CA1040940A - Curing catalyst combination for textile resins - Google Patents

Abstract

Title: CURING CATALYST COMBINATION
FOR TEXTILE RESINS.

ABSTRACT OF THE DISCLOSURE
Mixtures of aluminum sulfate and magnesium sulfate are curing catalyst for thermosetting aminoplast textile finishing resins.

Description

-` lO~V940 The invention pertains to curing catalyst combinations for textile resins.
Various catalysts and accelerators have been employed in the curing of thermosetting aminoplast resins in the finishing of cellulosic textile materials. Such catalysts include metal salts of the strong inorganic acid salts of such metals as zinc, magnesium, and the like. Van Loo et al in U.S.
Patent 3,084,071 teach the use of water-soluble aluminum salts of aluminum chloride, aluminum nitrate, and aluminum sulfate as accelerators for water-soluble thermosetting aminoplast resins on 80 x 80 cotton percale. Such finishes normally produce wrinkle recovery values of about 250F. to about 300F. as measured on a Monsanto Wrinkle Recovery Tester. However, the total tensile strength ~warp ~ fill) of the materials so finished is lower than ; normally desired, usually being 20 to 60 pounds as measured on a Scott Tester, where an untreated value of 80-100 or more is desired. It has been recognized that as wrinkle recovery values increase, tensile strength losses also increase, therefore textile finishers are required to balance wrinkle recovery and tensile strength requirements. My invention shows improved tensile strengths while maintaining wrinkle recovery properties over the sluminum sulfate of the art.
Accordingly, the present invention provides in a process for curing ` a watcr-soluble thermosetting aminoplast resin treated textile material, the -improvement which comprises treating a textile material by applying to said material about 1% to 10% of a water-soluble thermosetting aminoplast resin, based on the weight of the textile material, and from about 1% to 25% of a mixture of aluminum sulfate and magnesium sulfate based on the weight of said resin, said mixture of salts comprising from between 0.5 and 2.0 parts of magnesium sulfate per part of aluminum sulfate and curing said resin to ' a water-insoluble state by heating the so treated textile material to a temperature of from about 3QQ to 40QF.
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The invention is the use of mixtures of aluminum " ' , ,, .

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1~40~40 sulfate and magnesium sulfate as curing catalysts or accel-erators for thermosetting aminoplast textile finishing resins.
Finished cellulosic textile materials cured with thermosetting aminoplast resins and the curing catalyst mixture of the in-vention have high wrinkle recovery with reduced losses intensile strength.
In the process of the invention about 1 to 10% pre-ferably about 3 to 5%, of a water-soluble thermosetting amino-plast resin is applied to a textile material, based on the weight of the textile material, and from about 1% to 25%, pre-ferably about 10 to 15% of curing catalyst solids, based on the weight of resin, and thereafter the resin is dried and cured to react the resin with the material.
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The cellulosic textile material to which the in-i 15 vention is applicable are formed textile fabrics whether knitted, woven, felted or otherwise formed, composed of at least 20% cellulose fibers, such as cotton, viscose rayon, jute, ~-ramie, hemp and the like. Preferably, the cellulosic textile materials are completely of cellulosic fibers and more speci- ~
fically cotton fibers. However, blends of cellulosic fibers -~ .:
with non-cellulose materials for example wool, various syn-:.
thetic fibers, for example, polyester fibers, such as that . .
sold under the trademark Dacron~ acrylic fibers such as those l sold under the trademarks Creslan~, Acrilan~, Orlon~, ~abrics .~ ~
;~ 25 and polyamide fibers such as nylon and the like are within the scope of the invention.
The thermosetting aminoplast resins useful in the invention are resins which impart wrinkle resistance to cellu-losic textile materials. These materials may be employed singly or in combination. For example, the urea-formaldehyde resins including the methylol ureas and the alkyl ethers thereof, particularly the methyl ethers, the cyclic ureas, for example, 2-imidazolidinone, 1,2- and 1,3-propylene urea, and

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104~9~() 4,5-dihydroxy-2-imidazolidinone, their formaldehyde conden-sates and alkylated (particularly methylated) derivatives, and the like, are within the scope of the invention. Poly-methylol melamines and their alkylated derivatives, and more particularly their methylated derivatives wherein from 1-6 moles of formaldehyde are combined with the melamine and from 1-6 moles of an alcohol are useful resins within the scope of the invention. For example, dimethoxymethylmelamine, tri-methoxymethylmelamine, tetramethoxymethylmelamine, hexa-10 methoxymethylmelamine, and the like are useful. Methylol derivatives of 4,5-dihydroxy-2-imidazolidinone and the methy-lated derivatives thereof and mixtures of the methylol and alkoxymethyl derivatives of 4,5-dihydroxy-2-imidazolidinone with alkylated urea-formaldehyde resins and alkylated poly-15 methylol melamines are useful resins in the invention. These aminoplast resins are water-soluble and essentially monomeric -in form. Minor amounts of polymer may be present in these .. .
resins in the form of dimers, trimers, tetramers. The amino-plast resins may also be used in combination wlth other tex- ~ ~
20 tile finishing materials such as, for example, water and oil -repellents. Water repellents such as methylolated fiber re-active nitrogenous compounds containing long-chain (C6-Cl~) alkyl or alkoxyl groups, such as N-methylol stearamide, are ~ useful. Oil repellents such as polycarbon fluorocarbons, for t 25 example, are also useful in the invention. Curing catalysts are usually applied as aqueous solutions containing 20 to 100 ' - by weight of catalyst solids. The catalyst mixture of the in-vention comprise aqueous solutions containing about 20~ total catalyst solids comprising a mixture of from about 0.50 part 30 to about 2.0 parts, preferably from about 0.75 part to about J 1.5 parts, magnesium sulfate per part of aluminum sulfate.
The curing catalysts may be applied to textile materials with the resinous composition. The catalyst and resinous composi-J ~

11)4~9~0 tion may be applied by any conventional technique, such as immersion, padding, spraying and the like and followed, where necessary, by squeezing, hydroextraction or similar processes, in order to affix the desired amount of catalyst solids onto the fabric. For fibrous cellulosic materials, concentrations of total catalyst solids of from about O.01 to 2.5% and more, particularly from 0.15 to 0.75~, based on the dry weight of the fabric may be used. In the examples below the concentra-tion of the catalyst is reported on the weight of the pad bath employed.
Following the application of the resin and curing catalyst to the textile fabric, the material is subject to drying and curing operations to effect the properties of shrinkage control and wrinkle resistance. The drying and curing operation may be carried out in a single step or in separate steps. The temperatures at which the drying and - - -curing operations are effective vary widely and are influ-i enced to some extent by the fabric and type of resin employed.
Normally, the range of temperature extends from about 180F.
to about 400F. or even higher. Generally, the time of the drying or curing operation is inversely proportional to the temperature employed, and iis influenced by whether or not separate or combined drying and curing steps are employed.
Generally, when drying and curing are carried out in a com-bined operation, at time of from about 1 minute to about 10 ~ minutes may be employed at temperatures from about 225F. to $ - 400F. respectively. When the fabric has been dried prelim-inary to curing, curing times of 5 minutes to about 0.5 minute at a temperature of from 300 and 400F., respectively, are successfully employed.
In the examples below, the wrinkle recovery of the ~ ~

treated fabric is measured in degrees on a Monsanto Wrinkle ~ - -Recovery Tester following the American Association of Textile 1(~4~)940 Chemists and Colorists (AATCC) Test Method 66-1972. The tensile strength of the fabric is measured in pounds on a Scott Tester by the Grab Method, accord-ing to the A.S.T~M. standards.
The following examples are illustrative of the invention and are not to be construed as limitative. Parts and percentages are by weight unless otherwise designated.
Example 1 An aqueous pad bath is prepared conta;ning 4.5% by weight solids of 1,3-bis(hydroxymethyl)-4,5-dihydroxy-2-imidazolidinone, 0.6% by weight of magnesium sulfate and 0.05% by weight of aluminum sulfate, an application is made to 80 x 80 cotton percale by padding, an 82% wet pickup on the weight of the untreated fabric being obtained. The fabric is dried at 225 F. and cured at 325 F. for 1.5 minutes. The results obtained are as follows: -pH of Total (Warp ~ Fill) Tensile Strength bath Wrinkle Recovery Warp (lbs.) Fill (lbs.) .--. -~ ......................................................................... ................. .."-;
4.1 251 43 31 ;
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xamples 2-8 Six aqueous pad baths are prepared each containing 4.5% by weight resin solids of 1,3-bis(hydroxymethyl)-4,5-dihydroxy_2_;m;dazolidinone, 0.1%
of a commercial non-ionic surfactant, Deceresol Surfactant NI* conc., and various amounts of either a~ ;num sulfate or magnesium sulfàte as the accelerator. Application is made to 80 x 80 cotton percale by padding, and 82% wet pickup on the weight of the untreated fabrics being obtained. The fabrics are then dried at 225 F. and cured at 325 F. for 1.5 minutes. The results are reported in Table I.

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~-` , l~4as40 Examples 9 -13 Five aqueous pad baths are prepared, each con-taining 4.5% by weight resin solids of 1,3-bis(hydroxymethyl)-4,5-dihydroxy-2-imidazolidinone, 0.1% of a commercial non-ionic surfactant (Deceresol Surfactant NI Conc.) and 0.29%
~` by weight of aluminum sulfate plus varying amounts of magne-sium sulfate as the accelerator. Application is made to 80 x 80 cotton percale by padding, an 80~ wet pickup on the weight of the untreated fabric being obtained. The fabrics are then dried at 225F. and cured at 325F. for 1.5 minutes. The results are reported in Table II. Example 11 shows that a higher total tensile strength is obtained with the accelerator of this invention for 305F. wrinkle recovery than obtained in Examples 5 and 6 of Table I with aluminum sulfate alone.

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Examples 14-l9 Five aqueous pad baths are prepared with the same ingredients as in Examples 9-13 except that the amount of aluminum sulfate used in each bath is 0.23% by weight. The application, drying, and curing are carried out as in Ex-amples 9-13. The results obtained are reported in Table III.
These results show again the higher total tensile strength obtained with the accelerator of this invention than that obtained with aluminum sulfate in Table I for comparable wrinkle recovery values.

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Examples 20-23 An aqueous solution containing 11.5~ by weight of aluminum sulfate and 9.8% by weight of magnesium sulfate was prepared by dissolving the required amounts of the respective salts in water. This composition was then evaluated on dif-ferent textile materials as an accelerator for pre-cure pro-cesses versus a commercial accelerator.
Four aqueous pad baths were prepared having the following compositions in percentage amounts as shown below 10 in Table IV.
TABLE IV
Example No. 20 21 22 23 Commercial Resin (1) 10 10 25 25 Commercial Accelerator (2) 2 -- 5 --15 Accelerator of this Invention-- 2 -- 5 -Deceresol Surfactant N.I. Conc. (3~ 0.1 0.1 0.1 0.1 ~ Pad Bath pH 5.4 3.8 4.0 3.6 t~ (1) The commercial resin is a 45~ aqueous solution of '! 1,3-bis(hYdroxymethyl)-4,5~dihydroxy-2-imidazoli-dinone.

(2) The commercial accelerator is an aqueous solution of 30% by weight magnesium chloride.

(3) A non-ionic surfactant comprising an ethylene oxide addition product of nonylphenol. - -'. `'' .
The pad baths containing 2% by weight of the ac- ;
celerator solution were applied to 80 x 80 cotton percale and the baths containing 5% by weight of the activator solutions - - were applied to 65/35 polyester/cotton, and viscose rayon -~
challis. Application was by padding to obtain a wet pickup of 70% on 80 x 80 cotton, 55~ on 65/35 polyester/cotton and 110% on viscose challis, respectively. All samples were dried i. at225F. for 1.5 minutes and cured at 350F. for 1.5 minutes except for the viscose challis which was cured for 2.0 minutes ,~ at 320F. The results obtained are reported in Tables V and VI.

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1~4~940 (1) All washes reported in Table V consisted of a normal cycle at 110F. using a 4 lb. load, a high setting and 90 grams of AATCC Standard Detergent No. 124, followed by tumble drying after the last wash.

(2) AATCC Test Method 114-1971 :' .
~3) Discoloration of fabric, both 80 x 80 cotton and 65/35 -polyester/cotton shirting, after heating with AATCC Scorch Tester for 60 seconds at 400F., initially and after treatment with chlorine as per (2) above. The higher the rating, the less the discoloration; a rating of 5 equals no discoloration. ~ -.'',-''-

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(5) AATCC Test Method 112-1972 (Modified) was used on fabric having 5-10% residual moisture. The results, in parts per million, are averages of four sepàrate tests.

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real of 1,3-bis(hydroxymethyl)-4,5-dihydroxy-2-imidazolidi-none, 5% by weight of a commercial water repellent (Aerotex Water Repellent 96) and 3% by weight of a commercial fluoro-carbon oil repellent (Pentel~ G-26, from Pennwalt Corp.).
One pad bath contains 2% by weight of a commercial accelera- "
tor, while the other contains 2~ by weight of an aqueous solution of the catalyst of this invention. The pad baths are applied to 80 x 80 cotton percale to obtain a wet pickup of 80%, and the treated fabrics are then dried for 1.5 minutes at 225F. and cured for 1.5 minutes at 350F. The water and oil repellencies of the treated fabrics are measured initi-ally, after one dry cleaning, and five washings. The results obtained are shown in Table VII.

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Claims (6)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. In a process for curing a water-soluble thermosetting aminoplast resin treated textile material, the improvement which comprises treating a textile material by applying to said material about 1% to 10% of a water-soluble thermosetting aminoplast resin, based on the weight of the textile material, and from about 1% to 25% of a mixture of aluminum sulfate and mag-nesium sulfate based on the weight of said resin, said mixture of salts comprising from between 0.5 and 2.0 parts of magnesium sulfate per part of aluminum sulfate and curing said resin to a water-insoluble state by heating the so treated textile material to a temperature of from about 300° to 400°F.

2. A process according to Claim 1 in which the mixture of salts com-prises from between about 0.75 part and 1.5 parts of magnesium sulfate per part of aluminum sulfate.

3. A process according to Claim 2 in which the thermosetting resin comprises 1,3-bis(hydroxymethyl)-4,5-dihydroxy-2-imidazolidinone.

4. A process according to Claim 3 in which the curing is effected between 325°F. and 350°F.

5. A process according to Claim 4 wherein the thenmosetting resin and mixture of salts are applied in combination with water repellent and oil repellent materials.

6. A process according to Claim 4 wherein the water repellent material comprises a water-dispersible reactive nitrogenous compound containing a long-chain alkyl C6-C18 or alkoxyl C6-C18 group and the oil repellent material comprises a polycarbon fluorochemical.