamide solution has
been used can be obtained by the addition of 10-30 % of sodium
sulfate. Further, from the fact that no dye exhaustion effects are
demonstrated when the dyeing is conducted with the use of the N,N'
-dimethylformamide in an amount of 10 % or the sodium sulfate in an
amount of 30 % independently of each other, the synergistic effects
due to the conjoint use of these two components are obvious.
On the other hand, when the length of carbonization resulting from
burning was measured, the fabric dyed in accordance with the
invention method demonstrated a length of carbonization of the same
degree as that of the undyed fabric. It is thus clear that the
fabric dyed according to the invention method possesses fire
resistance.
The colorfastness ratings to light, laundering and crocking were
respectively Classes 3-4, 4 and 5.
EXAMPLE 9
A 2-ply yarn consisting of filaments obtained by melt-spinning a
novolak type phenolic resin and thereafter curing with formaldehyde
was dyed with a dye solution of the following composition.
Sumikalon Violet R (C.I.: 20 % (based on weight of Disperse Violet
22 material dyed) N,N'-diethylformamide 8 % (based on weight of dye
bath) Water-soluble metal sulfate 20 % (based on weight of
indicated in Table 9 dye bath)
The material to be dyed was dipped in each of the dye solutions
containing the several salts, and the dyeing of the material was
carried out by starting the dyeing at 40.degree.C., after which the
temperature was raised up to 130.degree.C. during a period of 30
minutes, at which temperature the dyeing was continued for a
further 60 minutes. The dyed material was then washed in water and
thereafter submitted to a reductive washing for 20 minutes at
80.degree.C. in a solution consisting of 1 gram per liter of
hydrosulfite, 1 gram per liter of soda ash, 1 gram per liter of a
nonionic surfactant and water followed by water-washing and drying.
The dyeing and reductive washing were carried out in liquids
amounting to 50-fold the weight of the material treated. The
results of these dyeings are shown in Table 9.
Table 9
__________________________________________________________________________
Additive Dye Residual No. N,N'-diethyl- Sulfates Amount exhaustion
N,N'-diethyl- formamide added formamide (%) (%) (%)
__________________________________________________________________________
1 8 sodium sulfate 20 54.7 no 2 8 potassium sulfate 20 51.7 no 3 8
magnesium sulfate 20 54.7 no 4 8 aluminum sulfate 20 48.4 no 5 8
cobalt sulfate 20 38.5 no 6 8 nickel sulfate 20 35.8 no 7 8
potassium alum 20 45.6 no 8 8 -- -- 8.6 yes 9 20 -- -- 40.5 yes
__________________________________________________________________________
As is apparent from the foregoing results, whereas there is
practically no dye exhaustion when only 8 % of
N,N'-diethylformamide is contained in the dye solution, a marked
improvement is demonstrated when 20 % of the various salts are used
conjointly in the dye solution with 8 % of N,N'-dimethylformamide,
an even higher rate of dye exhaustion than in the case of a dye
solution containing 20 % of N,N'-diemthylformamide being
demonstrated especially when either sodium sulfate, potassium
sulfate, magnesium sulfate, potassium aluminum sulfate or potassium
alum is added. Again, a rate of dye exhaustion of about the same
degree is demonstrated when cobalt sulfate or nickel sulfate is
used. Further, the concentration (amount used) of the N,N'
-diethylformamide can be greatly reduced by about one-half or more.
In addition, the defect that the flame spreads during burning due
to the adhesion of the amide compound is also improved.
EXAMPLE 10
A tweed fabric made up of 2-ply yarn consisting of the phenolic
filaments of Example 8 was dipped in a dye solution consisting of
20 % (o.w.f.) of Sumikalon Blue GR (CI: Disperse Blue 55 produced
by Sumitomo Chemical Company), 10 % (based on weight of dye
solution) of methylbenzamide, and 20 % (based on weight of dye
solution) of a salt indicated in Table 10. The dyeing was started
at 40.degree.C., and the temperature was raised up to 110.degree.C.
during a period of 30 minutes, at which temperature the dyeing was
continued for a further 90 minutes. The so dyed fabric was then
washed in water and thereafter submitted to a reductive washing for
20 minutes at 80.degree.C. in a solution consisting of 1 gram per
liter of hydrosulfite, 1 gram per liter of soda ash, 1 gram per
liter of a nonionic surfactant and water followed by water-washing
and drying. The dyeing and reductive washing were carried out in
liquids amounting to 50-fold the weight of the material treated.
The results obtained are shown in Table 10.
Table 10
__________________________________________________________________________
Additive Dye Length of Methyl- Amount Exhaus- Residual carboni-
benzamide added tion methyl- zation No. (%) Salt added (%) (%)
benzamide (cm)
__________________________________________________________________________
1 10 -- 3.8 No. 12.1 2 10 sodium 20 52.5 No 10.5 sulfate 3 10
sodium 20 2.7 No 10.5 acetate 4 10 sodium 20 3.2 No 10.6 carbonate
5 10 sodium 20 2.9 No 10.6 phosphate 6 10 lead acetate 20 3.7 No
10.7 7 10 magnesium 20 4.4 No 10.8 chloride 8 undyed -- -- 0 No
10.2 fabric 9 20 -- -- 50.1 Yes 12.5
__________________________________________________________________________
As is apparent from the foregoing results, a marked improvement in
the rate of dye exhaustion is noted when 10 % of methylbenzamide
and 20 % of sodium sulfate are conjointly used, the rate being
equivalent to that were the methylbenzamide is used alone in an
amount of 20 %. However, in the case of the salts other than
sulfate, such, as for example, sodium acetate, sodium carbonate,
sodium phosphate, lead acetate and magnesium chloride, the rate of
dye exhaustion is exceedingly low and hence is of no practical use.
Thus, it can be seen that the effectiveness of the conjoint use of
a salt is only possible in the case where a sulfate is used, its
effects being obvious from the above results.
EXAMPLE 11
A curtain material made up of single yarns consisting of the
phenolic resin of Example 8 was dipped in a dye solution consisting
of 30 % of Diacryl Pink FG (cationic dye produced by Mitsubishi
Chemical Company), 8 % of N,N'-dimethylformamide, 25 % of sodium
sulfate, 1 % of sodium cetyl sulfate (penetrant) and 36 % of water
and, after padding, was rolled up and immediately steamed for 60
minutes at 120.degree.C. This was followed by washing the material
in water and thereafter washing it for 20 minutes in a wash liquid
(80.degree.C.) consisting of an aqueous solution of 1 gram per
liter of a nonionic surfactant followed by water-washing and
drying. By way of comparison, the foregoing experiment was
repeated. In one case the experiment was carried out without adding
the N,N'-dimethylformamide; in another case, without adding the
sodium sulfate; and in still another case, without adding either of
these components. The results obtained are shown in Table 11.
Table 11
__________________________________________________________________________
Length of Residual Dye- carboni- N,N'-dimethyl- ability zation
formamide No. Additive (K/S) (cm)
__________________________________________________________________________
The case where N,N'- 1 dimethylformamide 0.23 16.0 No and sodium
sulfate were not added 2 Invention method 12.91 16.0 No The case
where only 3 N,N'-dimethylform- 0.35 16.0 No amide was not added
The case where only 4 sodium sulfate was 0.59 17.5 Yes not added
__________________________________________________________________________
As is apparent from the foregoing results, the material was dyed to
a deep shade and moreover evenly when conjoint use was made of the
N,N' -dimethylformamide and sodium sulfate (invention method).
However, in the case where N,N'-dimethylformamide was not added or
where sodium sulfate was not added, there was substantially no dye
uptake. Further, in the combustion test, the length of
carbonization of the dyed product according to the invention method
was short as in the case where the dyeing was carried out without
adding the other components, thus demonstrating the fire resistance
possessed by the product dyed according to the invention
method.
EXAMPLE 12
A knit fabric made up of single yarns of the phenolic filaments of
Example 8 was printed by means of the screen printing technique
with a printing paste consisting of 30 % of Dianix Fast Dark Green
B (disperse dye produced by Mitsubishi Chemical Co.), 10 % of
acetanilide, 10 % of potassium sulfate, 5 % of propyl alginate
(thickener) and 45 % of water and having a viscosity of 6000
centipoises, after which the fabric was immediately steamed for 40
minutes at 130.degree.C. The fabric was then washed in water and
thereafter washed for 20 minutes in a wash liquid consisting of an
aqueous solution containing 1 gram per liter of hydrosulfite, 0.5
gram per liter of soda ash and 1 gram per liter of a nonionic
surfactant followed by water-washing and drying.
The foregoing experiment was repeated but without adding the
acetanilide or potassium sulfate. The results are shown in Table
12.
Table 12 ______________________________________ Length of Resi-
Dye- carboni- dual ability zation acetan- No. Additive (K/S) (cm)
ilide ______________________________________ The case where acet- 1
anilide and potassium 0.23 17.2 No sulfate were not added 2
Invention method 11.52 17.2 No The case where only 3 acetanilide
was not 0.37 17.2 No added The case where only 4 potassium sulfate
0.48 18.2 Yes was not added
______________________________________
It can be seen from the foregoing results that a printed product
having beautiful clear-cut patterns of green was obtained when
conjoint use of acetanilide and potassium sulfate was made but that
in the case where the acetanilide was not added or the potassium
sulfate was not added there was substantially no dye uptake.
Further, there was no change in the length of carbonization in
either of the cases.
EXAMPLE 13
A plain weave fabric made up of yarns obtained by melt-spinning a
novolak type phenolic resin and thereafter curing with formaldehyde
was dyed with a dye solution of the following composition.
______________________________________ Dianix Brilliant Red BS-E 12
% (disperse dye produced by Mitsubishi Chemical CO.)
N,N'-dimethylformamide added in an amount indicated in Table 13
(based on weight of dye solution) Benzyl alcohol added in an amount
indicated in Table 13 (based on weight of dye solution) Amount of
dye solution: 50-fold the weight of material dyed.
______________________________________
The material to be dyed was dipped in the dye bath, and the dyeing
was started at 40.degree.C., after which the temperature was raised
up to 130.degree.C. during a period of 30 minutes. The dyeing was
continued for a further 60 minutes at this temperature. This was
followed by washing the material in water and thereafter submitting
the material to a reductive washing for 20 minutes at 80.degree.C.
with a reduction wash liquid consisting of 1 gram per liter of
hydrosulfate, 1 gram per liter of soda ash, 1 gram per liter of a
nonionic surfactant and water followed by water-washing and drying.
The results obtained are shown in Table 13.
Table 13 ______________________________________ Additive and
concentration thereof Dye Residual N,N'-dimethyl- benzyl Exhaus-
N,N'-dimethyl- No. formamide (%) alcohol tion formamide (%) (%)
______________________________________ 1 0 3 3.5 No 2 0 10 35.1 " 3
0 30 7.2 " 4 0 50 7.5 " 5 3 0 0 " 6 3 3 8.9 " 7 3 10 36.2 " 8 3 30
8.1 " 9 3 50 7.5 " 10 5 0 11.5 " 11 5 3 41.5 " 12 5 5 53.6 " 13 5
10 56.7 " 14 5 30 26.8 " 15 5 50 10.8 " 16 10 0 15.1 " 17 10 1 16.2
" 18 10 3 39.8 " 19 10 5 89.9 " 20 10 10 92.5 21 10 30 21.1 " 22 10
50 12.0 " 23 50 0 11.5 Yes 24 50 3 12.1 " 25 50 5 13.1 " 26 50 10
9.6 " 27 50 30 7.5 " 28 50 50 0 29 60 0 9.1 " 30 60 3 6.0 " 31 60 5
4.5 " 32 60 10 3.2 " 33 60 30 0 " 34 not added 2.1 No
______________________________________
As is apparent from the foregoing results, an adequate dye uptake
cannot be achieved when the content of the N,N'-dimethylformamide
is less than 3 %. On the other hand, when the content of
N,N'-dimethylformamide exceeds 50 %, the dye uptake is likewise
low. Further, there arises the necessity for more thorough washing,
since the N,N'-dimethylformamide remains behind. On the other hand,
when benzyl alcohol is conjointly used the range of 5-30 % under
the conditions of no residual N,N'-dimethylformamide, a marked
improvement is noted in the rate of dye exhaustion, whereas if the
benzyl alcohol is used in an amount less than 3 % of in excess of
50 %, no dye uptake effects are demonstrated.
EXAMPLE 14
A 2-ply yarn consisting of filaments obtained by melt-spinning a
novolak type phenolic resin and thereafter curing with formaldehyde
was dyed with a dye solution of the following composition.
______________________________________ Kayalon Polyester Dark 20 %
(based on Brown TSF (disperse weight of yarn) dye produced by
Nippon Kayaku Co.) N,N'-dimethylacetamide amount added as indicated
in Table 14 (% based on weight of dye solution) Dioxane amount
added as indicated in Table 14 (% based on weight of dye solution)
Amount of dye solution: 20-fold the weight of the material dyed.
______________________________________
The yarn to be dyed was dipped in the dye solution, and the dyeing
was started at 40.degree.C., after which the temperature was raised
up to 130.degree.C. during a period of 30 minutes, and the dyeing
was continued for a further 60 minutes at this temperature. This
was followed by water-washing the yarn and thereafter washing it
for 20 minutes at 80.degree.C. in a wash liquid containing 1 gram
per liter of hydrosulfite, 0.5 gram per liter of soda ash and 1
gram per liter of a nonionic surfactant followed by water-washing
and drying. The results obtained are shown in Table 14.
Table 14 ______________________________________ Additive and
concentration thereof (%) Dye N,N'-dimethyl- Exhaus- Residual No.
acetamide dioxane tion N,N'-dimethyl (%) acetamide
______________________________________ 1 0 10 7.9 No 2 0 30 15.8 "
3 5 0 17.1 " 4 5 5 56.2 " 5 5 10 77.7 " 6 5 30 81.6 " 7 5 50 18.5 "
8 10 0 23.6 9 10 5 70.1 " 10 10 10 86.5 " 11 10 30 28.6 " 12 10 50
10.0 " 13 50 5 17.1 Yes 14 50 10 15.1 " 15 60 5 11.2 " 16 not added
3.1 No ______________________________________
As is apparent from the foregoing results, the rate of dye
exhaustion is low when the N,N'-dimethylacetamide is not contained
or when it exceeds 50 %, even though conjoint addition is made of
dioxane. In addition, residual N,N'-dimethylacetamide is noted. On
the other hand, when either 5 % or 10 % of N,N'-dimethylacetamide
is conjointly used with dioxane, marked dye uptake effects are
noted with a dioxane content of 5-30 %. Moreover, no residual
N,N'-dimethylacetamide is noted.
EXAMPLE 15
A knit fabric made up of 2-ply yarn of filaments obtained by
melt-spinning a novolak type phenolic resin was dyed with a dye
solution of the following composition.
______________________________________ Terasil Brilliant Pink FG 18
% (o.w.f.) (disperse dye produced by Ciba-Geigy Co.) Various
compounds indicated amount added as in Table 15 indicated in Table
15 (based on weight of dye solution) Amount of dye solution:
20-fold the weight of material dyed.
______________________________________
After dipping the foregoing fabric in the dye solution and starting
the dyeing at 40.degree.C., the temperature was raised up to
130.degree.C. during a period of 40 minutes, and the dyeing was
continued for a further 60 minutes at this temperature. The fabric
was then water-washed and thereafter washed for 20 minutes at
80.degree.C. in a wash liquid containing 1 gram per liter of
hydrosulfite, 0.5 gram per liter of soda ash, 0.8 gram per liter of
a nonionic surfactant and water followed by water-washing and
drying. The results are shown in Table 15.
Table 15
__________________________________________________________________________
N,N'-dimethyl- N,N'-dimethyl- Concent- Dye formamide acetamide
ration Exhaus- No. (%) (%) Additive (%) tion (%)
__________________________________________________________________________
1 8 -- benzyl 6 89.1 alcohol 2 8 -- n-propanol 6 82.1 3 8 --
iso-propanol 6 71.2 4 8 -- n-butanol 6 72.5 5 8 -- iso-butanol 6
70.0 6 8 -- dioxane 6 81.5 7 8 -- cyclo- 6 69.7 hexane 8 8 --
acetone 6 63.5 9 8 -- -- -- 5.0 10 -- 8 benzyl 6 82.6 alcohol 11 --
8 n-propanol 6 80.5 12 -- 8 iso-propanol 6 69.1 13 -- 8 n-butanol 6
67.2 14 -- 8 iso-butanol 6 59.8 15 -- 8 dioxane 6 79.1 16 -- 8
cyclo- 6 58.1 hexane 17 -- 8 acetone 6 41.5 18 -- 8 -- -- 8.0 19 --
-- -- -- 0
__________________________________________________________________________
As is apparent from the foregoing results, although the rate of dye
exhaustion is low in the case of a dye solution containing only 8 %
of either N,N'-dimethylformamide or N,N'-dimethylacetamide, it is
obvious that by the conjoint use of 6 % of benzyl alcohol,
n-propanol, iso-propanol, n-butanol, iso-butanol, dioxane,
cyclohexane or acetone the rate of dye exhaustion is greatly
improved.
EXAMPLE 16
A twill fabric made up of filaments obtained by melt-spinning a
novolak type phenolic resin and thereafter curing with formaldehyde
was dyed with a dye solution of the following composition.
______________________________________ Sumiacryl Red 7B (cationic
dye 18 % (o.w.f.) produced by Sumitomo Chemical Co.)
N,N'-dimethylformamide 10 % (based on weight of dye solution)
Various compounds indicated in Table 16 8 % (based on weight of dye
solution) Amount of dye solution : 50-fold the weight of material
dyed. ______________________________________
The foregoing fabric was dipped in the dye solution, and the dyeing
was started at 40.degree.C., after which the temperature was raised
up to 110.degree.C. during a period of 30 minutes, at which
temperature the dyeing was continued for a further 80 minutes. The
fabric was then washed in water and thereafter washed for 20
minutes at 70.degree.C. in a wash liquid containing 1 gram per
liter of a nonionic surfactant followed by waterwashing and drying.
The results are shown in Table 16.
Table 16 ______________________________________ Dye Ex-
N,N'-dimethyl Concent- haustion No. formamide (%) Additive ration
(%) (%) ______________________________________ 1 10 n-propanol 8
90.8 2 10 iso-propanol 8 81.2 3 10 n-butanol 8 83.5 4 10
iso-butanol 8 78.6 5 10 methanol 8 9.1 6 10 methanol 30 8.2 7 10
ethanol 8 5.2 8 10 ethanol 30 4.5 9 10 -- -- 3.5
______________________________________
As is apparent from the results shown above, the rate of dye
exhaustion is low in the case of a dye solution containing only 10
% of N,N'-dimethylformamide but shows a marked improvement when 10
% of the N,N'-dimethylformamide is conjointly used with n-propanol,
iso-propanol, n-butanol or iso-butanol. On the other hand, the
conjoint use of methanol or ethanol was of no use in improving the
rate of dye exhaustion. Thus, the effects of the conjoint use of
either n-propanol, iso-propanol, n-butanol or iso-butanol are
obvious.
EXAMPLE 17
A plain weave fabric made up of yarns of phenolic filaments
obtained by melt-spinning a novolak type phenolic resin and
thereafter curing with formaldehyde was dyed with the following dye
solution.
______________________________________ Dianix Brown P-E (disperse
dye 15 % (o.w.f.) produced by Mitsubishi Chemical Co.)
N,N'-dimethylformamide 8 % (based on dye bath weight) Various
compounds indicated in Table 17 8 % (based on weight of dye
solution) Amount of dye solution: 30-fold the weight of material
dyed. ______________________________________
The fabric was dipped in the dye bath and the dyeing was started at
40.degree.C., the temperature being raised to 128.degree.C. during
a period of 40 minutes, where the dyeing was carried out for 80
minutes. The fabric was then washed in water and thereafter treated
for 20 minutes at 80.degree.C. with a reducing wash liquid
containing 0.8 gram per liter of hydrosulfite, 0.4 gram per liter
of soda ash and 1 gram per liter of a nonionic surfactant, followed
by water-washing and drying. The results obtained are shown in
Table 17.
Table 17
__________________________________________________________________________
Dye N,N'-dimethyl Concent- Exhaus- formamide ration tion No. (%)
Additive (%) (%)
__________________________________________________________________________
1 8 n-amyl alcohol 8 76.5 2 8 tetrahydrofurfuryl 8 69.8 alcohol 3 8
methyl ethyl ketone 8 70.2 4 8 diethyl ketone 8 58.6 5 8 methyl
formate 8 62.1 6 8 ethyl formate 8 68.2 7 8 propyl formate 8 50.2 8
8 methyl acetate 8 60.5 9 8 ethyl acetate 8 79.3 10 8 propyl
acetate 8 58.2 11 8 butyl acetate 8 53.6 12 8 none 0 7.6
13(Control) 0 n-amyl alcohol 8 12.6 14 0 tetrahydrofurfuryl 8 10.5
alcohol 15 0 methyl ethyl ketone 8 8.8 16 0 diethyl ketone 8 2.6 17
0 methyl formate 8 5.4 18 0 ethyl formate 8 6.2 19 0 propyl formate
8 3.2 20 0 methyl acetate 8 6.5 21 0 ethyl acetate 8 15.1 22 0
propyl acetate 8 7.1 23 0 butyl acetate 8 2.1 24 0 none 0 0
__________________________________________________________________________
As is apparent from the foregoing results although the rate of dye
exhaustion is low in the case of a dye solution containing only
N,N'-dimethylformamide, it is obvious that by the conjoint use of 8
% of n-amyl alcohol, tetrahydrofurfuryl alcohol, methyl ethyl
ketone, diethyl ketone, methyl formate, ethyl formate, propyl
formate, methyl acetate, ethyl acetate, propyl acetate or butyl
acetate the rate of dye exhaustion is greatly improved.
* * * * *