GB1583161A

GB1583161A - Finishing process for carpets

Info

Publication number: GB1583161A
Application number: GB1820777A
Authority: GB
Original assignee: Sandoz AG
Current assignee: Sandoz AG
Priority date: 1976-05-07
Filing date: 1977-05-02
Publication date: 1981-01-21
Also published as: NL7704847A; FR2350420A1; DE2718941A1; JPS52137088A

Description

(54) FINISHING PROCESS FOR CARPETS (71) We, SANDOZ LTD., of 35 Lichtstrasse, 4002 Basle, Switzerland, a Swiss Body Corporate, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:-- The present invention relates to a textile treatment process, in particular a process for the single bath washing and dyeing of textile substrates, particularly carpets.

Thus, according to the present invention, there is provided a process for the single bath washing and dyeing of a carpet substrate in a winch beck or modified winch beck machine, comprising applying to an un-pre-cleaned carpet substrate an aqueous liquor comprising a surface active agent and a dyestuff at a liquor to goods ratio of from above 5:1 to 10:1 by weight, operating the machine under conditions at which the dyestuff is substantially non-substantive to the substrate to cause even distribution of the dyestuff throughout the substrate and to cause the surface active agent to perform a washing action on the substrate, and subsequently adjusting the conditions to cause fixation of the dyestuff.

In Swiss Patent Specifications Nos. 541,653, 574,758 and 557,204 are disclosed short bath dyeing processes wherein the dye liquor contains a surface active which is capable of foam or microfoam formation, although it is not essential for a foam to be formed in such processes. In the present invention all surface active agents may be employed, although preference is given to those which are either capable of foam or microform formation or which possess especially good wetting properties. The amount of surface active agent employed in such prior disclosed processes is normally kept to a minimum i.e. that amount necessary to ensure full distribution of the dyestuff, usually, but not necessarily, by formation of a foam or microfoam.In the present invention, however, an excess over this amount is employed whereby the surface active agent can also perform a washing function on the un-precleaned substrate.

As will be appreciated, however, the amount needed to perform this double function will depend on the characteristics of the substrate and on the other contents of the dyebath. In some cases up to twice the amount of surface active agent, over that necessary merely to facilitate dyestuff distribution, may be required, but in general about 12 times the amount is needed. In general, from 0.5 to 70 grams per litre of both of surface active agent would be used, but, as will be appreciated, the optimum amount will depend on the nature of the substrate, the bath contents, the particular surface active agent employed and the necessary degree of cleaning of the substrate required.

By the process of the invention, since a low liquor to goods ratio is employed, undesirable floating or slipping of the substrate, as often results in combined wash/ dyeing processes at conventional higher liquor to goods ratios, and which tends to cause uneven dyeing, is avoided. Also, the relatively high concentration of surface active agent, over that used in the above mentioned normal low liquor dyeing processes, helps in the solubilising or dispersion of the dyestuff and other additives in the bath. For example, although the solubility of reactive dyestuffs is usually of a relatively high order, it can drop shalply in the presence of salts, such as Glauber's salt and common salt which are used in high concentration for good exhaustion of the dye bath, and this can result in uneven dyeing. The present invention alleviates this problem.Also, by the present invention, two operations are carried out effectively simultaneously in a relatively small amount of liquor, this leading to such advantages as water conservation as well as a saving in time and energy.

In the process of the invention, after applying Sthe liquor to the substrate, the dyeing machine is operated to set the substrate in continuous motion. During this phase, simultaneous washing of the substrate and thorough distribution of the dyestuff, generally aided by foam formation, takes place. Conditions such as would cause the dyestuff to be fixed, such as elevated temperatures, are avoided during this phase.

After thorough distribution of the dyestuff, however, the substrate is subjected to conditions, usually heating, e.g. using steam, to cause fixation of the dyestuff or, in the case of reactive dyes, reaction of the dye with the substrate. After treatment, the substrate will generally be rinsed and soaped in conventional manner.

The dyestuffs used and textile materials treated in the process of the invention are those generally used or treated in winch-beck dyeing as are other bath additives such as salts, acids and alkalis, and the surface active agents employed in the invention are conveniently those usually employed in textile washing operations.

Particularly good results, employing the process of the invention, are obtained on cotton and natural or synthetic polyamide carpet substrates.

The invention is illustrated by the following examples.

Example 1.

A plain un-precleaned carpet of polyamide 6 with a base of polypropylene is dyed as follows in a suitably modified carpet winch beck in a goods to liquor ratio of A dye liquor used contains the following components per 1000 parts: 0.1 parts of the dyestuff having the following structural formula

0.2 parts of the dyestuff C.I. Acid Red 57 0.4 parts of the dyestuff C.I. Acid Blue 288 0.3 parts of a commercial surface active agent based on a higher alkyl-benzene sulphonate 1 part od a mixture of the following components: 400 parts of benzyl alcohol 450 parts of monophenylglycol ether 150 parts of octylphenyl pentaglycol ether 0.05 parts of 60% acetic acid.

The carpet is moved over the spool and the dye liquor temperature is generally raised from 600 to boiling temperature. After the carpet has been treated for 30-60 minutes at 600 to boiling temperature, the dye liquor is drained away, the carpet is rinsed and dried in the usual manner, and is optionally given after-treatment to improve the electrostatic properties.

An evenly dyed carpet which is free of stripes is obtained.

Example 2.

A un-precleaned polyamide 66 carpet consisting of polyamide, dyeable by the deepdye, regular and basic methods is dyed as described in Example 1 with the following liquor, which contains the following components per 1000 parts: 0.5 parts of the dyestuff C.I. Acid Orange 145 0.3 parts of the dyestuff C.I. Acid Red 57 0.1 parts of the dyestuff C.I. Acid Blue i2 0.08 parts of the dyestuff C.I. Basic Orange 37 0.08 parts of the dyestuff C.I.Basic Orange 38 0.3 parts of a commercial surface active agent of cationic nature, based on a polyglycolated (10--20 alkoxy groups) behenylamine 0.1 parts od a commercial surface active agent based on a higher alkyl-benzene sulphonate 1 part of a mixture of the following components: 100 parts of benzyl alcohol 450 parts of monophenyiglycol ether 150 parts of octylphenyl pentaglycol ether 10 parts of 60% acetic acid.

An evenly dyed carpet with clear contrasts between the fibres is obtained.

Example 3.

An un-precleaned polyamide 66 carpet consisting of polyamide which can be dyeable by the basic, deep-dye and low-dye methods is dyed as described in Example 1 with the following liquor, which contains the following components per 1000 parts: 0.2 parts od the dyestuff C.I. Acid Blue 72 0.04 parts of the dyestuff C.I. Basic Orange 37 0.03 parts of the dyestuff C.I. Disperse Yellow 3 0.3 parts of a commercial surface active agent of cationic nature, based on a polyglycolated (10-20 alkoxy groups) behenylamine 0.1 parts of a commercial surface active agent based on a higher allryl-benzene sulphonate 5 parts od 60% acetic acid.

An evenly dyed carpet with clear contrasts is obtained Example 4.

A plain un-precleaned carpet ob polyamide/polyester with a polypropylene base is dyed as follows in a suitably modified carpet winch beck, in a goods to liquor ratio of 1:8.

The dye bath used contains the following components per 1000 parts: 0.3 parts of the dyestuff Disperse Yellow 23 0.006 parts of the dyestuff C.I. Acid Red 53 0.3 parts of the dyestuff C.I. Acid Blue 56 0.1 parts of a commercial finishing oil based on an anion-active, highly sulphonated oil sulphonte 0.05 parts of a commercial surface active agent on an aliphatic polyglycol ether 0.06 parts of a commercial surface active agent based on a higher alkyl-benzene sulphonate 0.05 parts of 60% acetic acid.

The carpet is moved over the spool and the dye liquor is heated at the same time to 600C to boiling temperature. After the carpet has been treated for 30 to 60 minutes at 600 to boiling temperature, the dye liquor is drained away, the carpet is rinsed and dried in the usual manner, and is optionally given the usual after-treatment to improve the electrostatic properties.

An evenly dyed carpet without stripes is obtained.

In a similar manner, a carpet of pure polyester material may be dyed evenly and without stripes.

ExampleS.

An un-precleaned modified polyacrylonitrile carpet consisting of yarns which can be dyed by basic and acid dyes is dyes as described in Example 4 with the following liquor, which contains the following components per 1000 parts: 0.07 parts of the dyestuff C.I. Basic Yellow 13 0.5 parts of the dyestuff C.I. Basic Orange 37 0.25 parts of the dyestuff C.I. Basic Blue 73 1 part of the dyestuff C.I. Acid Orange 3 0.25 parts of the dyestuff C.I.Acid Blue 72 3 parts of a commercial surface active agent of cationic nature, based on a poly- glycolated behenylamine 0.7 parts of a mixture of the following components: 400 parts of benzyl alcohol 450 parts of monophenylglycol ether 150 parts od octylpihenyl pentaglycol ether 2 parts of 60% sulphuric acid.

By the process of Example 4, an evenly dyed carpet is obtained, with clear contrasts between the fibres.

Example 6.

An un-precleaned polyacrylonitrile carpet is dyed as described in Example 4 with the following liquor, which contains the following components per 1000 parts: 0.03 parts of the dyestuff C.I. Basic Yellow 13 0.015 parts of the dyestuff C.I. Basic Red 44 0.05 parts of the dyestuff C.I. Basic Blue 73 3 parts of a mixture of the following components: 400 parts of benzyl alcohol 450 parts of monophenylglycol ether 150 parts of octylphenyl pentaglycol ether 0.5 parts of a commercial surface active agent based on a higher alkyl-benzene sulphonate 0.5 parts of 60% acetic acid.

An evenly dyed carpet without stripes is obtained.

Example 7.

A plain un-precleaned carpet made of cotton as the surface layer and a carrier material of polypropylene is dyed as follows in a suitably modified carpet winch beck in a goods to liquor ratio of 1: 8. The dye bath used contains the following components per 1000 parts: 1 part of the dyestuff C.I. Direct Orange 107 1.3 parts of the dyestuff C.I. Direct Red 220 0.4 parts of the dyestuff C.I. Direct Blue 90 5 parts of Glauber's salt 0.5 parts of a commercial surface active agent based on a higher aikyl-berDzene sulphonate.

The carpet is moved over the spool and the dyestuff is heated at the same time to boiling temperature. After the carpet has been treated for 30-120 minutes at boiling temperature, the dye liquor is drained away, the carpet is rinsed in the usual manner and is optionally treated with cationic substances to improve the wet fastness.

An evenly dyed carpet without stripes is obtained.

A plain carpet of regenerated cellulose may be dyed by the same method, and an evenly dyed carpet without stripes is obtained.

Example 8.

A plain un-precleaned carpet of cotton/polyamide, with a polypropylene base is dyed in a carpet winch beck in a goods to liquir ratio of 1: 8, by the two-stage process.

The liquor used contains the following components per 1000 parts: 0.6 parts of the dyestuff C.I. Reactive Orange 11 2.5 parts of the dyestuff C.I. Direct Yellow 42 0.5 parts of the dyestuff C.I. Direct Red 121 0.5 parts of sodium metanitrobenzene sulphonate 0.3 parts of a commercial sodium salt of an aromatic sulphonic acid 10 parts of calcined Glauber's salt 1.5 parts of crystalline trisodium phosphate 0.02 parts of 60% acetic acid.

An evenly, thoroughly dyed carpet is obtained.

Example 9.

An un-precleaned carpet of cotton/polyacrylonitrile is dyed by the usual two-bath dyeing process in a goods to liquor ratio of 1: 8.

The dye liquor used contains the following components per 1000 parts: 0.5 parts of the dyestuff C.I. Basic Orange 37 0.1 parts of the dyestuff C.I. Basic Brown 13 0.25 parts of the dyestuff C.I. Basic Blue 73 0.55 parts of the dyestuff C.I. Direct Orange 107 0.05 parts of the dyestuff C.I. Direct Red 220 0.08 parts of the dyestuff C.I. Direct Black 118 1 part of a commercial surface active agent based on an aliphatic polyglycol ether 3 parts of sodium acetate 10 parts of Glauber's salt.

An evenly, thoroughly dyed carpet is obtained.

Claims

WHAT WE CLAIM IS:

1. A process for the single bath washing and dyeing of a carpet substrate in a winch beck or modified winch beck machine, comprising applying to an un-precleaned carpet substrate an aqueous liquor comprising a surface active agent and a dyestuff at a liquor to goods ratio of from above 5:1 to 10:1 by weight, operating the machine under conditions at which the dyestuff is substantially non-substantive to the substrate to cause even distribution of the dyestuffs throughout the substrate and to cause the surface active agent to perform a washing action on the substrate, and subsequently adjusting the conditions to cause fixation of the dyestuff.

2. The process of Claim 1, wherein said liquor contains from 0.5 to 70 grams per litre of surface active agent.

3. The process od any preceding claim, wherein the substrate comprises cotton.

4. The process of any preceding claim, wherein the substrate comprises natural or synthetic polyamide.

5. The process of Claim 1, substantially as hereinbefore described with reference to any one of the foregoing Examples 1 to 9.

6. A carpet whenever treated by a process according to any one of the preceding claims.