CN102271506A - 赋予地毯持久抗菌特性的方法和处理组合物 - Google Patents

赋予地毯持久抗菌特性的方法和处理组合物 Download PDF

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CN102271506A
CN102271506A CN2010800041196A CN201080004119A CN102271506A CN 102271506 A CN102271506 A CN 102271506A CN 2010800041196 A CN2010800041196 A CN 2010800041196A CN 201080004119 A CN201080004119 A CN 201080004119A CN 102271506 A CN102271506 A CN 102271506A
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carpet
base material
foam
treatment compositions
fluoropolymer
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托德·马尔
詹姆斯·莱斯莉
丹尼·S·韦德
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Beaulieu Group LLC
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Abstract

本发明提供了赋予地毯持久抗菌特性的方法和处理组合物。该方法包括将包含第一抗菌化合物和含氟聚合物的组合物施用于地毯基材。然后将该地毯基材汽蒸。所述处理组合物可以包括：含氟聚合物；选自包括吡啶硫酮锌、含银抗菌化合物和其组合的组的抗菌化合物；和发泡剂。本发明还提供了使用所述处理组合物处理过的地毯产品或依照所述方法处理过的地毯产品。

Description

赋予地毯持久抗菌特性的方法和处理组合物
相关申请的交叉引用
本申请根据35 U.S.C. § 119(e)要求于2009年1月7日提交的美国临时专利申请号61/143,108的优先权，其内容通过引用整体结合入本文。
关于联邦资助的研究或开发的声明
不适用。
技术领域
本发明通常涉及地毯领域，尤其涉及具有抗菌性能的地毯。
背景技术
目前有各种各样的抗菌处理用于地毯工业以赋予人造地毯抗菌特性。最受欢迎的方法包括将抗菌化合物局部施于地毯基材或将抗菌化合物干施于地毯基材。然而，在工业中使用的常规抗菌处理方法对于地毯性能属性，如阻燃性、防污性和颜色牢固性，有破坏性的影响。例如，当在含氟聚合物处理后，在干燥机中干燥之前，将许多抗菌化合物局部地施用于地毯基材会增加地毯的可燃性。
发明内容
一方面，本发明提供了一种处理地毯基材的方法，该方法可以包括将包含第一抗菌化合物和含氟聚合物的组合物施用于地毯基材。
另一方面，本发明提供了一种处理地毯基材的方法，该方法包括将第一抗菌化合物和含氟聚合物施用于地毯基材，然后汽蒸该地毯基材。
又一方面，本发明提供了一种赋予地毯持久抗菌性能的处理组合物。该处理组合物可以包括：含氟聚合物；选自包括吡啶硫酮锌、含银抗菌化合物和其组合的组的抗菌化合物；和发泡剂。
本发明还提供了使用所述处理组合物处理过的地毯产品或依照所述方法处理过的地毯产品。
附图说明
图1 示出根据本发明一个或多个实施方案的赋予地毯持久抗菌特性的方法图。
具体实施方式
已经开发出多种方法使用现代化连续的施用设备为地毯提供持久抗菌特性，而不会消除或减小地毯的其它期望性能特征。本方法可以赋予包括各种类型纤维的多种地毯材料持久的抗菌特性，这些纤维包括，但不限于，尼龙、聚酯纤维、羊毛、聚丙烯纤维、PTT、丝、棉、人造纤维（rayon）、醋酸纤维、和其组合。
已发现用含氟聚合物进行连续的、单步的处理可以赋予地毯持久的抗菌特性，而不会减小综合性能属性。在一个实施方案中，在彻底施用（exhaust application）步骤中利用泡沫给液机（foam applicator）以泡沫的形式施用一种或多种抗菌化合物之后，立即将地毯送进汽蒸机，该泡沫给液机例如是商标为Küsters FluiconTM 的泡沫给液机(Andritz Küsters GmbH)。一旦地毯从汽蒸机出来，在进入干燥机之前，通常要将它进行清洗和抽提。
图1示出了所述方法的一个实施方案。处理过程10可以容易地与连续的制造过程整合，所述制造过程馈送地毯基材使其通过例如本领域公知的各种流水线（in-line）加工设备。在处理过程10中，地毯基材可以首先被馈送通过处理设备12，然后立即通过汽蒸机14，再通过清洗设备16和干燥机18。在处理设备12中，用包括一种或多种适合的抗菌化合物和含氟聚合物的泡沫对地毯基材进行泡沫处理。可以使用的各种抗菌化合物包括，但不限于，UltrafreshTM DM-50，可购自Thompson Research Associates (Canada)；AlphasanTM RC-5000，可购自Milliken Chemical (Spartanburg, SC)；Zinc OmadineTM 和ReputexTM 20，可购自Arch Chemical (Norwalk, CT)。在一个实施方案中，抗菌化合物是吡啶硫酮锌和/或AlphaSanTM ，AlphaSanTM是可购自Milliken Chemicals (Spartanburg, South Carolina)的抗菌化合物。Alphasan被认为是含银的磷酸锆基陶瓷离子交换树脂。
在一个优选的实施方案中，处理组合物被施用于地毯基材。该处理组合物可以是泡沫型，并且可以包括含氟聚合物、发泡剂、硫酸镁溶液、吡啶硫酮锌和含银的磷酸锆基陶瓷离子交换树脂。可以使用的各种含氟聚合物包括，但不限于，Centapel EFP-7，可购自Centaur Technologies (Dalton, GA)；UnidyneTM TG 580, TG 581, TG 2211 和 TG 2511，可购自Daikin America, Inc. (Orangeburg, N.Y.)；PM 1396, PM 1399, PM 1400 和 PM 1451，可购自3M Specialty Chemicals Division (St. Paul, Minn.)；CapstoneTM RCP 和 CapstoneTM TUC，可购自DuPont (Wilmington, Del.)。在一些实施方案中，处理组合物的含水组合物含有可购自3M Innovative Products (Minneapolis, Minnesota)的3M PM 1399。含氟聚合物可以以约0.05%至约20% owg（以物质重量计）的量提供，或以约0.4% owg的量提供。硫酸镁溶液可以以约0.1%至约20% owg的量提供，或以约2.0% owg的量提供。
可以使用的各种发泡剂包括，但不限于，Centafoam YEP-10，获自Centaur Technologies。所述发泡剂可以占所述处理组合物的约0.1至约100g/l或占所述处理组合物的约4.0g/L。所述处理也可以包括可从Centaur Technologies获得 的Centafresh，其量为地毯基材的约7g/sq.yd。所述处理组合物也可以包括各种pH值调节添加剂，例如System 404，其可获自Phoenix Chemical (Calhoun, Georgia)。所述处理组合物的pH值可以是约2.0至约12.0，或约2.1。
所述处理组合物可包括各种抗菌组合物，这些抗菌组合物包括，但不限于，吡啶硫酮锌和含银抗菌化合物。所述吡啶硫酮锌可以占所述处理组合物的约1至约50,000ppm，或占所述处理组合物的约500ppm。可以使用的各种含银抗菌化合物包括Alphasan，其可获自Milliken Chemicals (Spartanburg, South Carolina)。所述含银抗菌化合物可以占所述处理组合物的约1至约50,000ppm，或占所述处理组合物的约200ppm。
在一个实施方案中，地毯基材用含氟聚合物和抗菌化合物组合物处理后，该地毯基材立即在汽蒸机14中汽蒸。然后该地毯基材通过清洗设备16进行漂洗和抽提，在干燥机18中进行干燥。
观察到在单一阶段中用含氟聚合物和抗菌化合物处理地毯基材获得了意想不到的协同效应和提高的性能特性。特别地，被处理过的地毯显示了持久的抗菌性能，极好的防污性能和颜色牢固性，而阻燃性未降低。
实施例
在下面每个实施例中，用分散染料染色的簇绒聚酯长丝地毯用作地毯基材样品使用，该簇绒聚酯长丝地毯来自Beaulieu of America (Chatsworth, Georgia)。
在实施例中也使用了下列化学制品：吡啶硫酮锌，一种抗菌化合物，可获自Arch Chemicals (Norwalk, Connecticut)；Alphasan，一种含银抗菌化合物，可获自Milliken Chemicals (Spartanburg, South Carolina)；Invasan RCD，一种源于糖的清新剂，可获自Huntsman Textile Effects (Switzerland)；Centafresh，可获自Centaur Technologies；Centex Binder，一种结合剂，可获自Centaur Technologies；System 404，可获自Phoenix Chemical (Calhoun, Georgia)；和硫酸镁溶液。
实施例1
制备含0.4% owg（以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/L Centafoam YEP-10，7g/sq. yd Centafresh的泡沫。该泡沫的pH值用System 404调节至2.1。该泡沫溶液以100%吸湿率（wet pick up）被施用于聚酯长丝地毯。然后将该地毯汽蒸60秒，再漂洗和抽提，然后进入干燥机。
实施例2
以两步施用过程处理聚酯长丝地毯。所述第一步是通过泡沫的100%吸湿率的彻底施用。在第一步中使用的溶液含有0.4% owg （以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/L Centafoam YEP-10，7g/sq. yd Centafresh。该泡沫的pH值用System 404调节至2.1。该泡沫溶液被施用于纤维，然后将地毯汽蒸60秒，再漂洗和抽提。
抽提后，对地毯进行第二步处理。所述第二步是8%吸湿率的局部泡沫施用。在第二步中使用的溶液含有1000ppm的Alphasan和4.0g/l的Centafoam YEP-10。该溶液通过局部泡沫被施用于纤维，然后将地毯放进烘箱，140℃条件下直到烘干。
实施例3
以两步施用过程处理聚酯长丝地毯。所述第一步是通过泡沫的100%吸湿率的彻底施用。在第一步中使用的溶液含有0.4% owg （以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/L Centafoam YEP-10，7g/sq. yd Centafresh。该泡沫的pH值用System 404调节至2.1。该泡沫溶液被施用于纤维，并且汽蒸60秒，再漂洗和抽提。
抽提后，对地毯进行第二步处理。所述第二步是8%吸湿率的局部泡沫施用。在第二步中使用的溶液含有1000ppm的Alphasan、0.5% owg Centex Binder 和4.0g/l Centafoam YEP-10。该溶液通过局部泡沫被施用于纤维，然后将地毯放进烘箱，140℃条件下直到烘干。
实施例4
以两步施用过程处理聚酯长丝地毯。所述第一步是通过泡沫的100%吸湿率的彻底施用。在第一步中使用的溶液含有0.4% owg （以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/l Centafoam YEP-10，7g/sq. yd Centafresh。该泡沫的pH值用System 404调节至2.1。该泡沫溶液被施用于纤维，然后将地毯汽蒸60秒，再漂洗和抽提。
抽提后，对地毯进行第二步处理。所述第二步是8%吸湿率的局部泡沫施用。在第二步中使用的溶液含有500ppm的吡啶硫酮锌和4.0g/l Centafoam YEP-10。该溶液通过局部泡沫被施用于纤维，然后将地毯放进烘箱，140℃条件下直到烘干。
实施例5
以两步施用过程处理聚酯长丝地毯。所述第一步是通过泡沫的100%吸湿率的彻底施用。在第一步中使用的溶液含有0.4% owg （以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/l Centafoam YEP-10，7g/sq. yd Centafresh。该泡沫的pH值用System 404调节至2.1。该泡沫溶液被施用于纤维，然后将地毯汽蒸60秒，再漂洗和抽提。
抽提后，对地毯进行第二步处理。所述第二步是8%吸湿率的局部泡沫施用。在第二步中使用的溶液含有500ppm的吡啶硫酮锌、0.5% owg Centex Binder和4.0g/l Centafoam YEP-10。该溶液通过局部泡沫被施用于纤维，然后将地毯放进烘箱，140℃条件下直到烘干。
实施例6
以两步施用过程处理聚酯长丝地毯。所述第一步是通过泡沫的100%吸湿率的彻底施用。在第一步中使用的溶液含有0.4% owg （以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/l Centafoam YEP-10，7g/sq. yd Centafresh。该泡沫的pH值用System 404调节至2.1。该泡沫溶液被施用于纤维，然后将地毯汽蒸60秒，再漂洗和抽提。
抽提后，对地毯进行第二步处理。所述第二步是8%吸湿率的局部泡沫施用。在第二步中使用的溶液含有500ppm的Invasan和4.0g/l Centafoam YEP-10。该溶液通过局部泡沫被施用于纤维，然后将地毯放进烘箱，140℃条件下直到烘干。
实施例7
以两步施用过程处理聚酯长丝地毯。所述第一步是通过泡沫的100%吸湿率的彻底施用。在第一步中使用的溶液含有0.4% owg （以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/l Centafoam YEP-10，7g/sq. yd Centafresh。该泡沫的pH值用System 404调节至2.1。该泡沫溶液被施用于纤维，然后将地毯汽蒸60秒，再漂洗和抽提。
抽提后，对地毯进行第二步处理。所述第二步是8%吸湿率的局部泡沫施用。在第二步中使用的溶液含有500ppm的Invasan、0.5% owg Centex Binder和4.0g/l Centafoam YEP-10。该溶液通过局部泡沫被施用于纤维，然后将地毯放进烘箱，140℃条件下直到烘干。
实施例8
以两步施用过程处理聚酯长丝地毯。所述第一步是通过泡沫的100%吸湿率的彻底施用。在第一步中使用的溶液含有0.4% owg （以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/l Centafoam YEP-10，7g/sq. yd Centafresh。该泡沫的pH值用System 404调节至2.1。该泡沫溶液被施用于纤维，然后将地毯汽蒸60秒，再漂洗和抽提。
抽提后，对地毯进行第二步处理。所述第二步是8%吸湿率的局部泡沫施用。在第二步中使用的溶液含有200ppm的Alphasan、500ppm的吡啶硫酮锌和4.0g/l Centafoam YEP-10。该溶液通过局部泡沫被施用于纤维，然后将地毯放进烘箱，140℃条件下直到烘干。
实施例9
以两步施用过程处理聚酯长丝地毯。所述第一步是通过泡沫的100%吸湿率的彻底施用。在第一步中使用的溶液含有0.4% owg （以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/l Centafoam YEP-10，7g/sq. yd Centafresh。该泡沫的pH值用System 404调节至2.1。该泡沫溶液被施用于纤维，然后将地毯汽蒸60秒，再漂洗和抽提。
抽提后，对地毯进行第二步处理。所述第二步是8%吸湿率的局部泡沫施用。在第二步中使用的溶液含有200ppm 的Alphasan、500ppm的吡啶硫酮锌、0.5% owg Centex Binder和4.0g/l Centafoam YEP-10。该溶液通过局部泡沫被施用于纤维，然后将地毯放进烘箱，140℃条件下直到烘干。
实施例10
制备含0.4% owg（以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/l Centafoam YEP-10，7g/sq. yd Centafresh，200ppm的Alphasan，500ppm的吡啶硫酮锌的泡沫。该泡沫的pH值用System 404调节至2.1。该泡沫溶液被施用于地毯，然后将该地毯汽蒸60秒，再漂洗和抽提，然后放进干燥机。
实施例11
制备含0.4% owg（以物质重量计）3M PM 1399，2.0% owg硫酸镁溶液，4.0g/l Centafoam YEP-10，7g/sq. yd Centafresh，1,000ppm Invasan的泡沫。该泡沫的pH值用System 404调节至2.1。该泡沫溶液由于凝聚和沉淀未被施用于地毯。
实施例12
没有被处理的聚酯长丝地毯样品作为对照。
实施例13
所有实施例1-12的测试样品都经过美国纺织化学师与印染师协会(AATCC)测试方法138的测试，经受了10个循环的洗涤/抽提。这些样品进一步经过AATCC 测试方法123的测试，针对可燃性的燃烧测试（a pill test），抵抗性测试（repellency test）和40小时耐光性测试。
表1：结果
试验 # AATCC 123 第 I部分 AATCC 123 第II部分 AATCC 123 第III部分 燃烧测试 抵抗性 40 小时 耐光性
实施例 #1 不合格 不合格 不合格 合格 合格 合格
实施例 #2 不合格 不合格 不合格 合格 合格 合格
实施例 #3 不合格 合格 不合格 不合格 合格 合格
实施例 #4 不合格 不合格 不合格 合格 合格 合格
实施例 #5 合格 合格 不合格 不合格 合格 不合格
实施例 #6 不合格 不合格 不合格 合格 合格 合格
实施例 #7 不合格 不合格 不合格 不合格 合格 合格
实施例 #8 不合格 不合格 不合格 合格 合格 合格
实施例 #9 合格 合格 不合格 不合格 合格 不合格
实施例 #10 合格 合格 合格 合格 合格 合格
实施例 #11 未检测 未检测 未检测 未检测 未检测 未检测
实施例 #12 不合格 不合格 不合格 合格 不合格 合格
如表1所示，吡啶硫酮锌、Alphasan、Centafresh、PM 1399和 Centafoam YEP-1共耗尽时存在协同效应。通过这种意料不到的发现获得了出众的结果。获得了极好的抗细菌/抗真菌结果、抵抗性和耐光性，而未引起可燃性的不合格。
之前在实施例中已经列出的条件还可以有多种变化。本领域的技术人员知道设备和包括化学处理的彻底和局部施用在内的条件的多种变化。之前列出的说明是作为示例性的，而并非意味着限制。 

Claims (20)

1.一种处理地毯基材的方法，包括：
将包括第一抗菌化合物和含氟聚合物的组合物施用于地毯基材。
2.权利要求1所述的方法，进一步包括在将所述组合物施用于所述地毯基材后汽蒸所述地毯基材。
3.权利要求1所述的方法，其中所述第一抗菌化合物包括吡啶硫酮锌。
4.权利要求3所述的方法，其中所述组合物进一步包括含银抗菌化合物。
5.权利要求3所述的方法，其中所述组合物包括约1至约50,000ppm的吡啶硫酮锌。
6.权利要求1所述的方法，其中所述组合物以泡沫的形式施用于所述地毯基材。
7.权利要求1所述的方法，其中所述含氟聚合物以约0.05%至约20%owg的量施用于所述地毯基材。
8.一种处理地毯基材的方法，包括：
将第一抗菌化合物和含氟聚合物施用于地毯基材；并且之后
汽蒸所述地毯基材。
9.权利要求8所述的方法，其中所述第一抗菌化合物包括吡啶硫酮锌。
10.权利要求9所述的方法，进一步包括将含银抗菌化合物施用于所述地毯基材。
11.权利要求8所述的方法，其中所述第一抗菌化合物和含氟聚合物以泡沫的形式施用于所述地毯基材。
12.权利要求8所述的方法，其中所述含氟聚合物以约0.05%至约20%owg的量施用于所述地毯基材。
13.权利要求9所述的方法，其中所述第一抗菌化合物和含氟聚合物作为处理组合物施用于所述地毯基材，所述处理组合物包括约1至约50,000ppm的吡啶硫酮锌。
14.一种赋予地毯持久抗菌性能的处理组合物，包括：
含氟聚合物；
抗菌化合物，其选自包括吡啶硫酮锌、含银抗菌化合物和其组合的组；和
发泡剂。
15.权利要求14所述的处理组合物，其中所述处理组合物包括约1至约50,000ppm的吡啶硫酮锌。
16.权利要求15所述的处理组合物，其中所述处理组合物包括约1至约50,000ppm的含银抗菌化合物。
17.权利要求14所述的处理组合物，其中所述处理组合物的pH值为约2.0至约12。
18.一种根据权利要求1所述的方法处理过的地毯产品。
19.一种根据权利要求8所述的方法处理过的地毯产品。
20.一种用权利要求14所述的处理组合物处理过的地毯产品。
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US9493908B2 (en) 2016-11-15
US20140050879A1 (en) 2014-02-20
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US8586145B2 (en) 2013-11-19
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CA2749090A1 (en) 2010-07-15
US20100173121A1 (en) 2010-07-08
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