US20230071562A1 - Pad-dry cationization of textiles - Google Patents

Pad-dry cationization of textiles Download PDF

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US20230071562A1
US20230071562A1 US17/759,964 US202117759964A US2023071562A1 US 20230071562 A1 US20230071562 A1 US 20230071562A1 US 202117759964 A US202117759964 A US 202117759964A US 2023071562 A1 US2023071562 A1 US 2023071562A1
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textile
range
cationizing agent
seconds
independently selected
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Sandeep Nikam
Laura Havens
Ling Zhang-Watson
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Dow Global Technologies LLC
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Dow Global Technologies LLC
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    • 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
    • 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
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/32—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/36—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with oxides, hydroxides or mixed oxides; with salts derived from anions with an amphoteric element-oxygen bond
    • D06M11/38—Oxides or hydroxides of elements of Groups 1 or 11 of the Periodic Table
    • 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
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/322—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing nitrogen
    • D06M13/46—Compounds containing quaternary nitrogen atoms
    • D06M13/463—Compounds containing quaternary nitrogen atoms derived from monoamines
    • 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
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/322—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing nitrogen
    • D06M13/46—Compounds containing quaternary nitrogen atoms
    • D06M13/467—Compounds containing quaternary nitrogen atoms derived from polyamines
    • 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
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/52—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment combined with mechanical treatment
    • D06M13/525—Embossing; Calendering; Pressing
    • 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
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/52—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment combined with mechanical treatment
    • D06M13/53—Cooling; Steaming or heating, e.g. in fluidised beds; with molten metals
    • 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
    • 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
    • D06P1/673—Inorganic compounds
    • D06P1/67316—Acids
    • 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
    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/58—Material containing hydroxyl groups
    • D06P3/60—Natural or regenerated cellulose
    • 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
    • D06P5/002—Locally enhancing dye affinity of a textile material by chemical means
    • 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
    • D06P5/20—Physical treatments affecting dyeing, e.g. ultrasonic or electric
    • D06P5/2066—Thermic treatments of textile materials
    • D06P5/2072—Thermic treatments of textile materials before dyeing
    • 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
    • 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
    • D06M2101/02—Natural fibres, other than mineral fibres
    • 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
    • D06M2101/02—Natural fibres, other than mineral fibres
    • D06M2101/04—Vegetal fibres
    • D06M2101/06—Vegetal fibres cellulosic
    • 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
    • D06M2400/00—Specific information on the treatment or the process itself not provided in D06M23/00-D06M23/18
    • D06M2400/01—Creating covalent bondings between the treating agent and the fibre
    • 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
    • D06P1/673—Inorganic compounds
    • D06P1/67333—Salts or hydroxides
    • D06P1/6735—Salts or hydroxides of alkaline or alkaline-earth metals with anions different from those provided for in D06P1/67341
    • D06P1/67375—Salts or hydroxides of alkaline or alkaline-earth metals with anions different from those provided for in D06P1/67341 with sulfur-containing anions

Definitions

  • the current disclosure pertains to processes and systems for the cationization of natural fiber-containing (e.g., cotton-based) textiles which can be used to improve association of dyes with the cationized textile.
  • natural fiber-containing e.g., cotton-based
  • Textile dyeing is the process of applying pigments or dyes on textile materials such as fabrics, yarns, and fibers.
  • the dyeing process is efficient and rapid, and provides the dyed textile with a desired degree of coloring, and resistance to fading and running of the dye (color fastness).
  • the dyeing process and the materials used therein preferably do not adversely affect the aspects of the textile, such as its flexibility, durability, and tactile properties like softness, smoothness, stiffness.
  • various dye types are used.
  • Salt is commonly used in a dyebath to reverse the charge on the cotton fiber, and alkali is used to allow the dyes to react with and associate with the induced positively-charged surface of the cotton fiber.
  • alkali is used to allow the dyes to react with and associate with the induced positively-charged surface of the cotton fiber.
  • these traditional processes can consume significant amounts of water, energy, and chemicals, which is undesirable.
  • Cationic reagents with appropriate chemistries can react with chemical groups on cellulose to provide a permanent cationic (positive) charge on the surface of the cotton fiber (“cationic cotton”).
  • cationic cotton The positive surface charge on the cotton fiber allows it to associate with a greater variety of dyes, and can also allow for a range of color variation (e.g., color depth).
  • Cationization processes for cotton-based textiles may also consume less water, energy, and chemicals, making them desirable for industrial scale operations.
  • CHTAC 3-chloro-2-hydroxypropyl trimethyl ammonium chloride
  • the CHTAC is dechlorinated to form the reactive intermediate epoxypropyl trimethyl ammonium chloride (EPTAC), and the epoxide group of this compound can react with a deprotonated hydroxyl group of cellulose, thereby covalently linking the cationic ammonium chloride group to the cellulose backbone through an ether linkage.
  • EPTAC epoxypropyl trimethyl ammonium chloride
  • 2,3-DHTAC 2,3-dihydroxypropyl trimethyl ammonium chloride
  • Carrying out “batch” treatment of a textile in the presence of base and cationizing agent at low temperature and an extended period of time can allow better reaction of the cationizing agent with the fiber and can minimize formation of waste product, but such prolonged processing steps are impractical for commercial operations.
  • the methods and systems of the current disclosure improve cationization of textiles, such as textiles that include natural fibers such as cotton, while reducing use of chemicals in the process.
  • the cationized textile can then be used as an improved substrate in a dyeing process to provide a textile with better color properties.
  • the current disclosure provides methods and systems that facilitate the cationization of textiles that contain, or are derived from, natural fibers, such as cotton.
  • the process of the disclosure forms improved cationized textiles that facilitate subsequent textile dyeing and improves properties of the dyed textile, such as coloration.
  • cationization of textiles can be performed in a short period of time with good results and reduction in waste. Hydrolysis of the cationizing agent is minimized and its reaction with the textile is improved. Subsequent dyeing of the cationized textile provides desirable coloration and color fastness. In turn, the process improves use of reagents by creating less waste products, saves energy by minimizing processing times, and improves overall industrial processing efficiency.
  • the disclosure provides a method for cationizing a textile including a natural fiber or derivative thereof.
  • the method includes a step of treating a textile including a natural fiber or derivative thereof with an aqueous solution that includes an alkali metal hydroxide and a mono- or di-quaternized cationizing agent.
  • the textile is then heat treated at a temperature(s) in the range of 90° C. but less than 110° C. for a period of time in the range of 1 min to 10 min to react the cationizing agent with the textile.
  • the textile is treated at a temperature in the range of 90° C. to 109° C. for a period of time in the range of about 2 to 8 minutes. In embodiments the textile is treated at a temperature in the range of 90° C. to 105° C. for a period of time in the range of about 2 to 8 minutes.
  • a portion of the aqueous solution is mechanically removed from the textile.
  • steps of treating with the aqueous solution and mechanically removing are performed at a temperature(s) of less than 35° C., and for a total period of time not greater than 1 minute.
  • the steps of treating with aqueous solution, mechanically removing, and heat treating the textile can be performed for a total a period of time of not more than 11 minutes, such as in the range of 1 minute to 11 minutes, in the range 1 minute to 8 minutes, or in the range 1 minute to 8 minutes, which significantly enhances textile throughput, while at the same time providing good cationization of the textile and incorporated nitrogen content, which in turn facilitates a subsequent dyeing process.
  • the textile is then neutralized with an acid-containing solution.
  • the cationic textile can subsequently be dyed in a composition comprising a dye, using the same system that is used for padding and heat treatment, or can be dyed using a different system.
  • Exemplary cationizing agents include mono-quaternized nitrogen compounds capable of generating a single epoxide group in the presence of alkali metal hydroxide, such as 3-chloro-2-hydroxypropyl trimethyl ammonium chloride.
  • Other exemplary cationizing agents include di-quaternized nitrogen compounds capable of generating two epoxide groups in the presence of alkali metal hydroxide, such as bis ether halogenated di-hydroxylated di-quaternized ammonium compounds like bis[(3-chloro-2-hydroxypropyldialkylammonium) alkyl] ether dichloride.
  • Such bis-based compounds are preferred when used in conjunction with the methods of the disclosure as they are able to promote cationization and dyeing with significantly reduced chemicals, water, energy, and wastewater generation, while at the same time facilitating the formation of dyed textiles that have desirably bright, bold, and long lasting colors.
  • the solution has an alkali metal hydroxide to cationizing agent molar ratio of 3.5:1 or greater, or 8.0:1 or less, such as in the range of 3.5:1 to 8.0:1, or 3.75:1 to 7.5:1. In other embodiments, the solution has an alkali metal hydroxide to cationizing agent molar ratio of greater than 1:1, such as in the range of 1.8:1 to 5:1, or 2.0:1 to 4.5:1.
  • the disclosure provides a system for cationizing and dyeing a textile including a natural fiber or derivative thereof.
  • the system includes a padding bath configured to allow treatment of a textile including a natural fiber or derivative thereof with an aqueous solution in the padding bath, the solution including an alkali metal hydroxide and a mono- or di-quaternized cationizing agent.
  • the system also includes a solution removal apparatus to remove aqueous solution from the padded textile after treatment in the padding bath, with the system including a conveyor apparatus capable of moving the textile through the padding bath and the solution removal apparatus in about a minute or less.
  • the system also includes a heat treatment apparatus configured to treat the padded textile, at a temperature(s) that is in the range of 90° C. to less than 110° C.
  • the system can also include a neutralization bath to neutralize the textile with an acid-containing solution.
  • the system can include a process controller, such as a computer-based controller, which can be programmed to perform the treatment method as described herein.
  • the system can include a dye bath for dyeing the cationized textile.
  • FIG. 1 is an illustration of an exemplary system for cationization and dyeing of a textile.
  • FIG. 2 is a graph of nitrogen content on cationized cotton as prepared using a di-quaternized cationizing agent at different heating conditions and times versus a cold batch process treatment.
  • FIG. 3 is a graph of nitrogen content on cationized cotton as prepared using a di-quaternized cationizing agent at different heating conditions and times versus a cold batch process treatment.
  • compositions of the disclosure described as “comprising” or “including” can include those recited step and compounds, respectively, and optionally can include other steps and components. If methods or compositions of the disclosure are described as “consisting of,” those methods or compositions have the recited steps or compounds but do not include steps or compounds that are not recited.
  • the term “consisting essentially of” generally refers to compositions that include the recited compounds and may include other non-recited compounds, but in unsubstantial amounts. For example, such compositions can include one or more other non-recited components but not in an amount that is greater than about 1% (wt), greater than about 0.5% (wt), or greater than about 0.1% (wt), of the total composition. In a composition “consisting of” the recited components there is no other measurable amount of component other than the recited component, or a method “consisting” of certain steps includes no other steps than those ones recited.
  • the present disclosure describes methods and systems for cationizing a textile that includes a natural fiber, such as cotton, or derivative thereof.
  • the cationization process can be carried out in a relatively short time period, wherein the process generates low levels of waste and uses minimal energy.
  • the method and system treats the textile in an aqueous solution (which can also be referred to as a “padding” solution) that includes an alkali metal hydroxide and a cationizing agent, such as a mono- or di-quaternized nitrogen compound capable of generating one or two epoxide group(s), respectively, in the presence of alkali metal hydroxide.
  • the padding treatment can be performed quickly, such as in a period of not greater than a minute, and at temperatures, such as ambient temperatures, that does not require heating of the aqueous solution.
  • excess solution is removed from the textile, and then the textile is introduced into a heating apparatus to cause reaction of the cationizing agent with the textile.
  • the heat treatment is also performed rather quickly and in a defined temperature range.
  • the textile is heated at a temperature(s) in the range of 90° C. to less than 110° C. for a period of time in the range of 1 min to 10 min. In some embodiments more specific temperature and time ranges can be used.
  • good cationization is achieved without requiring long padding and reaction times (such as periods of time of hours) characteristic of cold batch padding processes. Instead, it has been discovered that the treatment temperatures and times of the disclosure provide good cationization of the textile while minimizing loss of reagent through hydrolysis.
  • the cationization method of the disclosure renders the textile in excellent condition for association with a dye, and the dyeing process can in tum provide good coloration of the textile.
  • Textile dyeing can be performed using a different system, or with the same system used for padding and heat treatment as described herein.
  • a “system” according to the disclosure includes apparatus (“system members”) that allow methods of the disclosure to be performed.
  • the system can include one or more of the following apparatuses: baths to hold treatment solutions (padding bath, wash bath, neutralization bath, and/or optionally dyeing bath); textile movement apparatus, such as a conveyor including rollers; solution removal apparatus, such as roller pairs; heating apparatus for the padded textile; control apparatus, such as a computer-based operation unit.
  • Steps of the method of the invention can be carried out using a continuous process, a semi-continuous process, a batch process, or a combination thereof.
  • a continuous process is a flow product method that is used to manufacture, process, or produce an article avoiding stoppage of the processing flow.
  • an article that is being processed or manufactured is in motion.
  • the textile is often in the form of a sheet that is moved through two or more processing areas (e.g., “treatment zone(s)”, with the sheet being subjected to different chemical, mechanical, and/or physical processes in each processing area while it is being moved. Movement of the textile in a continuous process can be facilitated by a system apparatus such as a textile conveyor having rollers, which contact and facilitate movement of the textile in a continuous process.
  • a continuous process can be performed using a system of the disclosure as described herein.
  • two or more steps of the method of the disclosure can be described as a continuous process.
  • steps of padding the textile in a solution of the base and cationizing agent, mechanically removing a portion of the solution from the padded textile, and then heat treating the textile the textile can be continuously moved through treatment zones which provide prescribed treatments of the textile in motion.
  • Other steps in the process of cationizing and dyeing e.g., washing, neutralizing, and/or optional dyeing
  • FIG. 1 illustrates a system than can be used for the continuous processing of a textile according to methods of the disclosure.
  • a semi-continuous process can include those wherein a flow product operation (continuous) is stopped and then restarted after a period of time.
  • two or more steps of the method of the disclosure can be described as a semi-continuous process.
  • movement of the textile can be stopped in a treatment zone for a period of time and then restarted to move the textile out of the treatment zone.
  • Methods of the disclosure can use a semi-continuous process wherein movement of the textile is stopped in the heat treatment apparatus for a period of time and temperature described herein suitable for reaction of the cationizing agent with the textile, and then movement of the textile is restarted after the time period to move the textile out of the heat treatment apparatus.
  • a semi-continuous process can be performed on a system of the disclosure as described herein.
  • one or more steps in the method of the disclosure can be performed in a batch process.
  • the textile before a processing step of the disclosure, or after a processing step of the disclosure, the textile can be altered in a way such that it is configured for use in a batch process rather than a continuous process. Alteration may be performed by cutting the textile to provide textile portions which are then used in one or more batch processing steps.
  • the system can include apparatus configured in a way where the textile is not automatically moved from one apparatus to the other otherwise associated with apparatus of a continuous process.
  • system features such as a conveyor apparatus which otherwise transports the textile from one apparatus to another in a continuous process may not be present in at least some of the apparatus of a system used for batch processing.
  • a textile is provided and then processed according to steps as described herein.
  • the term “textile” refers to a flexible material that includes a network of fibers and that is intended to encompass all forms of textile-based articles, including woven textiles, knitted textiles, and non-woven textiles.
  • Textiles can be in the form of sheets (fabrics) or thin strands (yarns). Textiles can be formed by art-known techniques involving one or more processes of weaving, knitting, crocheting, felting, or braiding strands of fiber-containing materials together.
  • Exemplary textile substrates can be provided in the form of a textile roll which provides a continuous sheet of textile which may have a width of greater than 1 meter and a length of up to 100 meters or more. With reference to FIG. 1 , the arrangement of textile roll 10 to be treated, in relation to other components of the system, is illustrated.
  • Textiles that are cationized using the cationizing agent and heat treatment according to methods of the disclosure include a natural fiber or derivative thereof.
  • a natural fiber of the textile can be obtained from plants such as cotton, hemp, ramie, flax, jute, kapok, coir, bamboo, and the like. Plant raw fibers can be spun to produce long strands, and the strands can be included in the textile by weaving (interlacing of the strands), knitting (interlooping of the yarns), etc., as known in the art of woven fabrics. In nonwovens, the plant-based fibers are not converted into strands or yarns but are rather directly intermingled with each other or other fibers to produce non-woven fabrics.
  • the natural fiber in the textile material can include natural polymers such as naturally-occurring polysaccharides like cellulose or cellulosic material, or chitin, or combinations thereof, or derivatives thereof.
  • Cellulose or cellulosic material which can include modified cellulose, as well as chitin and derivatives thereof, have chemistries that allow reaction with the cationizing agent.
  • Cellulose is composed of repeating glucopyranose subunits which presents three hydroxyl groups on each subunit.
  • Chitosan is composed of repeating glycosamine subunits which presents two hydroxyl groups and one amine group on each subunit. The hydroxyl groups of these polysaccharides are reactive with the hydroxide-activated cationizing agent.
  • Cellulosic materials also include rayon (viscose), which is generated from wood pulp, and lyocell (e.g., TencelTM), which is a form of rayon.
  • Textile substrates treated according to the disclosure can also include cellulose derivatives such as cellulose acetate, or imidazolidinone-modified cellulose.
  • the textile can be a blend or mixture of different materials, such as a blend of natural and synthetic fibers.
  • Blends include blends of different types of natural fibers, such as wool/cotton blends, silk/cotton blends, and angora/cotton blends.
  • Animal-based materials can include collagen fibers, keratin fibers, fibroin fibers, or a mixture thereof.
  • Other exemplary blends include blends of cellulosic and synthetic fibers, such as cotton/polyester blends, cotton/polyolefin blends, cotton/polyacrylonitrile blends, cotton/polyamide blends (e.g., cotton/nylon blends), as well as blends of cellulose fibers and cellulose derivative fibers, such as cotton/rayon blends.
  • the textile includes a blend of fibers, it preferably has at least about 5% (wt) of a natural fiber such as cotton, or derivative thereof, and more preferably about 25% (wt) or greater, about 35% (wt) or greater, or about 40% (wt) or greater, of the natural fiber (e.g., cellulosic), or derivative thereof.
  • exemplary blends include a natural fiber (or derivative thereof; e.g., cellulosic)) to synthetic fiber weight ratio in the range of about 5:95 to about 95:5, 25:75 to about 25:75, or 40:60 to about 60:40.
  • the woven textile can also be described in terms of textile weight (weight/area) which is often expressed in terms of ounces per square yard, or grams per square meter. Textile weight can be affected by the type or types of fibers in the textile and their properties, the type of weave of the textile, and the finish of the textile. Exemplary textile weights typically range from about 50 g/m 2 to about 1000 g/m 2 , or about 100 g/m 2 to about 750g/m 2 .
  • the process of the disclosure utilizes a bleached textile, or the process further includes a process step of bleaching the textile.
  • a bleached textile can have removed from it natural color, odor, and impurities otherwise present in when the fiber of the textile is in a raw (natural) form.
  • Oxidative bleaching is typically performed using oxidative bleaching agents such as hydrogen peroxide, sodium hypochlorite, sodium chlorite, sulfuric acid, or a combination thereof.
  • Sodium hydrosulphite is often used for reductive bleaching of textiles.
  • the textile can be placed in a bleaching bath for treatment with a bleaching solution for a desired period of time.
  • An exemplary bleaching solution includes hydrogen peroxide or sodium hypochlorite in an aqueous solution at a concentration in the range of about 0.5 to 5.0% (wt). After bleaching, the textile can be washed and dried.
  • the method of the disclosure includes a step of treating the textile with an aqueous treatment solution comprising an alkali metal hydroxide (base) and a cationizing agent.
  • Treatment of the textile with a solution including base and cationizing agent can be referred to as a “padding” process in which the aqueous solution with the treatment compounds (treatment solution, or padding solution) are placed in contact with the textile.
  • the treatment solution is present in a container (e.g., a “padding bath” or simply a “padder”) into which the textile is submerged.
  • the padding bath the textile can become saturated with the treatment solution.
  • the base and cationizing agent come into contact with material of the textile (and in a subsequent process step the activated cationizing agent is reacted with the textile in the presence using heat).
  • the aqueous treatment solution can be applied using a spray apparatus, a roller, or a brush.
  • padding is performed for a short period of time, such as not greater than one minute.
  • a cationizing agent refers to a compound that is able to associate with the textile material, such as by chemical reaction resulting in covalent bonding between the agent and material of the textile. The reaction imparts a positive (cationic) charge to the textile material.
  • Cationizing agents for use in methods and systems of the disclosure include mono- and di-quaternized nitrogen compounds.
  • the mono- and di-quaternized nitrogen compounds can include halogenated and hydroxylated ammonium compounds.
  • the compound can become dehalogenated and deprotonated to form a reactive glycidyl (epoxy) intermediate compound which in turn can react with hydroxyl groups of cellulosic material in the textile textile.
  • Amine groups of chitosan-containing textiles can also be reacted with glycidyl-containing ammonium compounds to provide cationization to the textile.
  • One type of a cationizing agent is a mono-quaternized nitrogen compound capable of generating a single epoxide group in the presence of alkali metal hydroxide.
  • the mono-quaternized nitrogen compound is of formula I:
  • R 1 is an alkylene (divalent) group, such as a C1-C6 alkylene group like methylene, ethylene, propylene, etc.
  • R 2 , R 3 , and R 4 are independently selected from alkyl (monovalent) groups, such as a C1-C6 alkyl group like methyl, ethyl, propyl, etc
  • X and X′ are independently halogen atoms, such as Cl, Br, or I.
  • Exemplary compounds of formula I include 3-chloro-2-hydroxypropyltrimethylammonium chloride (see, for example, U.S. Pat. No. 5,006,125)
  • cationizing agent is a di-quaternized nitrogen compound capable of generating two epoxide groups in the presence of alkali metal hydroxide.
  • exemplary cationizing agents include bis ether di-halogenated di-hydroxylated ammonium compounds, such as those of the following formula I:
  • R 1 and R 1′ are independently selected from alkylene (divalent) groups, such as a C1l-C6 alkylene groups like methylene, ethylene, propylene, etc.
  • R 2 , R 2′ , R 3 , and R 3′ are independently selected from alkyl (monovalent) groups, such as a C1-C6 alkyl groups like methyl, ethyl, propyl, etc
  • R 4 and R 4′ are independently selected from alkylene (divalent) groups, such as a C1-C6 alkylene
  • X-X′′′ are independently selected from halogen atoms, such as Cl, Br, or I.
  • the halogenated hydroxylated ammonium compound is a bis[(3-chloro-2-hydroxypropyldialkylammonium) alkyl]ether dichloride compound.
  • R 1 and R 1′ are methylene, and preferably R 2 , R 2′ , R 3 , and R 3′ are independently selected from methyl, ethyl and propyl, and R 4 and R 4′ are preferably methylene, ethylene, or propylene.
  • Exemplary compounds include bis[(3-chloro-2-hydroxypropyldimethylammonium)ethyl]ether dichloride, bis[(3-chloro-2-hydroxypropyl-dimethylammonium)ethyl]ether dichloride, and bis[(3 -chloro-2-hydroxypropylmethylethyl-ammonium)propyl]ether dichloride. See, for example, U.S. Publication No. 2015/0210627.
  • the treatment solution includes desired types and amounts of base and cationizing agent which facilitate rapid downstream processing in a heating step, described herein.
  • the concentration of the cationizing agent in the aqueous treatment solution is at least about 20 g/L but preferably not greater than 125 g/L.
  • the concentration of the cationizing agent in the aqueous treatment solution is in the range of about 40 to about 105 g/L, about 50 to about 95 g/L, or about 55 to about 85 g/L.
  • the concentration of cationizing agent can also be expressed in terms of molarity.
  • the concentration of the cationizing agent in the aqueous treatment solution can be at least about 0.05 molar.
  • the concentration of a dihalogenated cationizing agent is in the range of about 0.05 molar to about 0.3 molar, about 0.1 molar to about 0.25 molar, about 0.125 molar to about 0.225 molar, or about 0.14 molar to about 0.2 molar.
  • Exemplary alkali metal hydroxide bases are potassium hydroxide and sodium hydroxide.
  • the amount of base used can be determined by the type and amount of cationizing agent, and the heat treatment time and temperature.
  • the concentration of the base in the aqueous treatment solution is at least about 10 g/L but preferably not greater than 60 g/L, or not greater than 55 g/L.
  • Exemplary concentration of the base in the aqueous treatment solution is in the range of about 15 g/L to about 60 g/L, or about 20 g/L to about 55 g/L.
  • the concentration of the base in the aqueous treatment solution can be at least about 0.25 molar, or at least about 0.35 molar, but preferably not greater than 1.5 molar, or not greater than 1.375 molar.
  • Exemplary concentrations of the base are in the range of about 0.25 molar to about 1.5 molar, or about 0.35 molar to about 1.375 molar.
  • a mono-quaternized cationizing agent may use more base as compared to a di-quaternized cationizing agent.
  • the amounts of base and cationizing agent in the treatment solution can also be described with reference to the molar ratio of the base to the cationizing agent.
  • the aqueous solution has an alkali metal hydroxide to cationizing agent molar ratio of 3.5:1 or greater, or 8.0:1 or less, such as in the range of 3.5:1 to 8.0:1, or 3.75:1 to 7.5:1.
  • the solution has an alkali metal hydroxide to cationizing agent molar ratio of greater than 1:1, such as in the range of 1.8:1 to 5:1, or 2.0:1 to 4.5:1.
  • the aqueous treatment solution further includes a viscosity enhancer (also referred to as an “anti-migration agent”).
  • a viscosity enhancer can improve immobilization of the cationizing agent in the padded textile, which in turn improves reaction efficiency, and then subsequent dyeing of the cationized textile.
  • Exemplary viscosity enhancers include polyvinyl methyl ethers (e.g., having a mean molecular weight of about 100,000), sodium alginates, Gaur gum, carboxymethylcellulose (CMC), low molecular weight cellulose ethers, polyethylene glycols (e.g., having a mean molecular weight in the range of 8,000 to 10,000), poly vinyl caprolactam, and acrylic polymers, with acrylic polymers being a preferred viscosity enhancer.
  • Preferred viscosity enhancers should not disturb the dye, should not cause loss in color brilliance, should have adequate liquor stability, should not cause any hardening of the handle, should have good solubility at room temperature, and should provide good effects in small amounts.
  • the viscosity enhancer is provided to the padding bath to provide a viscosity in the range of about 50 to about 350 cP.
  • the viscosity enhancers can be used in an amount in the range of about 2% to about 20% (wt), or about 5% to about 10% (wt) in the aqueous padding solution.
  • the aqueous padding solution is generally maintained at a temperature (or temperatures) not greater than 35° C.
  • the aqueous padding solution is at a temperature(s) in the range of about 15° C. to about 27° C., or about 18° C. to about 25° C.
  • the method is a continuous process wherein the textile is fed into a treatment bath, the textile is moved through the bath, and then exits the bath.
  • the padding step can be performed quickly
  • a sheet 12 of textile is advanced from textile roll 10 and into padding bath 20 which holds treatment solution 22 including cationizing agent and base.
  • Padding bath 20 includes roller set ( 24 a - 24 c ) to facilitate movement and positioning of the advancing textile sheet in the treatment solution 22 .
  • the residence time (“padding times”) in the padding bath is defined by the time where a particular portion of the textile enters the bath and then ends when that particular portion leaves the padding bath.
  • this is greater than 0.5 second, greater than 1 second, or greater than 2 seconds, and generally less than 1 minute, about 45 seconds or less, or about 30 seconds or less.
  • An exemplary padding time is in the range of 1 second to 1 minute, 1 second to 45 seconds, 1 second to 30 seconds, 1 second to 20 seconds, 1 second to 15 seconds, 1 second to 10 seconds, or 2 seconds to 5 seconds.
  • the residence time of the textile in the padding bath can be determined by the speed of the machine as well as other aspects of the system. For example, based on the rate that the textile conveyor apparatus of the system moves the textile though a treatment area, and the length of the travel path through the treatment area, the residence time of the textile in the treatment area can be known.
  • the textile conveyor apparatus moves the textile through at least the padding bath at a rate in the range of about 20 meters/min to about 50 meters/min.
  • Exemplary lengths of travel paths through the padding bath can be in the range of about 0.5 meter to about 5 meters, or about 1 meter to about 4 meters.
  • the padding process can result in the textile becoming “soaked” or “saturated” with the treatment solution.
  • excess treatment solution can be removed from the textile and returned to the padding bath.
  • the textile can be advanced out of the treatment solution 22 and through roller pair ( 26 a, 26 b ) which applies pressure to the padded textile to remove excess treatment solution, which is returned to the padding bath 20 .
  • sufficient treatment solution is maintained in the textile to provide an amount of base and cationizing agent for reaction with the textile in the subsequent heat treatment step.
  • the padded textile can be described in terms of the amount of aqueous treatment solution present in the textile (an “effective concentration”).
  • the padded textile can be referred to in terms of a “wet pickup,” which is the amount (weight) of treatment solution present in the textile divided by the weight of dry textile before padding.
  • the padding step provides a wet pick up of the treatment solution of greater than about 50%.
  • the padding step provides a wet pick up of the treatment solution in the range of about 60% to about 80%.
  • the effective concentration of the cationizing agent in the textile is 70 g/L, or 7%.
  • the padding process and removal of any excess treatment solution from the saturated textile can be performed rather quickly, which facilitates the overall process of cationization and dyeing of the textile.
  • a sheet 12 of textile is advanced from roller pair ( 26 a, 26 b ) into heating apparatus 30 through opening 32 .
  • Heating apparatus 30 includes roller set ( 34 a - 34 e ) on which the textile can be supported and moved through the heating chamber.
  • the chamber can have a heating element (not shown) to maintain the atmosphere therein at a desired temperature according to the disclosure.
  • the heat treatment step is carried out for a short period of time in a well-defined temperature range. Heating can carried under normal atmospheric conditions and a steam or modified gas environment is not required.
  • the padded textile Upon introduction to the heat chamber, the padded textile is rapidly heated to the desired temperature set for the apparatus. Generally the textile will be heated to the desired temperature in a short period of time, such as less than 15 seconds or less than 10 seconds. The textile may be moved through the heat chamber as it reaches the desired temperature.
  • the textile is heated to a temperature in the heat chamber, or more than one temperature, that is in the range of about 90° C. to less than about 110° C., and then held at this temperature(s) for a period of time in the range of about 1 min to about 10 min to react the cationizing agent with the textile.
  • the textile is heated to a temperature in the heating chamber, or more than one temperature, in the range of in the range of about 90° C. to about 109° C., in the range of about 90° C. to about 108° C., in the range of about 90° C. to about 107° C., in the range of about 90° C. to about 106° C., in the range of about 90° C. to about 105° C., in the range of about 90° C. to about 104° C., in the range of about 90° C. to about 103° C., in the range of about 90° C. to about 102° C., in the range of about 90° C. to about 101° C., or in the range of about 90° C.
  • Heating can be carried out at one or more temperatures in any of the aforementioned ranged for a period of time in the range of 1 to 10 minutes, about 1 to 9 minutes, about 2 to 9 minutes, about 2 to 8 minutes, about 2 to 7 minutes, about 3 to 8 minutes, about 3 to 7 minutes, about 3 to 6 minutes, or about 4 to 6 minutes.
  • the textile is heated to a temperature in the heating chamber, or more than one temperature, in the range of in the range of about 91° C. to about 109° C., in the range of about 92° C. to about 109° C., in the range of about 93° C. to about 108° C., in the range of about 93° C. to about 107° C., in the range of about 94° C. to about 106° C., in the range of about 95° C. to about 105° C.
  • Heating can be carried out at one or more temperatures in any of the aforementioned ranged for a period of time in the range of 1 to 10 minutes, about 1 to 9 minutes, about 2 to 9 minutes, about 2 to 8 minutes, about 2 to 7 minutes, about 3 to 8 minutes, about 3 to 7 minutes, about 3 to 6 minutes, or about 4 to 6 minutes.
  • the method may also be described with regards to the total time period to perform the steps of treating with aqueous solution, mechanically removing, and treating the textile with heat.
  • these steps can be performed in period of time of not more than 11 minutes, not more than 10 minutes, not more than 9 minutes, not more than 8 minutes, not more than 7 minutes, or not more than 6 minutes, or for a period of time in the range of 1 minute to 11 minutes, 1 minute to 10 minutes, 1 minute to 9 minutes, 1 minute to 8 minutes, 1 minute to 7 minutes, or 1 minute to 6 minutes.
  • the heat treatment temperatures and times of the disclosure can promote rapid reaction of the cationizing agent with reactive chemistries on the textile while minimizing hydrolysis of the cationizing agent, which otherwise renders it nonfunctional.
  • the treated textile can be described in terms of a reaction efficiency of the cationizing agent with the textile.
  • Reaction efficiency can by expressed by the amount of cationizing agent reacted per weight unit of the textile (e.g., mmol cationizing agent per gram of textile material).
  • the reaction efficiency (cationization degree) can be determined by the amount of nitrogen content of the textile as imparted by the cationizing agent.
  • the process of the disclosure provides at least about 0.075 mmol nitrogen (from the cationizing agent) per gram of textile. More typically there is at least about 0.085 mmol, at least about 0.09 mmol, or at least about 0.095 mmol nitrogen (from the cationizing agent) per gram of textile.
  • Determination of reaction of cationizing agent can be determined by analyzing the added ammonium groups to the textile such as by Kjeldahl method or combustion method (e.g., see Schwarzinger, C., et al. (2002) Monatshefte fur Chemie 133:1-17; or Ma, W., et al. (2017) Molecules, 22:2235).
  • the cationized textile After the cationized textile has been heat treated, it can be washed with a hot aqueous solution.
  • the hot water wash can remove at least a portion of any unreacted or hydrolyzed cationizing agent, base, and/or other optional component (e.g., viscosity enhancer) carried over from the padding bath.
  • the heat-treated textile can exit the heating apparatus 30 through an aperture 36 , and can be fed into a hot water bath 40 .
  • Hot water bath 40 includes roller set ( 44 a - 44 e ) to facilitate movement and positioning of the advancing textile sheet in the hot water.
  • the hot aqueous solution can have a pH in the range of 6-8.
  • the temperature of the hot water bath is preferably in the range of about 70° C. to about 90° C., or even more preferably in the range of about 75° C. to about 85° C.
  • the cationized textile can be maintained in the hot aqueous bath for a period of time less than 20 min, less than 15 min, such as a time in the range of about 5 to 15 minutes.
  • the textile can be moved through the bath, such as on rollers in the bath, and then the textile can exit the bath after the desired period of washing.
  • the washed textile can be transferred to a neutralization bath without removing water from the textile.
  • the cationized textile After the cationized textile has been hot water washed, it can be neutralized by treatment with an acid.
  • the acid can react with any remaining base present in the textile, thereby neutralizing the cationized textile.
  • the washed cationized textile can exit the hot water bath 40 , can be mechanically treated, such as by passage through a roller pair (not shown) to remove the hot water solution, and then can be fed into a neutralization bath 50 including an aqueous composition with an acid.
  • the neutralization bath 50 can include roller set ( 54 a - 54 e ) to facilitate movement and positioning of the advancing textile sheet in the acid-containing solution of the bath.
  • the acid-containing solution can have an exemplary pH in the range of about 4 to about 5.
  • the acid solution can be formed using a weak acid, such as acetic acid, citric acid, or oxalic acid, or a combination thereof.
  • the amount of acid can depend on the acid type used, but an exemplary acid is acetic acid at a concentration in the range of about 1 about 2 grams per liter.
  • the acid treatment solution is generally maintained at a temperature (or temperatures) not greater than 35° C.
  • the acid treatment solution is at a temperature(s) in the range of about 15° C. to about 27° C., or about 18° C. to about 25° C.
  • the cationized textile can be maintained in the acid treatment solution for a period of time less than 20 min, less than 15 min, such as a time in the range of about 5 to 15 minutes.
  • the textile can be moved through the acid treatment solution, such as on rollers in the bath, and then the textile can exit the acid treatment solution after the desired period of washing.
  • a dyeing step and dyeing apparatus may or may not be a part of the method and system of the disclosure.
  • the system and method of the disclosure may optionally include one or more steps of cold or hot water wash(es) between after neutralization/acid treatment.
  • the cationized textile After the cationized textile has been neutralized, it can be dyed by treatment with in a dye solution.
  • the dyeing process can be performed using the same system as the padding bath and heat treatment apparatus, or can be performed in a different system, separate from the padding bath and heat treatment apparatus. If the dyeing process is performed using a different system, such as in a dyeing facility at a different location from the facility having the padding/heat treatment system, the cationized textile can be transported to that facility and dyed.
  • the neutralized cationized textile can exit the neutralization bath 50 , can be mechanically treated, such as by passage through a roller pair (not shown) to remove any excess acid solution, and then can be fed into a dye bath 60 including a composition with a dye.
  • the dye bath 60 can include roller set ( 64 a - 64 e ) to facilitate movement and positioning of the advancing textile sheet in the dye solution.
  • Cationized textiles can accept a variety of dyes and therefore provide good flexibility for color offerings.
  • the cationized textile can provide improved dye association by virtue of chemical interaction between the positively-charged quaternized nitrogens of the textile bound cationizing agent and, for example, anionic groups of an anionic dye.
  • the cationized textile can also accept other dye types that associate the dye with the textile in a way that does not rely on the textile-bound cationizing agent.
  • a “dyeing” process is one that imparts color to a textile, and “dye” refers to any substance that provides color to a textile, which can also include pigments, as described herein.
  • Dyes can be associated with a fiber of the textile by chemical reaction, absorption, dispersion, or a combination thereof. Dyes typically differ in their resistance to sunlight, perspiration, washing, gas, and alkali; their affinity for different fibers; their reaction to cleaning agents and methods; and their solubility and method of application.
  • Exemplary dye types that can be used to color the cationized textiles made using the methods and systems of the disclosure include natural dyes, basic (cationic) dyes, direct (substantive) dyes, sulfur dyes, pigment dyes, vat dyes, reactive dyes, and acid dyes
  • Reactive dyes can react with one or more chemical groups of the textile fiber.
  • Reactive dyes can be applied from alkaline solution or from neutral solutions which are then alkalized in a separate process. Heat treatment can also be used during dyeing to develop different color shades. After dyeing, the textile can be washed with soap to remove any unfixed dye.
  • Reactive dyes can be used for cationic textiles including cellulose fibers, as well as those including blends of wool, silk, nylon, and acrylics.
  • Direct dyes can color cellulose fibers directly without requiring the use of a mordant (a dye fixative). Direct dyes can be used for cationic textiles including cellulose fibers, as well as those including blends of wool, silk, nylon, rayon etc.
  • Sulfur dyes are water-insoluble and made soluble using a reducing agent and alkali pH (e.g., caustic soda and sodium sulfide). Dyeing is done at high temperature with large quantities of salt so that the color penetrates into the fiber. After dyeing the textile is oxidized by exposure to air or by using chemicals to provide desired color shades. Excess dyes and chemicals can be removed by thorough washing. Sulfur dyes are fast to light, washing, and perspiration, and are mostly used for cotton and linen.
  • alkali pH e.g., caustic soda and sodium sulfide
  • Vat dyes are insoluble in water and are typically made soluble by reduction in alkaline solution which allows them to be affixed to textile fibers. Subsequent oxidation or exposure to air restore the dye to its insoluble form.
  • An exemplary vat dye is Indigo. Vat dyes are the fastest dyes for cotton, linen and rayon. Vat dyes are commonly used with mordants to dye other textiles such as wool, nylon, polyesters, acrylics and modacrylics.
  • Pigments are not technically dyes, but still are used for coloring textiles like cotton, wool and other manmade fibers due to their excellent light fastness. Pigments are typically affixed to fibers of a textile using resins. After dyeing, the textiles are subjected to high temperatures.
  • a dyeing step according to the disclosure can use a pigment to color the cationized textile. Natural dyes, which are obtained from a natural source such as vegetable, animal, or mineral source, can be used with a cationized textiles. Direct printing is the most common approach to apply a color pattern onto a textile. If done on colored textile, it is known as overprinting. The desired pattern is produced by pressing dye on the textile in a paste form.
  • a thickening agent is added to a limited amount of water and dye is dissolved in it.
  • starch was preferred as a thickening agent for printing.
  • gums or alginates derived from seaweed are preferred as they allow better penetration of color and are easier to wash out.
  • Most pigment printing is done without thickeners because the mixing up of resins, solvents and water produces thickening.
  • Some dyes used for dyeing cationized textiles include “reactive” or anionic dyes.
  • Reactive, anionic dyes can include one or more anionic groups, such as sulfonate or carboxylate groups.
  • the anionic dye can include one or more sodium sulfonate (-S0 3 Na) groups.
  • the one or more anionic groups can be present in a dye molecule cable of absorbing light in the visible spectrum and having at least one chromophore/color-bearing group with a conjugated system.
  • Commonly used anionic dyes include those based on azo chemistries, anthraquinone chemistries, and triphenyl methane chemistries.
  • Azo dyes are chemically characterized by the group R—N ⁇ N—R′, where R and R′ commonly include an aryl group, with various chemical substituents attached to the aryl groups.
  • Other anionic dyes include those having nitro chemistries, azine chemistries, and quinoline chemistries.
  • Acid dyes are a type of anionic dyes that can include acid groups such as carboxylic acid, sulfonic acid, or phosphoric acid groups.
  • Anionic dyes that can be used in methods of the disclosure are described in various references, such as Aspland, J. R., (1997) Textile Dyeing and Coloration, American Association of Textile Chemists and Colorists, AATCC; Knutson, L.
  • the concentration of the anionic dye in the dyeing solution is in the range of about 0.001 g/L to about 5.0 g/L, about 0.01 to about 2 g/L, with more concentrated dye solutions providing a more intense dye color to the textile.
  • the anionic dye solution is generally maintained at a temperature(s) in the range of about 30° C. to about 80° C.
  • Dyeing can be carried out for a desired period of time, such as in the range of about 30 minutes to about 60 minutes. With reference to FIG. 1 , after dyeing the textile can be washed (not shown) and then rolled to a roller 72 .
  • Operation of one or more parts of the system can be controlled using a process controller (not shown), such as a computer-based controller, which can be programmed to perform the treatment method as described herein.
  • a process controller such as a computer-based controller, which can be programmed to perform the treatment method as described herein.
  • a bleached cotton fabric (A4 size) was dipped in various solutions containing the di-quaternized cationizing agent bis[(3-chloro-2-hydroxypropyldimethylammonium)ethyl]ether dichloride (bis-CHPDMAEEDC) which is commercially available under the tradename ECOFASTTM Pure; Dow) and sodium hydroxide. Concentrations of bis-CHPDMAEEDC and NaOH base are listed in Table 1.
  • the solutions were at ambient temperature (20° C.) and the fabric was maintained in the solutions for approximately 2-3 seconds before being removed.
  • the soaked fabric was then passed through two rollers with 70% expression to squeeze the excess solution from the fabric. Accordingly, the effective concentration of the cationizing agent on the fabric was 49 g/L (0.119 molar).
  • the cationizing agent and base 70 gpl bis-CHPDMAEEDC and 20 gpl NaOH
  • a low temperature 25° C.
  • the cationized fabric was washed in hot water at a temperature of 80° C. for 10 min, then the washed fabric was neutralized in a solution containing acetic acid (1/5 g/L) as per NaOH concentration in ambient condition (temperature 30° C.) for 10 min. After cationization, nitrogen content on the fabric was assessed by the combustion method.
  • Dyeing was performed by placing 2 gm of the cationized cotton in a dye composition including 3% Reactofix Red ME4BL dye solution and 15 g/L sodium carbonate to improve the fixation and performance properties.
  • the dye solution was at a temperature 60° C. and the fabric was maintained in the solution for 30 min. This was followed by washing process of a cold wash and neutralization, a hot wash at 60° C. for 10 min, and then cold wash. Results of the rapid heat treatments were compared and standardized against a cotton fabric prepared as the controlled standard.
  • Pad-dry treatments of bleached cotton fabric were carried out according to Example 1, but using the mono-quaternized cationizing agent 3-chloro-2-hydroxypropyltri-methylammonium chloride (CHPTMAC; commercially available under the tradename Ecofast CR 2000; Dow), and the di-quaternized compound bis-CHPDMAEEDC at different temperatures for various periods of time.
  • CHPTMAC mono-quaternized cationizing agent 3-chloro-2-hydroxypropyltri-methylammonium chloride
  • results of fabric dyeing revealed that fabric samples treated with bis-CHPDMAEEDC and CHPTMAC at temperatures of 90° C. or 100° C. and for periods of time of 5 or 10 minutes provided results better than comparative temperatures and times, with treatment times of 5 minutes at 90° C. or 100° C. providing the best results.
  • Nitrogen content on the cationic cotton resulting from treatment with bis-CHPDMAEEDC at different conditions was measured and is shown in Table 3 and FIG. 2 .
  • Nitrogen content on the cationic cotton resulting from treatment with CHPTMAC at different conditions was measured and is shown in Table 4 and FIG. 3 . Again temperatures of 90° C. or 100° C. and for periods of time of 5 or 10 minutes provided results better than comparative temperatures and times, with treatment times of 5 minutes at 90° C. or 100° C. providing the best results.

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