Classifications

• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
  • C11D3/0005—Other compounding ingredients characterised by their effect
  • C11D3/0021—Dye-stain or dye-transfer inhibiting compositions
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D17/00—Detergent materials or soaps characterised by their shape or physical properties
  • C11D17/04—Detergent materials or soaps characterised by their shape or physical properties combined with or containing other objects
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
  • D06P1/44—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed using insoluble pigments or auxiliary substances, e.g. binders
  • D06P1/655—Compounds containing ammonium groups
  • D06P1/66—Compounds containing ammonium groups containing quaternary ammonium groups
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
  • D06P5/22—Effecting variation of dye affinity on textile material by chemical means that react with the fibre
  • D06P5/225—Aminalization of cellulose; introducing aminogroups into cellulose

Definitions

• the present invention relates to a dye scavenging textile material and method for manufacturing thereof.
• the currently employed methods have the drawback that the formed textile material needs to be treated with the dye scavenging compound, which requires a long and laborious process and specialized equipment. It is an object of the present invention to provide an alternative method for manufacturing a dye scavenging substrate that simplifies existing processes.
• the inventors of the present invention have found that some or all of the above objects may be achieved by an alternative process in which not the preformed textile material, but rather the fibers from which the textile material is formed are treated with the dye scavenging compounds prior to the formation of the textile material and then combined with untreated fibers to obtain the dye scavenging textile material.
• the thus obtained materials are more versatile with respect to their properties and show improved dye scavenging capabilities and increased sustainability while retaining good mechanical strength.
• the present invention thus provides for a dye scavenging textile material, preferably a nonwoven, woven or knitted fabric, a braided rope or ball, comprising
• the invention also encompasses a method for manufacturing a dye scavenging textile
• At least one relates to one or more, i.e. 1, 2, 3, 4, 5, 6, 7, 8, 9, or more. If used in combination with a compound, the term does not relate to the absolute number of molecules but rather to the number of different types of said compound. "At least one dye scavenging compound” thus means that at least one type but that also 2 or more different dye scavenging compound types can be present.
• Free of or "essentially free of”, as used herein interchangeably in relation to a specific type of component means that the referenced composition does not contain the respective component in deliberately added form. In various embodiments, this means that the respective component is present in concentrations of no more than 1 wt.%, preferably no more than 0.5 wt.%, more preferably no more than 0.1 wt.% of said component relative to the total weight of the composition. Most preferably, said component is not contained at all.
• Absorbent as used herein in relation to the fibers, means that said fibers can absorb other compounds, in particular the dye scavenging compounds, in liquid form, such as an aqueous solution.
• the absorbent fibers are preferably cellulosic fibers, i.e. comprise or consist of cellulose.
• the fibers can be natural or regenerate cellulose-based fibers, such a cotton or rayon, or mixtures of natural and regenerate fibers. Particularly preferred are regenerated cellulose fibers, such as viscose, modal and lyocell or combinations thereof. It is preferred that the fibers used are made from purified cellulose, in particular cellulose that contains less than 10% by weight of other components, such as hemicellulose or lignin. It is preferred that the cellulose from which the fibers are formed is essentially free of hemicellulose and lignin. It is also preferred that the fibers used in the textile materials and methods described herein are not wood pulp. In any case, the fibers used herein are water-insoluble, i.e. they do not dissolve in water under the given conditions, but remain in solid form.
• regenerate cellulose fibers are well-known in the art and involve the chemical conversion of purified cellulose, for example from wood pulp or other natural sources, into a soluble compound, which is then dissolved and forced through a spinneret to produce filaments which are chemically solidified, resulting in fibers.
• Suitable lyocell fibers are for example marketed under the Tencel® brand by Lenzing, AT.
• fibers are preferably cellulose-based, it is similarly possible to use fibers that comprise or consists of cellulose derivatives, such as cellulose ester, in particular cellulose acetate.
• the fibers particularly applies to the absorbent fibers used for the application of the dye scavenging compounds.
• the polymeric fibers that are combined with the fibers treated with the dye scavenging compound may be any of the afore-described cellulosic fibers and even may be the same fiber type as the one treated with the dye scavenger, in various embodiments, the untreated polymeric fibers that are combined with the treated polymeric fibers are a different type of fiber.
• the fibers may be selected from cellulose or synthetic fiber types, such as polyester. Particularly preferred are polyester fibers, such as poly(lactic acid) fibers. However, alternatively also cotton or viscose fibers, such as for example lyocell fibers, may be used.
• Treated fiber relates to those fibers to which the dye scavenging compounds have been applied, in particular according to the methods described herein.
• Untreated fiber as used herein, thus relates to those fibers not treated with the dye scavengers. Both are combined in the materials and methods of the invention, as it has surprisingly been found that a combination of such treated and untreated fibers provides for materials with advantageous properties compared to a fabric that has been completely treated with dye scavengers.
• the absorbent fibers are cellulosic fibers, preferably viscose, and the untreated fibers are non-cellulose polymeric fibers, preferably polyester fibers, more preferably poly(lactic acid) fibers.
• the treated fibers are preferably used in amounts by weight of 30 to 95 % by weight, preferably 50 to 90% by weight, more preferably 65 to 80 % by weight, such as, for example 70, 75 or 80 % by weight, relative to the total weight of the fibers of which the textile material consists.
• the untreated fibers are used in amounts of 5 to 70 % by weight, preferably 10 to 50 % by weight, more preferably 20 to 35 % by weight, such as, for example, 20 or 25 or 30% by weight, relative to the total weight of the fibers of which the textile material consists.
• the textile material does not contain any other fiber types, i.e. is completely formed from the treated and untreated fibers described herein.
• Any diameter or denier of fiber can be used in the present invention. Preferred are however dimensions as typically used in yarn/textile manufacturing.
• the dye scavenging compound is a compound of formula (I) or (II), wherein R 1 , R 2 , R 3 or R 4 , R 5 , R 6 are each independently methyl, ethyl, propyl, butyl, benzyl or a hydroxyl substituted derivative thereof, preferably methyl, ethyl, n-propyl or n-butyl, more preferably methyl or ethyl, most preferably methyl.
• X' is a halogen atom, preferably selected from Cl or Br.
• Y' - and/or Y" - are selected from chloride, bromide, sulfate or sulfonate, preferably chloride. It is understood that when Y' or Y" is a sulfate or sulfonate anion, that this refers to 1 ⁇ 2 sulfate/sulfonate ion, i.e. that the anion is shared by two positively charged ammonium compounds.
• the dye scavenging compound is preferably a salt of epoxy propyl ammonium having the general formula (II), preferably a glycidyltrimethylammonium salt, also known as (2,3-epoxypropyl)trimethylammonium salt, more preferably the chloride salt, available in solid form or as a 72% aqueous solution from Sigma Aldrich, wherein R 4 , R 5 , R 6 are each methyl and Y" - is chloride.
• the compound may be a compound of formula (I), for example 3-chloro-2-hydroxypropyltrimethylammonium chloride, available from Sigma Aldrich, wherein R 1 , R 2 , R 3 are each methyl, X' is chlorine, and Y' - is chloride.
• formula (I) for example 3-chloro-2-hydroxypropyltrimethylammonium chloride, available from Sigma Aldrich, wherein R 1 , R 2 , R 3 are each methyl, X' is chlorine, and Y' - is chloride.
• dye scavenging compound(s) or formula (I) or (II) are used in an amount of at least 30 wt.-%, preferably at least 50 wt.-% relative to the total weight of dye scavenging compounds used.
• the dye scavenging compound is applied to, absorbed by or impregnated into the fibers.
• the dye scavenging compound is applied to the fibers in form of an aqueous solution, preferably an alkaline aqueous solution comprising a base and optionally further comprising at least one surface active agent to improve wetting of the fibers.
• Suitable surface active agents are known in the art.
• the aqueous solution may be contacted with the fibers by any suitable means, for example by dipping or submerging the fibers in the bath or by spraying the solution onto the fibers.
• the step may be carried out continuously in that the fibers are passed by a suitable means through a bath of the solution or the solution is sprayed onto the fibers while they are transported.
• the alkaline solution comprises a basic solution comprising water and a base, preferably NaOH.
• the caustic solution for use in the preparation of the alkaline solution comprises water and the base, such as NaOH, in a range by weight of from 5% NaOH to 50% NaOH or 2-40% NaOH or 5-35% NaOH or about 5% or about 30% NaOH.
• the water and the base (e.g. NaOH) in the caustic solution used for preparation of the alkaline solution may alternatively be used in a respective ratio by weight of from about 10:90 to about 50:50, preferably from about 80:20 to about 60:40, more preferably about 70:30 water:base.
• the caustic solution may be a 30% solution of NaOH available under the trade name Caustic Soda Liquor from Micro-Bio (Ireland) Ltd, Industrial Estate, Fermoy, County Cork, Ireland.
• the alkaline solution comprises a final ready-to-use concentration of NaOH of about 0.5 to about 5% by weight relative to the total weight of the solution, for example about 0.6 to about 3.0% or about 0.7 to about 2.0 or about 0.8 to about 1.5 or about 0.9 to about 1.1 % by weight. This may for example mean that 3% of a 30% caustic solution of NaOH in water is used.
• the alkaline solution preferably comprises the dye scavenging compound in an amount of from 0.5 to 20 % by weight, for example 1 to 15 % by weight or 2 to 12 % by weight, for example about 6, 7, 8, 9, 10, 11 or 12 % by weight.
• the ratio of the dye scavenger to the remaining parts of the alkaline solution, namely the basic solution (comprising water and the base and optional additional components, such as surfactants), by weight ranges of from about 0.02:1 to about 0.5:1, for example 0.05:1 to about 0.2:1. It will be appreciated that these ratios preferably refer to the dye scavenging compound in solid form, preferably to glycidyltrimethylammonium chloride.
• the dye scavenging compound (I) and/or (II) is preferably used in an amount such that in the final textile material after step (c), it is present in amounts of from about 4.4 g to about 5.5 g, more preferably from about 4.6 g to about 5.1 g, most preferably about 4.9 g per square meter (m 2 ) of the final textile material.
• "Final textile material”, as used herein, refers to the textile material in its ready to use form, i.e. in its dry form.
• the amount of the dye scavenging compounds in the final textile material ranges from 5 to 20 % by weight of the textile material, preferably 10 to 15% by weight.
• the alkaline solution is at a temperature of from about 10 °C to about 70 °C, more preferably about 15-50°C. In various embodiments, its temperature is about 20°C or about 45°C.
• the method may optionally comprise the step (b1) of contacting the fibers with an acid solution, for example, but without limitation, by passing the fibers through a bath containing an acid solution.
• the acid solution may be applied by other means, such as those described above for the alkaline solution.
• the acid solution may comprise water and an acid, such as a hydrochloric acid (HCI) solution, preferably a 4-12 M, for example about 4.3 to about 5 or about 11.6 M, HCI solution.
• HCI hydrochloric acid
• the acid solution preferably has a pH from about 1.5 to about 2.5, more preferably a pH of about 2.1.
• a pH probe is placed in the bath containing the acid solution in order to maintain the pH at about 2.1.
• the pH probe conveniently signals the water requirement and this is dosed when required to give the correct pH automatically.
• the acid solution is at a temperature of from about 10 °C to about 70 °C, more preferably about 15-50°C, more preferably about 20 or about 45 °C.
• the acid solution may also contain a perfume and/or a non-ionic surfactant, such as an alkoxylated fatty alcohol (FAEO).
• a non-ionic surfactant such as an alkoxylated fatty alcohol (FAEO).
• FAEO alkoxylated fatty alcohol
• such components may be used to treat the fibers in a later step or used to treat the formed textile material after step (c).
• the fibers may be subjected to pressure to remove the liquid from the fibers.
• Said pressure may be applied by passing the fibers through rollers, e.g. a pair of rollers, optionally pneumatically actuated rollers, or using an air manifold to maintain constant and consistent air pressure.
• rollers e.g. a pair of rollers, optionally pneumatically actuated rollers, or using an air manifold to maintain constant and consistent air pressure.
• Such application of pressure is particularly preferred after step (b1), as it is desirable to remove the liquid (the acid solution used to neutralize the alkaline solution containing the dye scavenging compound), prior to drying the fibers.
• step (b), i.e. the contacting step may comprise the additional steps of subjecting the fibers to pressure, preferably of from about 0.04 MPa to about 0.40 MPa; and/or wrapping the fibers in a water impermeable material and rotating the fibers, preferably for a period of from about 12 hours to about 60 hours; removing the water impermeable material, if present; and subjecting the fibers to a pressure of from about 0.15 MPa to about 0.40 MPa.
• steps may, for example, be carried out prior to step (b1).
• a drying step (b2) is carried out before the fibers are used in step (c) for the formation of the textile material.
• the drying temperature is from about 95 °C to about 125 °C, preferably from about 100 °C to about 120 °C, most preferably about 115 °C.
• the substrate is dried by passing the substrate along one or more drying cylinders, which drying cylinders are optionally at a temperature of from about 95 °C to about 125 °C, preferably from about 100 °C to about 120 °C, most preferably about 115 °C.
• step (b)/(b1) and prior to step (b2)/(c) may comprise one or more of the additional steps of:
• the first and second fresh water rinses take the form of a bath containing water, optionally at a temperature of from about 10 °C to about 30 °C, preferably about 20 °C.
• step (c) the fibers of step (b) and the untreated fibers are used to form a textile material.
• the textile material may be any textile material, including, without limitation, a woven, non-woven or knitted fabric, a braided rope or ball or any other desirable configuration.
• the purpose of the textile material is to provide a carrier for the dye scavenging material, and to provide a sufficient area over which said dye scavenging material is accessible to the liquid in the bath or wash water in which the dye scavenging textile material is to be used.
• the untreated fibers may be used to provide the material with sufficient mechanical strength. Preferred applications are in laundry applications, in particular in automatic washing machines, such as front loaders or top loaders widely used.
• the textile material typically is selected such that it has sufficient wet strength and sufficient resistance to abrasion with other materials in a bath such as laundry wash or rinse waters. Consequently, the textile materials of the present application are strong and robust to be suitable for all washing machine types. Strength and robustness might be defined by the tensile strength. Tensile strength refers to the resilience of the sheet against ripping. The direction of tensile strength can be distinguished between machine direction (MD) and cross direction (CD). When the textile material, for example in form of a cloth or laundry sheet, is produced, the lengthwise direction (direction of production) is the machine direction. The direction rectangular thereto is the cross direction. Relevant is of course also the tensile strength in respect of moisture.
• the sheets should be robust and stable if wet (i.e. if immersed for 10 seconds in water) as well as if dry (as obtained by a supplier).
• the textile material has, if wet, preferably a tensile strength in machine direction (MD) from 200 N/m to 1500 N/m, preferably from 400 N/m to 1400 N/m, especially from 600 N/m to 1300 N/m, especially preferred from 750 N/m to 1200 N/m and/or in cross direction (CD) from 50 N/m to 1000 N/m, preferably from 100 N/m to 800 N/m, especially preferred from 150 N/m to 500 N/m.
• MD machine direction
• CD cross direction
• MD machine direction
• CD cross direction
• the thickness of the sheet is preferably from 0.62 mm to 1.5 mm, preferably from 1.0 mm to 1.2 mm.
• the thickness is especially relevant for the question of permeability. Thicker sheets might not be permeable to washing liquor. Thinner sheets might not be robust enough; especially in aggressive top loaders with spindles they might be destroyed. This would not lead to a reduced efficacy of the laundry sheet but to reduced approval by the consumer.
• the textile material is a non-woven.
• a non-woven may, for example, be wet-laid or spun-laid, defining the length of the fibers. It is preferred that the fibers have a length of about from 2 mm to 5 mm for wet-laid non-woven and/or from 30 mm to 50 mm for spun-laid non-woven.
• the fibers prepared as described herein are used in combination with untreated fibers (i.e. without a dye scavenging compound).
• all the fibers may be in form of a yarn.
• the textile material made from the fibers may be a cellulosic material, but depending on different fiber types used in addition to the ones treated with the dye scavenging compounds, is preferably a composite material in that it also comprises non-cellulosic material. Accordingly, the material may comprise a naturally occurring material or a synthetic material or a mixture thereof.
• the textile material may additionally comprise a binder such as polyvinylacetate, although in various embodiments no such a binder is included.
• the textile material is preferably formed to a density of 40-200 g/m 2 , 40-80 g/m 2 , 55-75 g/m 2 , or 60-75 g/m 2 , more preferably about: 65g/m 2 .
• the values apply to the textile material in its ready-to-use form, i.e. its dry form.
• the density can be determined according to ISO 9073-1 (of the year 1989).
• Such a density is preferred as respective textile sheets have an improved performance compared with other sheets, as they can absorb large amounts of dyes from the washing liquor in short times compared with other dye catching laundry sheets.
• the sheets are still flexible and water permeable, so that they provide for consumer acceptance and allow to add them to delicate textile fabrics such as microfiber fabrics or others.
• the textile material preferably takes the form of a cloth or laundry sheet.
• the dimensions of the material, once cut for use in a domestic wash, are approximately 25 cm x 12 cm. It will, however, be appreciated that any other suitable dimensions may be used.
• the textile material further comprises a dye transfer inhibitor (DTI) different from the dye scavenging compounds of formula (I) or (II).
• DTIs are known in the art and are typically polymeric in nature.
• Polymeric dye transfer inhibiting agents are known in the art for reducing or preventing dye-transfer during the laundering process.
• Polymeric dye transfer inhibiting agents useful herein include polyvinylpyrrolidone and copolymers thereof.
• Polyvinylpyrrolidone (“PVP”) has an amphiphilic character with a highly polar amide group conferring hydrophilic and polar attracting properties, and also has apolar methylene and methane groups, in the backbone and/or the ring, conferring hydrophobic properties.
• the rings may also provide planar alignment with the aromatic rings, in the dye molecules.
• PVP is readily soluble in aqueous and organic solvent systems. PVP is commercially available in either powder or aqueous solutions in several viscosity grades.
• the detergent compositions of the present invention preferably utilize a copolymer of N- vinylpyrrolidone and N- vinylimidazole (also abbreviated herein as "PVPVI"). It has been found that copolymers of N-vinylpyrrolidone and N-vinylimidazole can provide excellent dye transfer inhibiting performance when utilized in this invention.
• the copolymer of N-vinylpyrrolidone and N-vinylimidazole polymers has an average molecular weight range from 5,000 to 1 ,000, 000, more preferably from 5,000 to 200,000.
• a highly preferred copolymer for use in detergent compositions according to the present invention has a number average molecular weight range from 5,000 to 50,000, more preferably from 8,000 to 30,000 and, most preferably from 10,000 to 20,000.
• the number average molecular weight range is determined by light scattering as described in Barth J. H. G. and Mays J. W. Chemical Analysis Vol 1 13. "Modern Methods of Polymer Characterization .”
• the copolymers of N-vinylpyrrolidone and N-vinylimidazole useful in the present invention can have a molar ratio of N-vinylimidazole to N-vinylpyrrolidone from 1:1 to 0.2:1 , more preferably from 0.8:1 to 0.3:1 , most preferably from 0.6:1 to 0.4:1. It should be understood that the copolymer of N-vinylpyrrolidone and N-vinylimidazole can be either linear or branched.
• Copolymers of poly (N-vinyl-2-pyrollidone) and poly (N-vinyl-imidazole) are commercially available from a number of sources including BASF.
• a preferred DTI is commercially available under the tradename Sokalan® HP 56 K from BASF (BASF SE, Germany).
• Mixtures of more than one polymeric dye transfer inhibiting agent may be used.
• the DTIs are used in amounts such that the final textile material contains them in an amount that ranges from about 0.005 to about 0.5 % by weight relative to the total weight of the textile material, preferably of from about 0.02 to 0.05 % by weight. In various embodiments, this equals absolute amounts of from about 0.0001 to about 0.5 g/square meter, preferably about 0.01 g/square meter.
• the DTIs may be added during fiber preparation but alternatively may also be applied to the formed textile material. In various embodiments, it is added after the textile materials has already been formed. The addition may be inline (in a continuous process) or, alternatively, off-line.
• the textile materials as obtainable according to the methods described herein may comprise further components, including, without limitation, enzymes, such as cellulases, perfumes, softening additives, surfactants, soaps, soil repellents and other components typically used in laundry detergents and textile treatment additives, such as softeners.
• enzymes such as cellulases, perfumes, softening additives, surfactants, soaps, soil repellents and other components typically used in laundry detergents and textile treatment additives, such as softeners.
• GyroWash is a mechanical device used to carry out washing tests for textiles. Is equipped with a water bath, has a rotor fixed to an axis, which has arranged radially several stainless containers of 75 ⁇ 5mm of diameter, 125 ⁇ 10mm of height and a capacity of 550 ⁇ 50mL. The shaft-and-vessel assembly rotates with a frequency of 40 ⁇ 2min -1 . The water bath temperature is regulated by means of a thermostat, to maintain the test solution at the specified temperature ⁇ 2°C.
• Treatment was carried out for 30 minutes at 40°C. Water volume was 100 mL. Number of replicates (internal/external) was 2 fabrics per cylinder (1 cotton; 1 polyamide) / 2 external repetitions for each color.
• the recommended dosage of the detergent ECE2 (standard detergent ex WFK, product number 88031) is 95.6 g for 15L of water.
• Dye donator 0.3 g
• dye acceptor cotton
• Both textiles are not fixed to each other.
• the volume to give the correct liquor: fabric ratio 100:1 is added and the containers are placed in the preheated (40oC) GyroWash machine.
• the dye acceptors (cotton (CO)) are used for all 4 dye donators. After the washes the textiles are removed and rinsed twice.
• the textiles were evaluated spectrophotometrically at the beginning and at the end of the test in order to calculate the amount of color accepted (stained) for each specimen.
• the characteristics for the measurements are the following:
• the color sheets were evaluated spectrophotometrically at the end of the test in order to calculate the color strength (K/s) of each.
• Table 2 K/S average DB2 T2B T2E T2F T2G T2H Dye 1 0.2529 0.2699 0.3697 0.2435 0.2529 0.2147 Dye 2 0.7914 0.7635 0.9796 1.0390 0.9095 0.8760 Dye 3 0.1138 0.1127 0.1822 0.1160 0.1126 0.0986 Dye 4 0.1358 0.0823 0.1427 0.1333 0.1255 0.1180

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• 2018
  • 2018-05-25 EP EP18174342.8A patent/EP3572495B1/fr active Active
  • 2018-05-25 ES ES18174342T patent/ES2847403T3/es active Active
  • 2018-05-25 PL PL18174342T patent/PL3572495T3/pl unknown

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