Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/39—Aldehyde resins; Ketone resins; Polyacetals
  • D06M15/41—Phenol-aldehyde or phenol-ketone resins
  • D06M15/412—Phenol-aldehyde or phenol-ketone resins sulfonated
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
  • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
  • D06M2101/16—Synthetic fibres, other than mineral fibres
  • D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M2101/34—Polyamides
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2201/00—Chemical constitution of the fibres, threads or yarns
  • D06N2201/02—Synthetic macromolecular fibres
  • D06N2201/0263—Polyamide fibres
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2205/00—Condition, form or state of the materials
  • D06N2205/02—Dispersion
  • D06N2205/023—Emulsion, aqueous dispersion, latex
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2209/00—Properties of the materials
  • D06N2209/14—Properties of the materials having chemical properties
  • D06N2209/146—Soilproof, soil repellent
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2209/00—Properties of the materials
  • D06N2209/14—Properties of the materials having chemical properties
  • D06N2209/147—Stainproof, stain repellent

Definitions

• the present invention relates to stain-resistant polyamide or polyamide blend carpets. More particularly, it relates to stain-resistant polyamide or polyamide-blend carpets according to the precharacterising part of claim 1 and having improved after-wash stain performance due to the incorporation of a stainblocker into the adhesive that is used to anchor the yarn tufts into the primary backing.
• Polyamide substrates such as carpeting, upholstery, fabric and the like, are subject to staining by a variety of foodstuffs containing acid-dye colorants.
• Stain-resist agents comprising sulfonated naphthol- or sulfonated phenol-formaldehyde condensation products and methods for treating polyamide carpets or carpet yarn with these compositions to render the carpets resistant to staining by acid dyes are disclosed in Ucci and Blyth US-A-4,501,591, Blyth and Ucci US-A-4,592,940, Blyth and Ucci US-A-4,680,212, and Greschler, Malone, and Zinnato US-A-4,780,099.
• Stain-resist compositions comprising mixtures of sulfonated phenol-formaldehyde condensation products with a hydrolyzed polymer of maleic anhydride and one or more ethylenically unsaturated aromatic monomers are described in Fitzgerald, Rao, Vinod, and Alender, US-A-4,883,839. Processes for applying these stain-resist compositions to polyamide substrates are also described in Fitzgerald, et. al. US-A-5032136 which is a divisional application of the above-mentioned patent. An alternate process for applying these stain-resist compositions is disclosed in Fitzgerald, Materniak, Moores, Openstone, and Rivet in their US-A-5,087,121.
• EP-A-332,342 discloses a method for imparting stain resistance to fibrous polyamide materials that involves contacting the materials with an aqueous solution comprising polymethacrylic acid, copolymers of methacrylic acid, or combinations thereof.
• GB-A-2,129,841 discloses tufted nylon carpets having an adhesive backing composition containing fixing agents for anionic dyestuffs, at least some of which are also stain-resist agents of the type described herein. The purpose of the addition of those agents is to prevent water spotting.
• stain-resist properties of polyamide carpets that have been prepared using the stain-resist compositions and procedures referenced above may be degraded when the carpet is cleaned with various detergents. When this occurs, the carpet is no longer sufficiently resistant to re-staining in the areas where washing has occurred, and subsequent stains resulting from spills containing acid-dyestuffs will leave a stained area that cannot be completely cleaned, leaving an undesirable visible stain. In some instances, this problem may be overcome by applying more stain-resist composition to the carpet pile in the initial treatment process.
• the present invention provides stain-resistant polyamide or polyamid carpets which exhibit improved stain-resist performance after washing with a detergent, through addition of a stain-resist composition, suitable for rendering polyamide fibers resistant to staining by acid dye stuffs, to the adhesive used to anchor the carpet tufts in the primary backing.
• the present invention also makes it possible to apply less of the stain-resist composition to the carpet pile than is normally required.
• the stain-resist agent may be applied to the carpet pile under milder pH conditions than would have been necessary to achieve acceptable afterwash performance when using standard adhesives that do not contain a stain-resist composition, thus increasing the life of the equipment used to apply the stain-resist compositions.
• the present invention increases the "tuft-bind" which is the term used to describe the force necessary to completely remove a yarn tuft from the carpet.
• the invention therefore, serves to more securely anchor the carpet yarns into the primary backing.
• the carpets of the current invention are constructed using methods well known in the art, except that a modified adhesive composition containing a stain-resist composition is used.
• a typical tufted carpet has a primary backing of polypropylene or jute which may be woven or nonwoven, stitched with tufts which generally are loops and/or cut loops of polyamide carpet yarn which extend upward from the backing to form the carpet pile.
• the underside of the primary backing is coated with an adhesive composition which serves to anchor the tufts in the primary backing.
• the carpet pile may be comprised exclusively of polyamide yarns or of polyamide-blend yarns in which polyamide fibers are blended with fibers of one or more other types commonly used in carpeting, i.e. wool, polypropylene, acrylic, etc.
• a secondary backing of woven jute or polypropylene is usually applied to the underside of the carpet following application of the adhesive.
• the adhesive typically is a latex emulsion, which is dried and heated in a separate curing step. Normally the weight of the dry latex as applied to the carpet ranges from about (20-32 ounces/square yard) 0.68-1.05 kg/m2, with (24 ounces/sq. yard) 0.81 kg/m2 being most common.
• the carpet is typically installed with an underpad between the floor and the carpet.
• a foam may be applied to the primary backing which serves to anchor the tufts as well as to replace the secondary backing and padding.
• an adhesive is considered to be any composition which is used to anchor the carpet tufts in the primary backing.
• examples include the latex emulsions and foam compositions described above.
• the specific adhesive used depends on the type of carpet construction and end use (for example, residential, commercial, carpet tile, automotive carpet, etc.).
• Examples of adhesive compositions which may be used in the present invention comprise latex emulsions which are known in the art for binding tufts of fiber in primary carpet backings.
• Examples of adhesive polymers useful in these emulsions are disclosed in Ucci US-A-4,579,762 and include, but are not limited to, polyvinyl acetates, polyacrylates, ethylene-vinylacetate copolymers, styrene-butadiene copolymers and carboxy styrene-butadiene copolymers.
• Typical foams include urethane and latex compositions.
• the amount of stain-resist agent required in the adhesive composition to provide a carpet having improved afterwash performance will depend on the particular stain-resist composition being used. It will also depend on the nature of the carpet pile fibers, including the specific polyamide polymer, the type of heatsetting process used, the amount of stain-resist composition originally on the carpet pile and the process used to apply the stain-resist agent to the carpet pile fibers. The same stain-resist agent that was used to treat the carpet pile fibers may be used in the adhesive. Alternatively, a different stain-resist agent may instead be used.
• the latex contains from 0.04 to 3.0 weight percent of the active stain-resist agent, the agents typically being supplied in the trade in the form of aqueous stain-resist compositions having concentrations from 20-30%. It is most preferred to use compositions containing from 0.04 weight percent to 0.9 weight percent of the stain-resist agent based on the weight of the latex.
• the stain-resist agents are polymeric in nature and are either condensation polymers, addition polymers derived from one or more monomers having ethylenic carbon-carbon unsaturation, or mixtures of such condensation and addition polymers.
• the condensation polymers are derived from formaldehyde and either a sulfonated phenol or a sulfonated naphthol, and preferably a monosulfonated phenol.
• the addition polymers contain repeating units derived from maleic acid or methacrylic acid and up to 70 weight percent of a comonomer having ethylenic unsaturation and containing from 2 to 20 carbon atoms.
• polymers include those such as the type described in EP-A-0329899, published August 30, 1989, or in the aformentioned US-A-4,883,839 to Fitzgerald et al., the disclosure of each of which is incorporated herein by reference.
• These polymers contain repeating units derived from a hydrolyzed polymer of maleic acid and one or more ethylenically unsaturated aromatic comonomers. Examples of such comonomers are styrene, alphamethyl styrene, and stilbene.
• the maleic acid generally is derived from maleic anhydride, that is, maleic anhydride is polymerized to form either a homopolymer or a copolymer such as with styrene.
• the polymerized maleic anhydride can be hydrolyzed to maleic acid which, in turn, can be partially or wholly converted to its stereoisomer fumaric acid, such as by treating at an elevated temperature.
• Other types of addition polymers include those of the type disclosed in the aforementioned EP-A-332,342 to Chang et al. and US-A-4,822,373 to Olson et al., each of which is also incorporated herein by reference.
• Examples of these include the homopolymer polymethacrylic acid and copolymers of methacrylic acid with up to 70 weight percent of an ethylenically unsaturated monomer such as alkyl acrylates having 1-4 carbon atoms, itaconic acid, and sodium sulfostyrene.
• an ethylenically unsaturated monomer such as alkyl acrylates having 1-4 carbon atoms, itaconic acid, and sodium sulfostyrene.
• alkali metal salts of both the condensation and addition polymers may also, of course, be used.
• soil-resist composition may also be added to the adhesive in combination with the stain-resist.
• the soil-resist compositions contain organic compounds having a plurality of fluorine atoms which tend to repel foreign materials, i.e., soil.
• Soil-resist compositions may also, of course, be topically applied to the fibers in the tufts in the conventional manner.
• the polyamides used to form the fibers in the tufts are aliphatic or cycloaliphatic in nature. Generally, they have the formula where -R-, -R1-, and -R2- are divalent aliphatic or cycloaliphatic radicals containing 4 to 20 carbon atoms.
• Such polyamides include polyhexamethylene adipamide, polyhexamethylene dodecamide, polycaprolactam, 6,6/6 copolyamide, polyaminoundecanoic acid, etc.
• the subscripts n and m represent integers large enough to ensure fiber forming characteristics of the polyamide. Generally, the number average molecular weight of the polymer will be from 10,000 to 500,000.
• stain-resist compositions containing from as little as 0.2 to as much 1.5 weight percent active stain-resist agent (on weight of fiber) are directly applied to the fibers in the tufts to provide satisfactory stain-resistance both before and after washing.
• the amount actually used will, of course, vary depending on such factors as the specific stain-resist being applied, the fiber polymer, heat-setting method, pH and other application conditions.
• comparable performance can be achieved with as much as about 10% less stain-resist, i.e. by treating the carpet pile with about 0.18 to 1.35 wt.% of the active agent.
• Stain Test 1 used herein consists of two parts: 1) a 24 hour stain test on "As Is", i.e. tufted, dyed, and latexed, but unwashed carpet; and 2) a 24 hour stain test on a carpet which has been subjected to a wash prior to staining (referred to as "After Wash”).
• the staining agent for both the "As Is” and “After Wash” evaluations is a solution containing 0.054 g/l of Red Dye No. 40 prepared from commercially-sold, cherry-flavored, sugar-sweetened "Kool-Aid" (TM) premix.
• the solution is made by dissolving 45 grams of this "Kool-Aid" premix powder in 500 ml of water, and it is allowed to reach room temperature, i.e. (75°F ( ⁇ 5°F) 24°C ( ⁇ 3°C), before using.
• a carpet sample tufted from approximately 15 grams of fiber is prepared. Half of this sample is immersed in 40 cm3 of the staining agent. The staining agent is worked into the tufts for uniform staining. The sample is then placed on a flat non-absorbent tray or surface. The sample is left undisturbed for 24 hours ( ⁇ 4). Then the stained sample is rinsed thoroughly with cool tap water, extracted to remove excess liquid, and dried.
• a 15 gram sample of carpet is prepared.
• a detergent solution is made by adding 57 grams of "Dupanol WAQE” (TM), an aqueous composition containing about 30 weight percent of a surfactant made by neutralizing the reaction product of chlorosulfonic acid and lauryl alcohol (predominantly sodium lauryl sulfonate), to 3.8 liters of water and adjusting the pH to 10.0 with an aqueous solution of about 0.2% trisodium phosphate, and allowing the solution to reach room temperature, i.e. (75°F ( ⁇ 5°)) 24°C ( ⁇ 3°), before using.
• the carpet sample is completely immersed in the detergent solution for 5 minutes, the detergent solution being discarded after each wash. Then the sample is rinsed thoroughly with cool tap water, extracted to remove excess liquid, and dried.
• the staining agent is then applied and evaluated in the same manner as described above in the "As Is" evaluation.
• a carpet For a carpet to be considered to have a commercially acceptable level of stain-resistance, it should have a rating of at least 4 on the above-described Stain Rating Scale for both the "As Is" and "After Wash” evaluations.
• Stain Test 2 The procedure followed in Stain Test 2 is identical to that described for Stain Test 1, both for "As Is” and "After Wash” evaluation, except that a different method is used for staining the carpet sample. Instead of immersing half of the carpet sample in the staining agent, the specimens are placed on a flat non-absorbent surface and 20 ml of the staining agent is poured on each specimen through a cylinder ((1-1/2 to 2 inches) 3.8 to 5.1 cm diameter) to form a (1-1/2 to 2 inch) 3.8 to 5.1 cm circular stain. The cylinder is removed and the solution worked into the tufts for uniform staining. The samples are left undisturbed for 24 ⁇ 4 hours, rinsed thoroughly with cool tap water, squeezed dry and an extractor used to remove excess solution.
• Tuft-bind is measured using ASTM D 1335.
• BCF bulk continuous filament nylon 6,6 yarns of 1150 total denier and comprised of 68 filaments (of trilobal cross-section) were produced by a conventional process. Two of these yarns were plied and twisted to provide a yarn having a balanced twist of 3.5 turns per inch (tpi). The resulting yarn was then conventionally heat-set in a Superba heat-set apparatus at (270 degrees F) 132°C. A cut pile tufted carpet was constructed from the heat set yarn to the following specifications: (40 oz/sq.yd.) 1.36 kg/m2, (3/4 inch) 1.9 cm pile height, (1/8 inch gauge) 31.5 tufts/decimeter, (8 1/4 stitches per inch) 3.25 stitches/cm.
• This carpet was dyed to a light blue shade using a Kusters "Fluidyer” TM on a continuous dye line.
• a conventional continuous dye process at 400% wet pick up
• TM Tectilon Biue 4R-200
• TM Tectilon Red 2B-200
• TM 0.0045% Tectilon Orange 3G-200
• TM C.I. Acid Orange 156
• pH 6.0
• the carpet was then treated with a bath containing a stain-resist composition on a Kusters "Flex-Nip" (TM) dyeing apparatus.
• the specific stain-resist composition used was an aqueous mixture of a hydrolyzed styrene/maleic anhydride copolymer and a sulfonated phenol-formaldehyde condensate, as described in the previously referenced US-A-4,883,839. (The molar ratio of the copolymer was 1:1 styrene:maleic anhydride, and the copolymer had a number average molecular weight of 1600).
• the stain-resist composition was 75.3 wt% of a 30 wt% solution of the styrene:maleic anhydride copolymer, 13.3 wt% of a 30 wt% solution of the phenol-formaldehyde condensate, and 11.4% of the anionic surfactant "Alkanol ND" (TM), which contains 45 wt% of the disodium salt of dodecyldiphenyl oxide disulfonic acid as its active ingredient.
• TM anionic surfactant
• the bath was prepared by water dilution of the stain-resist composition to contain 5.4 wt% of the composition owf (on the weight of fiber) or 1.2% owf based on active ingredient of the hydrolyzed styrene/maleic anhydride copolymer, 0.22% owf based on active ingredient of the sulfonated phenol-formaldehyde condensation product, and 0.28% based on active ingredient owf of the anionic surfactant "Alkanol ND" (TM).
• the carpet sample was treated by adjusting the pH of the stain-resist bath to 2.3 using sulfamic acid.
• the bath was applied to the carpet samples in a Kusters "Flex-Nip" (TM) at about (80 degrees F) 26.7°C and 400% wet pick-up on weight of fiber, followed by steaming in a vertical steamer for a residence time of 3 minutes. After the steamer, the carpet was rinsed and extracted. The carpet was subsequently treated with a commercial fluorochemical in a conventional spray application and the carpet was dried in an oven. This carpet sample is designated as Sample A.
• TM Kusters "Flex-Nip”
• Samples B, C, and D were processed using the same procedure as for Sample A except that the pH was adjusted to 3.0, 3.5, and 4.0. These samples are referred to as Samples B, C, and D respectively.
• a commercially available styrene-butadiene latex composition (Latex-V 9370 (TM) made by Colloids Inc., 207 Canal Ave. Gastonia, N.C. 28054) was hand applied to sections of the carpet samples A-D and the carpets were oven-cured at (250 degrees F) 121°C for 5-7 minutes. Another set of samples was prepared using carpet Samples A-D except that the latex composition was modified to contain 1 wt% on the weight of latex (owl) of the same stain-resist solution that was applied to the carpet pile.
• This stain-resist composition was added to the latex while stirring slowly for about 5 minutes using a Gifford Wood (TM) mixer, Model 76-IL, made by J. W. Greer, Inc.
• This set of carpet samples is designated by sample numbers A' - D' in TABLE 1 below.
• the dried latex weight on the carpet both for these samples and for all the carpets described in these Examples was approximately (30 oz/sg.yd.) 1.02 kg/m2.
• the carpet was tested for stain resistance by Stain Test 2.
• the results from the Table 1 show that the samples with modified latex containing the stain-resist composition exhibited improved "after wash” stain performance versus samples with standard latex for all the samples regardless of the application pH of the stain-resist composition.
• the "as is” performance was almost equal for all the samples. This demonstrates that it is possible to apply the stain-resist composition to the carpets at a higher pH (i.e. milder conditions) and to achieve acceptable afterwash performance through the addition of stain-resist to the latex.
• the dyed carpet and the stain-resist composition as described in Example 1 were used for this experiment. Two samples were prepared, one at 4.5% owf and the other at 3.75% owf of the stain-resist composition, and are designated as Samples E and F, respectively.
• the stain-resist bath was adjusted to a pH of 2.3 with sulfamic acid.
• the samples were finished with the standard latex and also with the modified latex containing 1% owl of the stain-resist composition as described in Example 1. These samples are referred to as Samples E' and F' in TABLE 2 below.
• the samples were tested using Stain Test 2. This example demonstrates that the use of the stain-resist composition in the latex improves the staining performance for the samples which are processed with less stain-resist composition applied to the carpet pile.
• a mill-processed carpet sample was used in this example.
• the carpet was made from a BCF nylon 6,6 yarn of 1410 total denier. Two of these yarns were plied and twisted to provide a yarn having a balanced twist of 4.0 tpi.
• the resulting yarn was then heat-set in a Superba heat-set apparatus with stuffer box attachment at (270 degrees F) 132°C.
• a cut-pile tufted carpet was constructed from the heat-set yarn to the following specification: (28 oz/sq.yd ) 0.94 kg/m2, (3/4 inch) 1.9 cm pile height, (3/16 inch gauge) 21 tufts/decimeter, (7.8 stitches per inch) 3.07 stitches/cm.
• This carpet was dyed to an off-white color using levelling acid dyes on a Kusters continuous dye line.
• the carpet was then treated in a Kusters "Flex-Nip" (TM) with 6.0% owf of the same stain-resist composition as described in the Example 1, except that the composition did not contain the "Alkanol ND” (TM) surfactant.
• the stain resist composition was applied at a pH of approximately 2.25.
• Example 3 The same dyed and stain-resist treated carpet samples as described in above Example 3 were used in this example.
• two further modified latex compositions were used for this experiment.
• the first comprised the commercial latex used in previous examples and 1 wt% owl of a combined stain and soil resist composition, identified as SRC-1.
• SRC-1 contains 8.72 wt% based on active ingredient of the hydrolyzed styrene/maleic anhydride copolymer, 1.74 wt% based on active ingredient of the sulfonated phenol formaldehyde condensate and 3.8 wt% based on active ingredient of "Teflon" MF (TM) (a 30% active, anionic fluorochemical commercially available from E. I. du Pont de Nemours and Company, Wilmington, DE).
• the second modified latex contained the commercial latex and 1% owl of the "Teflon" MF fluorochemical composition.
• the carpet samples were hand latexed, oven-cured and then stain tested according to Stain Test 1.
• the results show that the afterwash stain improvement is greatest where the latex is modified with the stain-resist composition alone, followed by the one where the latex contains both stain resist and soil resist (fluorochemical).
• the sample where the latex is modified with the soil-resist chemical (fluorochemical) alone did not improve the afterwash stain performance.
• the dyed BCF carpet sample tufted from Superba-set yarns as described in Example 1 was used in this example, except the carpet was not treated with a stain-resist composition.
• One sample was prepared with the standard latex and four others were prepared with modified latex.
• the latex of each of these samples was modified to contain between 1% to 10% owl of the same stain-resist composition as that used for Example 3 (referred to as SRC-2 for identification purpose below).
• the addition of 1%, 3%, 5%, and 10% owl of this composition corresponds to the addition of 0.27 wt%, 0.81 wt%, 1.35 wt%, and 2.7 wt% respectively of the active components.
• Another sample was prepared with the standard latex to which was added 3 wt% owl of a solution containing 30 wt% active ingredient of a sulfonated phenolic formaldehyde condensate type stain-resist composition (referred to as SRC-3 for identification purpose below), i.e. 0.9 wt% owl of the condensation product itself.
• SRC-3 sulfonated phenolic formaldehyde condensate type stain-resist composition
• a mill-processed carpet sample made from 4.5 denier, unheatset nylon 6,6 staple was used in this example.
• the carpet had the following construction: (16 oz/sq.yd.) 0.54 kg/m2, (1/10 inch gauge) 39.4 tufts/decimeter and (1/4 inch) 0.64 cm pile height.
• the carpet was dyed to a light yellowish beige color in a beck dyeing process using premetallized dyes.
• One sample was prepared by using a standard latex while others were prepared with a modified latex containing varying percentages of a stain-resist composition. All samples were hand latexed, and oven-cured, after which a jute backing was applied.
• the stain-resist compositions added to the latex were SRC-2 and SRC-3, as previously described in Example 5.
• the SRC-2 concentration was varied between 1 wt% and 5 wt% owl, while SRC-3 was used at 3 wt% owl. All the samples were then stain tested using Stain Test 1.
• Stain Test 1 The results reported in Table 6 below show that there is a marginal improvement in the afterwash performance for the latex samples containing the stain-resist composition SRC-2 at 5% owl addition (1.35 wt% owl of the active components) and at 3% owl (0.9 wt% owl of the active component) of stain-resist composition SRC-3.
• Examples 5 and 6 demonstrate that the degree of improvement in afterwash stain performance depends upon the nature (i.e. the dye rate) of the pile yarn used.
• the Superba-set yarn being more open in structure, has a higher dye rate than unheatset yarn, and thus is more susceptible to staining.
• the Superba-set yarn requires that more of the stain-resist agent be used in order to achieve a specified level of stain performance.
• Suessen-set yarn is less susceptible to staining than Superba-set yarn. It can therefore be expected that less stain-resist agent would be required for effective results on carpets tufted from Suessen-set yarns.
• nylon 6,6 is less vulnerable to staining than other polyamides such as nylon 6, it can be expected that adjustments in the amount of stain-resist agent added to the latex will be required depending on the specific polymer type in the fiber.
• the dyed carpet as described in the Example 1 was used for this experiment.
• the carpet was treated in a Kuester's "Flex-Nip" (TM) whith 6.0% owf (1.62 wt% active components) of the same stain resist composition as described in Example 1, except that it did not contain the "Alkanol ND” (TM) surfactant.
• the stain resist composition was applied at a pH of approximately 2.5.
• the samples were finished with the standard latex and also with modified latex compositions containing 2% owl of three stain-resist compositions used commercially. Each of these stain-resist compositions is chemically different from one another as outlined in different patents.
• a carpet prepared and dyed as described in Example 1 was treated in a Kuester's "Flex-Nip" (TM) with a 5.0 % owf of a stain-resist composition, identified as SRC-4, at a pH of approximately 2.5.
• the SRC-4 stain-resist composition was a 25% active solution of the sodium salt of a hydrolyzed styrene-maleic anhydride copolymer of the type described in EP-A-0329899, published August 30, 1989. Samples were finished both with a standard latex and also with modified latex compositions containing 1.0, 2.0, and 3.0 % owl of two different stain-resist agents.
• SRC-4 which is the same as that applied on the fiber
• SRC-5 which is a nominal 30% active solution of "Mesitol” FC40556D (TM), a sulfonated phenolic formaldehyde condensate product sold by Mobay Corporation.
• TM sulfonated phenolic formaldehyde condensate product sold by Mobay Corporation.
• the samples were then stain tested using Stain Test 1 and evaluated for tuft-bind to determine the force required to pull a tuft completely out of each carpet sample.
• the results reported in Table 8 below show that the "As Is" and the "After Wash” stain performance are both improved by the modified latex compositions, whether the modification is by SRC-4 or SRC-5.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Artificial Filaments (AREA)

Applications Claiming Priority (2)

Publications (2)

Family

ID=24139941

Family Applications (1)

Country Status (6)

Families Citing this family (8)

Family Cites Families (2)

• 1991
  • 1991-06-11 WO PCT/US1991/003969 patent/WO1991019849A1/en active IP Right Grant
  • 1991-06-11 JP JP91510670A patent/JPH05507770A/ja active Pending
  • 1991-06-11 DE DE69101241T patent/DE69101241T2/de not_active Expired - Fee Related
  • 1991-06-11 CA CA 2084091 patent/CA2084091A1/en not_active Abandoned
  • 1991-06-11 EP EP19910910760 patent/EP0533737B1/en not_active Expired - Lifetime
  • 1991-06-11 AU AU80844/91A patent/AU646269B2/en not_active Ceased

Also Published As

Similar Documents

Legal Events