U.S. patent number 3,899,810 [Application Number 05/442,603] was granted by the patent office on 1975-08-19 for method of making chemically protected off-the-loom fabrics.
This patent grant is currently assigned to The Kendall Company. Invention is credited to Glynn E. Fouche, Jr., Leonard A. Stanley.
United States Patent |
3,899,810 |
Stanley , et al. |
August 19, 1975 |
Method of making chemically protected off-the-loom fabrics
Abstract
Methods of making chemically protected off-the-loom greige
fabrics by treating unsized warp yarns, usually of cotton or rayon,
in a size bath with a chemical protecting material added thereto,
drying the sized and chemically protected warp yarns and
interweaving them with untreated filling yarns to provide an
off-the-loom fabric wherein, after being exposed to water, both the
warp and filling yarns are chemically protected without subsequent
processing. Greige cloth resistant to such factors as fire, rot,
bacteria, fungus, insects and the like as well as fabrics having
desired additives such as herbicides, fertilizers, insecticides and
the like may be so provided.
Inventors: |
Stanley; Leonard A. (Charlotte,
NC), Fouche, Jr.; Glynn E. (Rock Hill, SC) |
Assignee: |
The Kendall Company (Walpole,
MA)
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Family
ID: |
26915675 |
Appl.
No.: |
05/442,603 |
Filed: |
February 14, 1974 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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221308 |
Jan 27, 1972 |
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36037 |
May 11, 1970 |
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36038 |
May 11, 1970 |
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Current U.S.
Class: |
28/166; 28/179;
139/426R; 28/169; 28/183 |
Current CPC
Class: |
D03J
1/00 (20130101); D03J 2700/02 (20130101) |
Current International
Class: |
D03J
1/00 (20060101); D02G 003/36 (); D06M 013/00 () |
Field of
Search: |
;28/72.6,72.5,74R,75R,76R ;117/136,137,138.5 ;106/15AF,15RF
;139/426R,42R,383R ;161/88-92 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Chi; James Kee
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of our earlier
application Ser. No. 221,308, filed Jan. 27, 1972 now abandoned,
which was in turn a continuation-in-part of our applications, Ser.
Nos. 36,037 and 36,038; both filed May 11, 1970 now both abandoned.
Its inventions relate to novel methods of making chemically
protected off-the-loom textile fabrics, that is, greige cloth,
having sized warp yarns.
Claims
What is claimed is:
1. A method of making chemically protected off-the-loom fabrics
comprising
treating unsized cellulosic warp yarns in a water bath with a water
compatible size containing a non-volatile substantially cold water
insoluble chemical protecting material
drying the sized and chemically protected warp yarns and
interweaving said warp yarns with unsized and untreated cellulosic
filling yarns to provide an off-the-loom fabric
exposing said fabric to moisture to cause partial transfer of said
chemical protecting material from said warp yarns to said filling
yarns to chemically protect the entire fabric without further
treatment thereof.
2. A method as claimed in claim 1 wherein said protecting material
is of the class consisting of:
flame retardants, rot and fungus retardants, bacteria retardants
and insect retardants for protection of said fabric.
3. A method of enhancing the flame resistance of a cellulosic
fabric comprising
treating unsized cellulosic warp yarns in a water bath with a water
compatible size containing a non-volatile, substantially cold water
insoluble size including three to twenty percent of a non-volatile
flame-retardant agent, based on the weight of the unsized warp
yarns, dispersed throughout the size
drying the sized warp yarns and
interweaving said warp yarns with unsized and untreated cellulosic
filling yarns to provide an off-the-loom fabric
exposing said fabric to moisture to cause partial transfer of said
flame-retardant agent from said warp yarns to said filling yarns to
flame retard the entire fabric without further treatment
thereof.
4. A method of enhancing the mildew and rot resistance of a
cellulosic fabric comprising
treating unsized cellulosic warp yarns in a water bath with a water
compatible size containing non-volatile, substantially cold water
insoluble size including one percent to five percent of a fungicide
agent, based on the weight of the unsized warp yarns, dispersed
throughout the size
drying the sized warp yarns and
interweaving said warp yarns with unsized and untreated cellulosic
filling yarns to provide an off-the-loom fabric
exposing said fabric to moisture to cause partial transfer of said
fungicide agent from said warp yarns to said filling yarns to
protect the entire fabric from mildew and rot without further
treatment thereof.
Description
BACKGROUND OF THE INVENTION
As is well known, the usual method of treating cellulosic and other
fabrics, particularly of cotton, as for example, to protect them by
imparting resistance to fire, rot, bacteria, fungus, insects and
the like is by impregnation of the cloth in an aqueous bath of
suitable chemicals. This procedure is relatively less effective for
cotton greige cloth, however, because such cloth is usually formed
of cotton yarns which still retain all of the natural oils and
waxes, in addition to the warp size necessary for weaving the warp
yarns, and hence are substantially nonabsorbent with respect to
protecting materials. For this reason, the usual procedure of
impregnating the cloth is not particularly effective with cotton or
rayon greige cloth because of substantial lack of absorbency
particularly in the sized warp yarns of the latter. The only manner
of making such cloth more receptive to such impregnation is by
desizing, bleaching and/or scouring. However, cloth so treated is
no longer inexpensive off-the-loom cloth but rather is relatively
expensive finished cloth to which the extra expense of still
further processing with protecting materials would be added.
Other fabrics made with spun or continuous filament rayon or other
synthetic yarns which, like natural cotton yarns, are substantially
nonabsorbent, have the same disadvantages with respect to normal
protective and other treatment, except they may not need bleaching
and scouring.
For example, flame resistance of fabrics, particularly apparel
fabrics, household fabrics and automotive fabrics, has been brought
into public focus because of the high incidence of accidents in
which serious, oftentimes fatal, burns and extensive property
damage has resulted from ignition of fabrics having undesirably low
flame resistance. Such fabrics, even when they have not been the
initial source of the accidental burning, are active in propagating
and augmenting the conflagration with subsequent increase in body
injury and property damage.
As a result of the attention directed to flammability of fabrics,
the Flammable Fabrics Act has been broadened in scope and new
standards are in the process of being promulgated. Thus, the
Federal Highway Administration has proposed flammability tests and
standards for interior materials for passenger vehicles, trucks and
busses, and comparable standards for household furnishings and wall
coverings are being considered. Many of the fabrics used as
linings, cushion coverings, and the like, have in the past been
made of off-the-loom cloth which has, with the exception of wall
coverings and the like, formed nonvisible and usually overcovered
portions of the seat, sides, backs and bottoms of household
furnishings and automobile interiors. Low count lightweight
off-the-loom fabrics formerly used in these constructions simply
are not sufficiently flame resistant to pass the proposed
automotive tests and probably will not pass finally approved tests
for flammability applicable to automotive interiors, home
furnishings and wall coverings. Such fabrics are by their very
nature in the lowest cost range. Any treatment which enhances flame
resistance, to be completely feasible, therefore, must be simple
and uncomplicated with a minimal cost increase from present
off-the-loom cloth processing. And this is not possible with
heretofore known processes, which require two additional steps,
first finishing and thereafter treating with flame retardants.
As another example, untreated cotton duck of about 12 to 14 ounces
per square yard after being wet out and buried in soil composed of
good topsoil or leaf mold, well rotted and shredded manure and
coarse sand in equal parts and rich in microbial life, is
completely deteriorated in from seven to ten days by rot and
mildew. It is well known that rot and mildew cause severe economic
losses in untreated cotton duck and other untreated cotton fabrics
used in tarpaulins, tents, seedbed covers, sandbags and the like,
which come in contact with the soil during ordinary use. Mildew
also causes substantial economic loss where untreated backing
fabrics for wall coverings in certain tropical and humid regions
are exposed to warm and moist conditions. As with imparting flame
resistance, however, the heretofore known method of imparting
mildew and rot resistance to such fabrics is by a separate
finishing operation in which off-the-loom cloth is desized and
impregnated in an aqueous bath containing a water miscible
fungicide such as copper naphthenate, and dried. While such an
operation is effective in imparting a degree of mildew and rot
resistance, the method is relatively expensive.
Quite apart from mildew and rot resistance and at a level which is
ineffective for substantially reducing mildew and rot deterioration
during soil burial procedures, certain warp sizings have been known
to contain minor solid percentages (of the order of 0.05 to 0.5
percent based on the weight of the untreated warp yarns) of a
fungicide as a preservative for the sizing to inhibit mildew growth
during storage under normal conditions of storage humidity and
temperatures.
SUMMARY OF THE INVENTION
It is an important object of this invention to provide novel
methods of making chemically protected off-the-loom cloth of
cellulosic fibers, such as cotton and rayon, substantially
resistant to one or more of such factors as fire, rot, bacteria,
fungus, insects and the like, as well as to provide fabric having
other desired additives, such as herbicide, fertilizer,
insecticides and the like, -- all without destroying its greige
character, without serious modification of its processing and
without substantial additional cost other than that of the
protective material added. These objectives are substantially
realized by the simple step of adding to the sizing fluid bath
during the preparation thereof a percentage by weight of a selected
generally cold water insoluble chemical protecting material.
Our invention, in general, lies in our discovery that, by the
addition of a sufficient quantity of any one of a number of known
chemical protecting materials, such as flame retardant or mildew
and rot resistant agents, directly to the warp yarn slasher sizing
bath, before the sized warp yarns are woven with the unsized
filling yarns into cloth, the woven gray fabric, without any
further chemical treatment, becomes chemically protected and so
made flame resistant or mildew and rot resistant without any
pretreatment of the unsized filling yarns.
We have unexpectedly discovered that exposing such fabrics to the
presence of moisture, such as by wetting with water and even by
ambient moisture occurring as water vapor present when the fabric
is subsequently used, allows a sufficient amount of the chemical
protecting material to diffuse from the warp yarn sizing into the
untreated, unsized filling yarns to protect them and thus protect
the entire fabric to render it highly flame resistant or rot and
mildew resistant or the like. This resistance may be obtained,
according to our invention, without substantial addition to the
processing steps or the expense of greige cloth, thus providing a
desirably economical product, easily produced.
More specifically, we have found that sizing agents in slashing
mixtures conventionally used for sizing the warp yarns, as is
necessary for weaving them into greige cloth, which sizing is not
normally removed, makes an excellent retentive carrier for the
desired protective material used in the preparation of greige
cloths of enhanced flame rot, bacteria, fungus, insects, or other
resistance, or cloths having other desired additives, such as
herbicide or fertilizer. Any water-compatible binding agent
including aqueous starch, polyvinyl alcohol, carboxymethyl
cellulose or other commonly used warp sizing agents or combinations
thereof, make suitable sizing carriers useful in the invention.
When fabrics of the invention are continuously exposed in use to
outside weather, particularly to heavy rainfall which tends to
leach out such usual sizings as starch, polyvinyl alcohol and
carboxymethyl cellulose, it is preferred to employ a less
water-soluble warp sizing to act as a carrier replacing wholly or
partially the usual sizing. Typical examples of such sizings are
emulsions of polyvinyl acetate and polyacrylates, and dispersions
of polyvinyl butyrals.
An effective percentage of flame retardant material is from about 3
to about 20 percent solids add-on based on the weight of the
unsized warp yarns, with a weight of about 8 to 14 percent being
preferred for the combination of low cost and effectiveness,
dispersed throughout the sizing. For fungus and rot resistance, an
effective percentage of a well known fungicide is from 1 to 5
percent solids added to the slashing fluid during its preparation.
Thus, if the wet pickup of slashing fluid is 100 percent of the
untreated warp yarn weight and the percentage of fungicide in the
slashing fluid is 3 percent, the percent solids add-on of the
fungicide would be 3 percent.
Whether or not the warp yarns are relatively nonabsorbent is of
little significance when a carrier is utilized. A variety of
materials may be made to adhere to the warp yarns without other
steps than merely mixing them into the sizing during its
preparation in the proper proportion to disperse them throughout
the sizing.
In accordance with our discovery, when warp yarns treated with a
chemical protecting material in accordance with the method of this
invention are interwoven with ordinary unprotected, untreated,
unsized cotton, rayon or other cellulosic filling yarns or other
filling yarns, the resultant cloth has enhanced protection both in
the warp direction and, unexpectedly, in the filling direction as
well, apparently by partial transfer of the chemical protecting
material from the warp yarns to the filling yarns in the presence
of moisture, even ambient moisture. The reason for this unexpected
protection of the otherwise untreated filling yarns is not
completely understood, by may possibly be due to a number of
factors; in the case of flame or fire resistance, reduction of
oxygen at the yarn intersections, partial decomposition of the
flame-resistant material and other phenomena which occur at flame
temperatures, and, in the case of rot, fungus and bacteria
resistance, by the paratial migration of sizing and fungicide from
the warp yarns to the intimately contacting filling yarns, which
comes about naturally when the cloth is wetted by water, even by
the presence of ambient moisture alone. Since moisture is necessary
to the development of rot and mildew fungae, the filling yarns are
rendered resistant at the time when conditions would otherwise be
optimum for fungus growth.
As for fire and flame resistance, any of the well known flame
retardants may be used in the methods of this invention to impart
enhanced flame-resistance to warp yarns and to fabrics of the
invention made from such treated yarns. Typical retardants which
are only representative of the broad class of available suitable
and well-known retardants are boric acid, borax, diammonium
phospate, sodium phosphate, aluminum sulfate, ammonium sulfate,
ammonium sulfamate, ammonium molybdate, sodium tungstate, ammonium
bromide, and trisodium phosphate. In the main, those mentioned are
relatively inexpensive and may be used alone or in combination with
each other or with other flame retardants.
Among the very large group of fungicides which are suitable in the
preparation of the rot and mildew resistant fabrics of this
invention, the following very commonly used fungicidal agents are
mentioned as representative but by no means exclusive agents:
Such quaternary ammonium compounds as methyl dodecyl benzyl
trimethyl ammonium chloride; quaternary ammonium naphthenate;
alkyldimethylbenzyl ammonium chloride; di-isobutyl phenoxy ethoxy
ethyl dimethyl benzyl ammonium chloride; and others.
Such organometallic compounds as diphenyl mercury
dodecenylsuccinate; copper-8-quinolinolate; zinc naphthenate;
phenyl mercuric acetate, lactate, oleate, proprionate;
bis(tributyl) tin oxide; and others.
Such melamine derivatives as melamine formaldehyde condensates,
such as trimethyl melamine and mono, and di- or tri-methylated
trimethylol melamine.
Such substituted phenols and bis-phenols as orthophenylphenol; 2,
4, 5-trichlorophenol; tetrachlorophenol; pentachlorophenol; coconut
amine salt of tetrachlorophenol; dihydroxydichlorodiphenylmethane;
4-chloro-2 cyclopentolphenol; methyl salicylate; orthohydroxy
biphenyl; dichlorophenoxyphenol; sodium pentachlorophenate; and
others.
Such organosulfur compounds as N-trichloromethylthio phthalimide;
dimethyldithiocarbamic acid (zinc salt); 2-mercaptobenzothiazole
(zinc salt); and others.
The addition of an antibacterial agent such as a combination
bis-phenol and zirconyl to water-resistant slashing size according
to the invention may be used for producing cloth having bacteria
protecting properties. Such material complexes on drying to a
slow-diffusing but highly wash and dry-cleaning fast odor
suppressor by retardation of bacterial putrefaction odors of
perspiration and other body exudates. Such off-the-loom cloth needs
only to be compressively shrunk and without any further treatment
for use in apparel interlinings. Specifically, treatment in the
warp size bath with one half to five percent addition (on weight of
warp sheet) of 5-chloro-2-(2, 4, dichlorophenyoxy) phenol with 1.5
to 3 mol. equivalents of ammonium zirconyl carbonate agent will
produce the desired results. The antibacterial agents are more
specifically described in U.S. Pat. No. 3,594,113.
An insect resistant fabric such as a carpet backing fabric with the
warps infused with a moth and carpet beetle insecticide may be
provided according to the invention. For example, a mixture of
emulsifiable hexachlorophenoxyoctahydroendo,
exo-dimethane-naphthalene with insecticidally active chlorinated
hydrocarbons may be provided in the warp size bath, with the
filling yarns being protected thereby as well as the warp
yarns.
Among the fabrics having other desired additives, which may be
produced according to the methods of the invention, are, for
example, insect repelling fabrics in which the purpose of the
insecticide is to prevent insects from passing through or remaining
near the fabric, in order to protect other materials. Illustrative
of such uses are agricultural nettings and outdoor gear, warp sized
according to the invention to include an insect repellent such as
an emulsion of beta butoxy beta thiocyano diethylether or a
miticide such as 1,1-bis(chlorophenyl)-2,2,2,-trichloro ethanol.
Such materials as fertilizers and herbicides may also be added.
For the purpose of more fully explaining the invention, reference
is now made to the following detailed description of preferred
embodiments thereof, taken with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a typical fabric of the invention; and
FIGS. 2 and 3, illustrate, respectively, schematic plan and side
views of a typical warp slasher useful in producing fabric of the
invention.
REFERRING IN MORE DETAIL TO THE DRAWINGS:
FIG. 1 illustrates a typical off-the-loom greige fabric 10 of the
invention of which the cellulosic warp yarns 11 are treated with
sizing modified by inclusion of a suitable agent. Filling yarns 12
are usually untreated, unsized cellulosic yarns of cotton or
rayon.
FIGS. 2 and 3 are, respectively, schematic illustrations in plan
and side view of a typical warp slasher 20 wherein warp beams 21
and 22 of unslashed warp yarns are mounted in the creel frame 31
from which the warp yarns 32 enter under the hood 25. The warp
yarns are then fed around idler rollers below the surface of the
size 29 in the size box 30. The sized yarns are led through the
squeeze rolls 28, after which they pass around dry cans 33 to 41 in
succession. From the dry cans, the yarns pass over idler rollers
41' and 42 to comb assembly 43 which separates them. Thence the
yarns pass over, under and over the rolls of tension device 44 and
onto the loom beam 45. The dried, treated and sized warp yarns are
then in condition to be interwoven with filling yarns on a
conventional loom, not shown.
The preferred embodiments of the invention are all cotton or
cellulosic fabrics made from normal twist yarns with the weight of
the filling yarn being not substantially greater than that of the
untreated warp yarns.
Preferred Flame Retardency Embodiments of the Invention
To illustrate the efficacy of the methods of this invention as
applied to flame retardency and the degree of flame retardency
achieved, a typical 14 .times. 10 fabric with cotton warp yarns 31
singles and cotton filling yarns 39 singles was used in a series of
tests involving two warp slashing fluids respectively 5 percent
cornstarch on weight of the solution and 3 percent carboxymethyl
cellulose on weight of the solution. The time of burning measured
in accordance with Federal Method 5908 (AATCC-33-1962) was
determined for these fabrics and for similar fabrics in which the
warp sizings were modified with various flame-retardant agents as
follows:
Control A : 5 percent cornstarch.
Control B : 3 percent carboxymethyl cellulose.
Example 1-A: 5 percent cornstarch, 8 percent ammonium sulfamate, 2
percent ammonium sulfate.
Example 2-A: 5 percent cornstarch, 10 percent ammonium
borophosphate.
Example 3-A: 5 percent cornstarch, 10 percent diammonium
phosphate.
Example 1-B: 3 percent carboxymethyl cellulose, 8 percent ammonium
sulfamate, 2 percent ammonium sulfate.
Example 2-B: 3 percent carboxymethyl cellulose, 10 percent ammonium
borophosphate.
Example 3-B: 3 percent carboxymethyl cellulose, 10 percent
diammonium phosphate.
In each example and the controls, the percentages are based on the
weight of the slashing solution and the wet pickup regulated by
squeeze rolls to 100 percent of the dry weight of the warp yarn in
the unsized state.
The burning times in seconds of 5 inches of fabric for the various
controls and example fabrics tested in the filling direction
(marked F) and in the warp direction (marked W) were as
follows:
TABLE I ______________________________________ Burning times in
seconds (AATCC-33-1962) F W ______________________________________
Control A 3.1 2.9 Control B 3.0 2.8 Example 1-A 3.7 3.6 Example 2-A
3.9 3.7 Example 3-A 3.6 3.4 Example 1-B 3.6 3.2 Example 2-B 3.4 3.3
Example 3-B 3.3 3.2 ______________________________________
It should be noted that the burning times in the warp direction of
fabrics whose warp yarns had been treated in accordance with the
method of the invention were increased over the controls. Likewise,
what was not anticipated, the burning times in the filling
direction of these fabrics were increased over the controls.
When a degree of flame resistance is required in fabric whose
untreated flame resistance is low, retardent sizing treatment of
the warp yarns may be inadequate to attain the desired level of
flame resistance. Supplemental measures which enhance the flame
resistance of the fabric may be employed as follows:
1. Treat the filling yarn before being woven with an aqueous or
solvent solution or emulsion of a suitable flame retardant either
as an individual yarn or in package form. This may be accomplished
by dipping, spraying, brushing, wiping or other means which attain
an effective level of solid pickup. Obviously, if the filling yarn
is or has been made absorbent, an effective level is more readily
obtained. But even with nonabsorbent yarns, the capillarity or
surface acceptance may be adequate to obtain satisfactory wet
pickup. Spun yarns generally have sufficient capillarity (unless
they are high twist yarns) for retaining an effective amount of
retardant material to enhance the flame resistance to a
considerably degree after the treated yarn is dried and interwoven
with warp yarns which have been subjected to sizing treatment in
accordance with the invention.
2. Replace the filling yarn of such a fabric with a synthetic yarn
which is inherently wholly flame resistant or of improved flame
resistance, such as yarns of glass, polyolefins, polyvinyls and
acrylates.
3. Replace the filling yarn of such fabric with flame-retardant
rayon or other cellulosic fiber whose molecule has been modified to
render it inherently flame resistant or whose structure includes
trapped polymeric flame retardants.
Obviously, one may further enhance the flame resistance of filling
yarns having improved but inadequate resistance and hence of the
fabric of (2) and (3) by the treatment of (1).
4. Treat the warp treated cloth with filling yarns which are
deficient in flame resistance whether of absorbent or nonabsorbent
cotton or of rayon or synthetic polymer, with an aqueous or solvent
solution or emulsion of a suitable flame retardant, and dry to
provide a cloth of still greater flame resistance. Spraying or
brushing the flame-retardant fluid onto the cloth is preferred
because excess liquid may cause loss of both sizing and retardant
and may involve further processing steps.
Examples 2, 3 and 6 in Tables II and III below illustrate further
embodiments of the invention and show comparative burning rates.
Examples 3 is an example of a fabric made with retardant sized warp
yarns in accordance with this invention and with an after-spray of
retardant in accordance with (4) above. Example 6 is an embodiment
of a fabric described in (3) above.
TABLE II ______________________________________ Spray Applications
Burning Rate No. Fabric Warp Retardant % Solids Horizontal* Size
Add-on ______________________________________ 1 Grey Starch none
none 10" 43 14.times.10 in/min cotton 2 Grey Starch + none none 10"
27 14.times.10 boro- in/min cotton phosphate complex 3 Grey Starch
+ Boro- 4.4 0** 0 14.times.10 boro- phosphate phosphate complex
complex in water ______________________________________ *Proposed
Motor Vehicle Safety Standard No. 302. ** Burning did not reach
11/2 inches from starting point.
TABLE III ______________________________________ Burning Rate
45.degree. incl. No. Fabric Warp Size AATCC-33-1962
______________________________________ 4 Grey 14.times.10 Starch 5
inches in 2.9 seconds cotton 5 14.times.10 grey Starch 5 inches in
3.4 seconds cotton warp AVISCO PFR rayon fill 6 14.times.10 grey
Starch and 5 inches in 4.4 seconds cotton warp borophosphate AVISCO
PFR complex rayon fill 7 14.times.10 100% Starch 5 inches in 5.5
seconds AVISCO PFR rayon ______________________________________
A borophosphate complex suitable for imparting enhanced flame
resistance is sold under the trademark PYROSAN B by Laurel Products
Corporation, 2600 East Tioga, Philadelphia, Pa. 19134. A somewhat
similar inorganic phosphate type retardant is sold under the
tradename APEX 311 by Apex Chemical Co., Inc., 200 South First St.,
Elizabethport, N. J.
AVISCO PFR is the trademark under which FMC Corporation, 1517 John
F. Kennedy Boulevard, Philadelphia, Pa. 19103, markets a permanent
flame retardant regenerated cellulose fiber made in accordance with
the teachings of U.S. Pat. No. 3,455,713. Another suitable
permanent flame retardant regenerated cellulose material is
available in fiber form from Courtaulds of North America, P.O. Box
9262, Plaza Station, Greensboro, N. C., under the tradename DURAFIL
FR.
A preferred embodiment of the invention which will pass the
45.degree. inclined test method AATCC-33-1962 is as follows:
1. A typical 14 .times. 10 off-the-loom fabric of the invention
with untreated cotton filling yarns and slash treated flame
resistant cotton warp yarns -- the slashing fluid being a solution
of 5 percent cornstarch and 10 percent ammonimum borophosphate with
a wet pickup of 100 percent of the weight of the untreated warp
yarns. The fabric had a burning time of 3.7 seconds.
Another preferred embodiment of the invention which will pass both
the 45.degree. inclined test method AATCC-33-1962 and the proposed
Motor Vehicle Safety Standard horizontal test method No. 302, is as
follows:
2. A typical 14 .times. 10 off-the-loom fabric of the invention
with AVISCO PFR rayon filling yarns and slash treated
flame-resistant cotton warp yarns -- the slashing fluid being a
solution of 5 percent cornstarch and 10 percent ammonium
borophosphate -- 100 percent wet pickup based on the weight of the
untreated warp yarns. Under the 45.degree. test the burning time
was 4.4 seconds. By the horizontal No. 302 test, the fabric was
self-extinguishing and after being ignited did not burn 1 1/2
inches from the starting point.
3. A third 14 .times. 10 preferred fabric of the invention, similar
in every way to preferred embodiment (1) was sprayed after leaving
the loom with a 10 percent aqueous solution of an inorganic
phosphate to apply 8 percent solids based on the off-the-loom
fabric. This fabric passes both tests and is less expensive than
embodiment (2). Under horizontal test No. 302 the fabric ignited
but self-extinguished before it had burned 1 1/2 inches from the
starting point.
Preferred Rot and Fungus Protection Embodiments of the
Invention
An example of the method of the invention, as applied to rot and
fungus protection used in treating the warp yarns before
interweaving them with untreated filling yarns is as follows:
EXAMPLE 1
Thirty-one singles cotton warp yarns were sized (and dried in the
usual manner) with the following sizing fluid:
Cornstarch 9 percent based on the weight of the solution;
Methyl dodecyl benzyl trimethyl ammonium chloride, 2.5 percent
based on weight of the solution.
Wet pickup was 100 percent based on the weight of the warp yarns or
a percent fungicide solids of 2.5 percent.
The dried rot-resistant warp yarns were interwoven with 39 singles
untreated cotton filling yarns to produce a 32 .times. 28
fabric.
In determining the mildew and rot resistance of cloth produced in
accordance with the invention, the soil burial method described in
Federal Method 5762 of May 15, 1951 (CCC-T-191b) published by
General Services Administration, Business Service Center, Region 3,
Seventh and D Sts. S.W., Washington, D.C., was utilized.
After burial, in accordance with Method 5762 for fourteen days, an
untreated control cloth similar to that in Example 1 (but without
fungicide) was substantially destroyed by rot and mildew whereas
treated samples of Example 1 were substantially free of rot and
mildew and retained from 70 percent to 90 percent of the original
tensile strength in both warp and fill directions. The preferred
sizing has a cornstarch base and includes from 2.5 to 5 percent
solids fungicide preferably a quaternary ammonium compound such as
methyl dodecyl benzyl trimethyl ammonium chloride.
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