WO2006108240A1

WO2006108240A1 - Method of treating carpet

Info

Publication number: WO2006108240A1
Application number: PCT/AU2006/000513
Authority: WO
Inventors: George Naguib
Original assignee: Feltex Australia Pty Ltd
Priority date: 2005-04-14
Filing date: 2006-04-18
Publication date: 2006-10-19

Abstract

A method of enhancing the stain resistance of a carpet by (i) applying a fluorochemical composition comprising a fluorochemical and an electrolyte and/or (ii) applying a stain blocker composition comprising a stain blocker and an electrolyte.

Description

Method of Treating Carpet

The present invention relates to a method of treating carpet, and in particular to a method of treating a carpet to enhance the carpet's resistance to staining, fading and repellency.

Background of the Invention

Carpets may be manufactured from wool, synthetic wool blends or purely synthetic fibres and may be woven or tufted in construction. Carpets made from synthetic materials are typically composed of fibres made from nylon, polyester or polypropylene compositions.

There is an increasing interest in developing methods of increasing the stain resistance of carpets. One method involves the addition of two compounds in two separate phases after a carpet has gone through a dye treatment process and has been washed. The first phase involves the addition of a stain blocker, which is generally a colourless dye in the form of an anionic polymer, to the surface of the carpet. A stain blocker is believed to "block" the remaining available dye sites located on the individual carpet fibres thereby inhibiting the mechanisms through which potentially staining substances may attach to the carpet fibres.

One conventional method of applying the stain blocker onto the carpet is mixing the stain blocker with water to form an aqueous medium or liquor. The aqueous medium is heated to a temperature of approximately 98 ⁰C and adjusted to a pH of 2.0. The carpet is then wet out in this aqueous medium in a wet-pick-up range of 300% to 500% for a period of 1 to 2 minutes.

After the stain blocker is applied, the carpet is then washed and a fluorochemical may be optionally applied, normally in the form of a foam or spray over the surface of the carpet at room temperature. Such fluorochemicals reduce the ability of soil and/water to adhere to the carpet fibres by forming a thin firm on the carpet surface. The carpet may then be dried.

The dual process results in a protective layer from stains and spills that surround the fibres of the carpet. However, the protective layer is only present around the outside of the carpet fibres. Hence this process is often termed a "ring dye" process as the protective layer only forms a protective ring around the outside of the carpet fibres. Once the carpet begins to wear through normal use, the protective layer is gradually warn through and the resistance to staining is no longer present.

Accordingly, the present invention seeks to provide a method of treating carpet to increase the carpet's resistance to staining and reduce the carpet's susceptibility to fade when exposed to sunlight.

Summary of the Invention

According to one aspect the present invention provides a method of enhancing the stain resistance of a carpet, the method including applying a fluorochemical composition including a fluorochemical and an electrolyte to the carpet.

Preferably the fluorochemical composition has a pH of below 4.0 and more preferably below 2.2. In order to achieve the low pH, acid is included into the fluorochemical composition such as for example sulfamic acid or acetic acid.

According to one embodiment the fluorochemical composition is in the form of an aqueous medium or liquor. According to this form, the aqueous medium is preferably applied to the carpet in a wet pick up of between 100% and 500%, and more preferably 250% and 350%, at a temperature of between 85°C and 100°C, and more preferably 90°C and 98°, and wherein the aqueous medium is permitted to dwell in the carpet for a period of 5 to 120 seconds and more preferably 5 to 60 seconds.

According to another embodiment the fluorochemical composition is in the form of a foam. According to this form, the foam is preferably applied to the carpet in a wet pick up of between 25% and 200% and more preferably 50% and 100%, at a temperature of between 85°C and 100°C, and more preferably 90°C and 98°, and wherein the foam is permitted to dwell in the carpet for a period of 5 to 120 seconds and more preferably 5 to 60 seconds.

Preferably, steam is applied to the carpet for a period of between 5 and 120 seconds after the application of the fluorochemical composition.

Preferably, the electrolyte included in the fluorochemical composition is magnesium sulphate.

The fluorochemical composition is preferably applied to a carpet after it has undergone a colour die treatment, hi one form, the fluorochemical composition may be applied before or after a stain blocker composition is applied to the carpet.

According to another aspect the present invention provides a method of enhancing the stain resistance of a carpet, the method including applying a stain blocker composition including a stain blocker and an electrolyte to the carpet.

Preferably the stain blocker composition has a pH of below 4.0 and more preferably below 2.2. In order to achieve the low pH, acid, such as for example sulfamic acid or acetic acid, is included into the stain blocker composition.

According to one embodiment the stain blocker composition is in the form of an aqueous medium or liquor. According to this form, the aqueous medium is preferably applied to the carpet in a wet pick up of between 100% and 500%, and more preferably 250% and 350%, at a temperature of between 85°C and 100⁰C, and more preferably 9O⁰C and 98°, and wherein the aqueous medium is permitted to dwell in the carpet for a period of 5 to 120 seconds and more preferably 5 to 60 seconds.

According to another embodiment the stain blocker composition is in the form of a foam. According to this form, the foam is preferably applied to the carpet in a wet pick up of between 25% and 200% and more preferably 50% and 100%, at a temperature of between 85°C and 100⁰C, and more preferably 90°C and 98°, and wherein the foam is permitted to dwell in the carpet for a period of 5 to 120 seconds and more preferably 5 to 60 seconds.

Preferably, steam is applied to the carpet for a period of between 5 and 120 seconds after the application of the stain blocker composition.

Preferably, the electrolyte included in the stain blocker composition is magnesium sulphate.

Preferably, the stain blocker is chosen from an anionic polymer.

The stain blocker composition is preferably applied to a carpet after it has undergone a colour die treatment. In one form, the stain blocker composition may be applied before or after a fluorochemical composition is applied to the carpet.

According to another aspect the present invention provides a method of enhancing the stain resistance of a carpet including the steps of:

(a) Applying an aqueous stain blocker composition, including a stain blocker compound and an electrolyte at apH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%;

(b) Optionally applying steam to the carpet for a period of between 5 to 120 seconds;

(c) Rinsing the carpet to remove excess water or chemicals; (d) Extracting excess water to reduce the carpet water content to between 15% and 45% water;

(e) Applying an aqueous fluorochemical composition, including a fluorochemical and an electrolyte at apH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99°C for 5 to 60 seconds at a wet pick up between 250% and 350%; (f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and

(g) Rinsing the carpet to remove excess water or chemicals.

(a) Applying an aqueous stain blocker composition, including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 90⁰C to 99°C for 5 to 60 seconds at a wet pick up between 250% and 350%;

(c) Rinsing the carpet to remove excess water or chemicals;

(d) Extracting excess water to reduce the carpet water content to between 15% and 45% water;

(e) Applying a fluorochemical composition in the form of a foam to the pile face of the carpet at a temperature of 90⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the fluorochemical composition including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0;

(f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and

(g) Rinsing the carpet to remove excess water or chemicals.

(a) Applying a stain blocker composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the stain blocker composition including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0; (b) Optionally applying steam to the carpet for a period of between 5 to 120 seconds;

(c) Rinsing the carpet to remove excess water or chemicals;

(e) Applying an aqueous fluorochemical composition, including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%; (f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and, (g) Rinsing the carpet to remove excess water or chemicals.

(a) Applying a stain blocker composition in the form of a foam to the pile face of the carpet at a temperature of 90⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the stain blocker composition including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0; (b) Optionally applying steam to the carpet for a period of between 5 to 120 seconds;

(c) Rinsing the carpet to remove excess water or chemicals;

(d) Extracting excess water to reduce the carpet water content to between 15% and 45% water; (e) Applying a fluorochemical composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the fluorochemical composition including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0; (f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and (g) Rinsing the carpet to remove excess water or chemicals.

According to another aspect the present invention provides a method of enhancing the stain resistance of a carpet including the steps of: (a) Applying an aqueous fluorochemical composition, including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 90⁰C to 99°C for 5 to 60 seconds at a wet pick up between 250% and 350%;

(c) Rinsing the carpet to remove excess water or chemicals,

(e) Applying an aqueous stain blocker composition, including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 90⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%; (JE) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and, (g) Rinsing the carpet to remove excess water or chemicals.

(a) Applying a fluorochemical composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the fluorochemical composition including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0;

(c) Rinsing the carpet to remove excess water or chemicals, (d) Extracting excess water to reduce the carpet water content to between 15% and 45% water;

(e) Applying an aqueous stain blocker composition, including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0, to the pile face ^* of the carpet at a temperature of 9O⁰C to 99°C for 5 to 60 seconds at a wet pick up between 250% and 350%;

(f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and,

(g) Rinsing the carpet to remove excess water or chemicals.

(a) Applying an aqueous fluorochemical composition including a fluorochemical and an electrolyte at apH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 90⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%;

(e) Applying a stain blocker composition in the form of a foam to the pile face of the carpet at a temperature of 90⁰C to 99°C for 5 to 60 seconds at a wet pick up between 50% and 100%, the stain blocker composition including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0;

(i) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and, (g) Rinsing the carpet to remove excess water or chemicals.

According to another aspect the present invention provides a method of enhancing the stain resistance of a carpet including the steps of: (a) Applying a fluorochemical composition in the form of a foam to the pile face of the carpet at a temperature of 90⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the fluorochemical composition including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0;

(c) Rinsing the carpet to remove excess water or chemicals,

(e) Applying a stain blocker composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the stain blocker composition including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0, (f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and, (g) Rinsing the carpet to remove excess water or chemicals.

Preferably, the foam in accordance with each aspect of the present invention has a thick consistency to provide a level application of the foam to surface of the carpet. The foam may be formed by blowing air through the solution including the stain blocker and/or fluorochemical. Optionally an additional foaming agent may be added to the solution if additional foaming is required

The foam wets out the carpet in a wet-pick-up range of 5% to 200% and more preferably 50% to 100%. Preferably, the foam is applied after the carpet has undergone a standard colour die treatment.

The electrolyte may be chosen from any compound that ionises when dissolved to produce an electrically conductive medium such as for example magnesium sulphate. According to another aspect the present invention provides a method of enhancing the stain resistance of a carpet including the steps of:

(a) forming a thick foam from a solution including a stain blocker wherein the foam has a pH between 3.0 to 1.0;

(b) applying the foam to the carpet wherein the carpet is wet out in a wet-pickup range of 5% to 100%;

(c) allowing the foam to dwell on the carpet for 0.5 to 24 hours;

(d) applying heat to the carpet to fix the stain blocker onto the fibres of the carpet;

(e) padding fluorochemical on to the carpet at a temperature between 85⁰C and 99⁰C and at a pH of between 3.0 and 1.0 for between 0.5 and 5 minutes; and

(f) rinsing the carpet to remove excess chemicals.

(a) forming a thick foam from a solution including a stain blocker and a fluorochemical wherein the foam has a pH between 3.0 to 1.0;

(b) applying the foam to the carpet wherein the carpet is wet out in a wet-pick- up range of 5 % to 100%;

(c) allowing the foam to dwell on the carpet for 0.5 to 24 hours;

(d) applying heat to the carpet to fix the stain blocker onto the fibres of the carpet; and,

(e) rinsing the carpet to remove excess chemicals.

(a) forming a thick foam from a solution including a stain blocker and a fluorochemical wherein the foam has a pH between 6.0 to 4.0; (b) applying the foam to the carpet wherein the carpet is wet out in a wet-pickup range of 5% to 100%; (c) allowing the foam to dwell on the carpet for 0.5 to 24 hours;

(e) applying a mixture of acid and electrolytes at a temperature between 90⁰C and 99⁰C at a pH of 2 for 0.5-5 minutes; and,

(f) rinsing the carpet to remove excess chemicals.

According to another aspect the present invention provides a method of enhancing the stain resistance of a carpet including the steps of: (a) forming a thick foam from a solution including a stain blocker wherein the foam has a pH between 3.0 to 1.0;

(c) allowing the foam to dwell on the carpet for 0.5 to 24 hours; (d) applying heat to the carpet to fix the stain blocker onto the fibres of the carpet;

(e) rinsing the carpet to remove excess chemicals; and,

(f) applying a fluorochemical in the form of a thick foam or spray and then drying the carpet.

(a) forming a thick foam from a solution including a stain blocker wherein the foam has a pH between 6.0 to 4.0; (b) applying the foam to the carpet wherein the carpet is wet out in a wet-pickup range of 5% to 100%;

(c) allowing the foam to dwell on the carpet for 0.5 to 24 hours;

(d) applying heat to the carpet to fix the stain blocker onto the fibres of the carpet; (e) applying a mixture of acid and electrolytes at a temperature between 9O⁰C and 99⁰C at a pH of 2 for 0.5-5 minutes; (f) rinsing the carpet to remove excess chemicals; and,

(g) applying a fluorochemical in the form of a thick foam or spray and then drying the carpet.

The present invention will become better understood from the following detailed description of preferred but non-limiting embodiments thereof.

Detailed Description of the Invention

In accordance with the present invention the term "carpets" may include any type of man made carpet such as those composed of wool, wool/synthetic blends, or purely synthetic carpets. The term "synthetic" covers all man made fibres such as for example nylon, polyester and polypropylene compositions. The term "nylon" specifically includes NYLON, NYLON6 and NYLON6,6 and the term "nylon" will be used herein to refer to these materials and any other nylon derived material.

The present invention may be equally applied to carpets constructed in a woven or tufted form regardless of the carpet construction.

The term "stain blocker" refers to an anionic polymer. Stain blockers are colourless dyes. Stain blockers are negatively charged molecules. Due to their size they are less likely to diffuse into the fibre. In order to diffuse the stain blocking molecules into the fibre, it is preferable to use either one of or a combination of heat, low pH and/or the addition of an electrolyte. They are held primarily onto the fibre by an ionic force. The dye sites on the fibre carry (+ve) positive charge (cationic) and the stain blockers carry (-ve) negative charge (anionic). Both anionic and cationic molecules have affinity to each other, which causes the driving force behind the attraction of the stain blocker and dye site on the fibre. The ionic driving force is greatly enhanced in an acidic environment (low pH) where the attraction between the stain blocker and the dye sites becomes greater. Several commercial stain block polymers (aniorήc polymers) are commonly used and have shown to work in accordance with the present invention. For example: FX 3607F from 3M, FX 668F from 3M, Megashield ABW, NRD 332 from Dupont, ARS7 AND TSR from Arrow engineering.

The term "fluorochemical" refers to any fluorocarbon or fluorochemical polymer or combination thereof which is suitable to form a thin film on the carpet surface that prevents soiling. Fluorochemicals protect against both water and oil borne soils and resists wetting by oily and watery liquids.

Several commercial fluorochemical polymers are commonly and have shown to work in accordance with the present invention. For example: PM 3703 from 3M, Fluorotex LB from Arrow Engineering and Teflon N130 from Dupont.

The term "electrolyte" refers to any compound that ionises when dissolved to produce an electrically conductive medium such as for example magnesium sulphate.

The term "colour dye treatment" refers to any process in which a coloured dye is applied to a carpet.

Where a particularly low pH is required in accordance with the present invention, a standard pH adjuster may be used such as for example sulfamic acid or acetic acid.

The present invention provides enhanced stain resistance to carpets wherein the fibres of a carpet treated in this manner include a number of advantageous features over those treated by conventional methods.

In particular the present invention provides a method whereby a fluorochemical composition or a stain blocker composition are exhausted into the fibres of the carpet. This provides some significant benefits to traditional treatments including: 1. Complete protection from soil from the top to the bottom of the yarn fibre.

2. Improved durability of stain/soil resistance of the carpet.

3. Offers additional oil and water repellency.

4. Improves the Lightfastness of treated white nylon. 5. Offers stain and repellency protection after hot water extraction.

The stain blockers and/or fluorochemicals are exhausted onto the fibre in a similar fashion to the acid dyes during a traditional carpet dying step. Under acidic conditions (low pH), they are readily adsorbed in the outer regions of the carpet fibres. Preferably, the fibres are then exposed to heat causing the fluorochemical and/or stain blocker to migrate from the solution to the carpet fibre surface. The heat also helps in expanding the carpet fibre, which in turn helps in the diffusion of the polymer's molecules into the fibre. The addition of an electrolyte helps in increasing the competition to the fibre sites. The penetration of the fluorochemical and stain blocker into the interior of the fibre is greatly dependent on the molecule size of the polymer and the heat being applied.

Fluorochemicals improve stain and soil resistance by lowering the surface energy of the carpet, (ie create a barrier) making the carpet more difficult to wet, hence liquid stains will not spread or wick over large areas and oils will not adhere as strongly. As long as capillary action (wicking) is the only driving force, the barrier resulting from the fluorochemical prevents both penetration into the fabric and wicking over a large area resulting in readily removed stains on the surface of the carpet by blotting. .

Stain blockers are anionic colourless dyes. They are attracted and held by the oppositely charged amine end groups occupying the active dye sites in the nylon fibre, and hence restrict the attachment of acid dyes found in food, drinks and cosmetic products. The latter explanation is too simplistic and does not explain how all the dye sites can be blocked with insufficient stain blocker molecules. To better understand the protective action it must be mentioned that a high negative repulsive thin film is created on nylon fibres treated with stain blockers, which repel the staining anionic dyes, like repelling magnets. The size of the stain blocker molecules plays a role in determining the stain protection. For stain blockers to be effective, they have to stay in the peripheral region of the fibres. However heat forces the stain block molecules to the interior of the fibre, greater stain- blocking efficiency was achieved. The small stain blocker molecules are believed to penetrate deeper into the fibre, leaving the larger and more effective molecules near the surface for better stain blocking effects.

In particular, the method of the present invention when used in relation to conventional carpets, that is yarn tufted into a backing material or woven carpets, results in complete protection from the top to the bottom of the yarn. This is a result of the stain blocking compound and/or the fluorochemical being more thoroughly saturated around and within the carpet fibres.

As the stain blocker and/or fluorochemical completely surrounds the fibre of the yarn, the stain repellency continues to work even as the carpet fibres become worn. This also has the effect of reducing the susceptibility of the carpet to fade over time, even when exposed to direct sunlight.

The present invention will become better understood from the following examples of preferred but non-limiting embodiments thereof.

Examples

Test samples of carpet, which had undergone a standard colour dye treatment, were then subjected to various methods treatments for increasing their stain repellency. The carpet samples were then subjected to the tests outlined in Table 1 and given a pass (P) or fail (F) qualification.

Control 1. Using a hot flood applicator, a hot aqueous medium containing a stain blocker compound electrolytes and acid is applied to the carpet sample at a pH of 2.2, wet ρick up of250% at 90°C

2. The carpet is then rinsed to remove excess chemicals and acid 3. A fluorochemical in the form of a foam is padded onto the carpet

4. The carpet is then dried.

Example 1

Stain block treatment:

1. Using the hot flood applicator, apply hot aqueous medium containing a stain blocker compound (stain resist compound), electrolytes and acid.

2. The aqueous medium will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 250% & 350% 4. The temperature of the hot flood is between 9O⁰C & 98 °C

5. The above aqueous medium should allow dwelling time on the carpet for 5 sec to 60 sec

6. Further steaming for 5 sec to 120 sec

7. Rinse the carpet to remove excess chemicals and acid 8. Extract the excess water to reduce the carpet water content to between 15% & 45%

Fluorochemical treatment:

1. Using the hot flood applicator, apply hot aqueous medium containing the fluorochemical, electrolytes and acid. 2. The aqueous medium will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 250% & 350%

4. The temperature of the hot flood is between 90⁰C & 98°C

5. The above aqueous medium should allow dwelling time on the carpet for 5 sec to 60 sec 6. Further steaming for 5 sec to 120 sec

Example 2

Stain block treatment:

2. The aqueous medium will have ph between pH 2.0 & pH 2.2 3. The wet pick up (wpu) is between 250% & 350%

4. The temperature of the hot flood is between 90⁰C & 98°C

6. Further steaming for 5 sec to 120 sec 7. Rinse the carpet to remove excess chemicals and acid

8. Extract the excess water to reduce the carpet water content to between 15% & 45%

Fluorochemical treatment:

1. Using the foam applicator, apply a foam layer containing the fluorochemical, electrolytes and acid.

2. The foam layer will have ph between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 50% & 100%

4. The above foam layer should allow dwelling time on the carpet for 5 sec to 60 sec

5. Steam for 5 sec to 120 sec 6. Rinse the carpet to remove excess chemicals and acid

7. Extract the excess water to reduce the carpet water content to between 15% & 45%

Example 3

Stain block treatment: 1. Using the hot flood applicator, apply hot aqueous medium containing a stain blocker compound (stain resist compound), electrolytes and acid.

2. The aqueous medium will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 250% & 350% 4. The temperature of the hot flood is between 90⁰C & 98⁰C

6. Further steaming for 5 sec to 120 sec

Fluorochemical treatment:

1. Using the foam applicator, apply a foam layer containing the fluorochemical but no acid or electrolyte. 2. The wet pick up (wpu) is between 50% & 100%

3. The above foam layer should allow dwelling time on the carpet for 5 sec to 60 sec

4. Steam for 5 sec to 120 sec

5. Rinse the carpet to remove excess chemicals and acid

6. Extract the excess water to reduce the carpet water content to between 15% & 45%

Example 4

Stain block treatment:

1. Using the foam applicator, apply a foam layer containing a stain blocker (stain resist compound), electrolytes and acid.

2. The foam layer will have ph between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 50% & 100%

4. The above foam medium should allow dwelling time on the carpet for 5 sec to 60 sec 5. Steam for 5 sec to 120 sec

6. Rinse the carpet to remove excess chemicals and acid 7. Extract the excess water to reduce the carpet water content to between 15% & 45%

Fluorochemical treatment:

1. Using the hot flood applicator, apply hot aqueous medium containing the fluorochemical, electrolytes and acid.

2. The aqueous medium will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 250% & 350%

4. The temperature of the hot flood is between 90⁰C & 98⁰C

6. Optional further steaming for 5 sec to 120 sec

7. Rinse the carpet to remove excess chemicals and acid

Example 5

Stain block treatment:

1. Using the foam applicator, apply a foam layer containing a stain blocker (stain resist compound), electrolytes and acid. 2. The foam layer will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 50% & 100%

4. The above foam medium should allow dwelling time on the carpet for 5 sec to 60 sec

Fluorochemical treatment:

2. The foam layer will have pH between pH 2.0 & pH 2.2 3. The wet pick up (wpu) is between 50% & 100%

5. Steam for 5 sec to 120 sec

Example 6

2. The aqueous medium will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 250% & 350%

4. The temperature of the hot flood is between 9O⁰C & 98°C 5. The above aqueous medium should allow dwelling time on the carpet for 5 sec to

60 sec

6. Further steaming for 5 sec to 120 sec

7. Rinse the carpet to remove excess chemicals and acid

Fluorochemical treatment:

1. Using the hot flood applicator, apply hot aqueous medium containing the fluorochemical only (no acid or electrolyte).

2. The wet pick up (wpu) is between 250% & 350% 3. The temperature of the hot flood is between 9O⁰C & 98⁰C

4. The above aqueous medium should allow dwelling time on the carpet for 5 sec to 60 sec

5. Further steaming for 5 sec to 120 sec

6. Rinse the carpet to remove excess chemicals and acid 7. Extract the excess water to reduce the carpet water content to between 15% & 45% Example 7

Fluorochemical treatment:

2. The aqueous medium will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 250% & 350%

4. The temperature of the hot flood is between 90⁰C & 98⁰C

6. Further steaming for 5 sec to 120 sec

7. Rinse the carpet to remove excess chemicals and acid

Stain block treatment:

2. The aqueous medium will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 250% & 350% 4. The temperature of the hot flood is between 90°C & 98°C

6. Further steaming for 5 sec to 120 sec

Example 8

Fluorochemical treatment: 1. Using the hot flood applicator, apply hot aqueous medium containing the fluorochemical only (no electrolyte or acid). 2. The wet pick up (wpu) is between 250% & 350%

3. The temperature of the hot flood is between 90⁰C & 98°C

4. The above aqueous medium should allow dwelling time on the carpet for 5 sec to 60 sec 5. Further steaming for 5 sec to 120 sec

6. Rinse the carpet to remove excess chemicals and acid

2. The aqueous medium will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 250% & 350%

4. The temperature of the hot flood is between 90⁰C & 98⁰C 5. The above aqueous medium should allow dwelling time on the carpet for 5 sec to

60 sec

6. Further steaming for 5 sec to 120 sec

7. Rinse the carpet to remove excess chemicals and acid

Example 9

Fluorochemical treatment:

2. The foam layer will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 50% & 100%

7. Extract the excess water to reduce the carpet water content to between 15% & 45% S tain block treatment:

1. Using the hot flood applicator, apply hot aqueous medium containing a stain blocker compound (stain resist compound), electrolytes and acid. 2. The aqueous medium will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 250% & 350%

4. The temperature of the hot flood is between 9O⁰C & 98°C

5. The above aqueous medium should allow dwelling time on the carpet for 5 sec to 60 sec 6. Optional further steaming for 5 sec to 120 sec

7. Rinse the carpet to remove excess chemicals and acid

Example 10

FIuorochemical treatment:

4. The temperature of the hot flood is between 90⁰C & 98°C

Stain block treatment:

Example 11

FIuorochemical treatment:

2. The foam layer will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 50% & 100% 4. The above foam layer should allow dwelling time on the carpet for 5 sec to 60 sec

5. Steam for 5 sec to 120 sec

6. Rinse the carpet to remove excess chemicals and acid

Stain block treatment:

2. The foam layer will have pH between pH 2.0 & pH 2.2

3. The wet pick up (wpu) is between 50% & 100% 4. The above foam medium should allow dwelling time on the carpet for 5 sec to 60 sec

5. Steam for 5 sec to 120 sec

6. Rinse the carpet to remove excess chemicals and acid

7. Extract the excess water to reduce the carpet water content to between 15% & 45% Table 1: Test Results

Although several preferred embodiments have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein by one ordinarily skilled in the art without departing from the spirit or scope of the present invention.

Claims

The claims:

1. A method of enhancing the stain resistance of a carpet, the method including applying a fluorochemical composition including a fluorochemical and an electrolyte to the carpet.

2. The method according to claim 1 wherein the composition has a pH below 4.0 and preferably below 2.2.

3. A method according to claim 1 or claim 2 wherein the fluorochemical composition is in the form of an aqueous medium.

4. A method according to claim 3 wherein the aqueous medium is applied to the carpet in a wet pick up of between 150% and 350%, at a pH of between 2.0 and 2.2, at a temperature of between 90⁰C and 98°, and wherein the aqueous medium is permitted to dwell in the carpet for a period of 5 to 60 seconds.

5. A method according to claim 3 or 4 wherein steam is applied to the carpet for a period of between 5 and 120 seconds after the application of the aqueous medium.

6. A method according to claim 1 or claim 2 wherein the fluorochemical composition is in the form of a foam.

7. A method according to claim 6 wherein the foam is applied to the carpet in a wet pick up of between 50% and 100%, at a pH of between 2.0 and 2.2, at a temperature of between 90°C and 98°, and wherein the foam is permitted to dwell in the carpet for a period of 5 to 60 seconds.

8. A method according to claim 6 or 7 wherein steam is applied to the carpet for a period of between 5 and 120 seconds after the application of the foam.

9. A method according to any one of claims 1 to 8 wherein the fiuorochemical is chosen from PM 3703, FLOUROTEX LB or TEFLON Nl 30.

10. A method according to any one of claims 1 to 9 wherein the electrolyte is magnesium sulphate.

11. A method according to any one of claims 2 to 10 wherein the pH of the fiuorochemical composition is obtained by including a pH adjuster chosen from sulfamic acid or acetic acid.

12. A method of enhancing the stain resistance of a carpet, the method including applying a stain blocker composition including a stain blocker and an electrolyte to the carpet.

13. The method according to claim 12 wherein the stain blocker composition has a pH below 4.0 and preferably below 2.2.

14. A method according to claim 12 or claim 13 wherein the stain blocker composition is in the form of an aqueous medium.

15. A method according to claim 14 wherein the aqueous medium is applied to the carpet in a wet pick up of between 250% and 350%, at a pH of between 2.0 and 2.2, at a temperature of between 90⁰C and 98°, and wherein the aqueous medium is permitted to dwell in the carpet for a period of 5 to 60 seconds.

16. A method according to claim 14 or 15 wherein steam is applied to the carpet for a period of between 5 and 120 seconds after the application of the aqueous medium.

17. A method according to claim 12 or claim 13 wherein the stain blocker composition is in the form of a foam.

18. A method according to claim 17 wherein the foam is applied to the carpet in a wet pick up of between 50% and 100%, at a pH of between 2.0 and 2.2, at a temperature of between 90°C and 98°, and wherein the foam is permitted to dwell in the carpet for a period of 5 to 60 seconds.

19. A method according to claim 17 or 18 wherein steam is applied to the carpet for a period of between 5 and 120 seconds after the application of the foam.

20. A method according to any one of claims 1 to 8 wherein the stain blocker is chosen from an anionic polymer.

21. A method according to any one of claims 1 to 9 wherein the electrolyte is magnesium sulphate.

22. A method according to any one of claims 13 to 21 wherein the pH of the stain blocker composition is obtained by including a pH adjuster chosen from sulfamic acid or acetic acid.

23. A method of enhancing the stain resistance of a carpet including the steps of: (a) Applying an aqueous stain blocker composition, including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%;

(c) Rinsing the carpet to remove excess water or chemicals;

(e) Applying an aqueous fluorochemical composition, including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%; (f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and (g) Rinsing the carpet to remove excess water or chemicals.

24. A method of enhancing the stain resistance of a carpet including the steps of:

(a) Applying an aqueous stain blocker composition, including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%;

(e) Applying a fluorochemical composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the fluorochemical composition including a fluorochemical and an electrolyte at a pH of between 2.2 and

2.0;

(g) Rinsing the carpet to remove excess water or chemicals.

25. A method of enhancing the stain resistance of a carpet including the steps of:

(a) Applying a stain blocker composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99°C for 5 to 60 seconds at a wet pick up between 50% and 100%, the stain blocker composition including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0; (b) Optionally applying steam to the carpet for a period of between 5 to 120 seconds;

(c) Rinsing the carpet to remove excess water or chemicals;

(e) Applying an aqueous fluorochemical composition, including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 90⁰C to 99°C for 5 to 60 seconds at a wet pick up between 250% and 350%; (f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and, (g) Rinsing the carpet to remove excess water or chemicals.

26. A method of enhancing the stain resistance of a carpet including the steps of: (a) Applying a stain blocker composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the stain blocker composition including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0;

(c) Rinsing the carpet to remove excess water or chemicals;

(e) Applying a fluorochemical composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the fluorochemical composition including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0;

(g) Rinsing the carpet to remove excess water or chemicals.

27. A method of enhancing the stain resistance of a carpet including the steps of:

(a) Applying an aqueous fluorochemical composition, including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%;

(e) Applying an aqueous stain blocker composition, including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%;

28. A method of enhancing the stain resistance of a carpet including the steps of:

(c) Rinsing the carpet to remove excess water or chemicals,

(d) Extracting excess water to reduce the carpet water content to between 15% and 45% water; (e) Applying an aqueous stain blocker composition, including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%; (f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and, (g) Rinsing the carpet to remove excess water or chemicals.

29. A method of enhancing the stain resistance of a carpet including the steps of: (a) Applying an aqueous fluorochemical composition including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0, to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 250% and 350%;

(b) Optionally applying steam to the carpet for a period of between 5 to 120 ^* seconds;

(c) Rinsing the carpet to remove excess water or chemicals,

(e) Applying a stain blocker composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the stain blocker composition including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0;

(f) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; and, (g) Rinsing the carpet to remove excess water or chemicals.

30. A method of enhancing the stain resistance of a carpet including the steps of:

(a) Applying a fluorochemical composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the fluorochemical composition including a fluorochemical and an electrolyte at a pH of between 2.2 and 2.0; (b) Optionally applying steam to the carpet for a period of between 5 to 120 seconds; (c) Rinsing the carpet to remove excess water or chemicals,

(e) Applying a stain blocker composition in the form of a foam to the pile face of the carpet at a temperature of 9O⁰C to 99⁰C for 5 to 60 seconds at a wet pick up between 50% and 100%, the stain blocker composition including a stain blocker compound and an electrolyte at a pH of between 2.2 and 2.0,

(g) Rinsing the carpet to remove excess water or chemicals.