Aqueous dispersion of dye, stain-blocker, and fluorochemical and its use in the manufacture of carpet

a technology of dye dispersion and fluorochemical, which is applied in the field of carpet industry, can solve the problems of dye reaction, large volume of water and steam still being used, and the prior art carpet finishing treatment process requires multiple steps, so as to reduce the rate of dyeing and create more level dyeing

Inactive Publication Date: 2014-02-06
INVISTA NORTH AMERICA R L
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0008]In a further aspect, a composition comprising an aqueous dispersion of a dye, stain blocker, and a retarder is disclosed. The retarder reacts with dye sites and competes for the fiber surface along with the dye, thus reducing the rate of dyeing and creating more level dyeing. The composition can further comprise an anti-soil component to make a four-part composition.

Problems solved by technology

Unfortunately, large volumes of water and steam are still being employed in the continuous range-dye processes currently used to finish carpets.
In either case, carpet finishing treatment processes of the prior art have required multiple steps because of reagent incompatibility, especially with respect to pH limitations.
Specifically, dyes react too quickly and therefore react with poor uniformity at low pH, while stain and soil resist chemistry require low pH to be effectively applied.

Method used

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  • Aqueous dispersion of dye, stain-blocker, and fluorochemical and its use in the manufacture of carpet
  • Aqueous dispersion of dye, stain-blocker, and fluorochemical and its use in the manufacture of carpet

Examples

Experimental program
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example 1

[0040]A control carpet sample was prepared as follows: Two 995 denier nylon 6,6 yarns (Fiber 995-476AS, a mild dull, medium acid dyeable, fiber with wavy trilobal cross section available from INVISTA) were twisted to 6 twists-per-inch and heat set via a Superba heat set process at a temperature of 265° F. with residence time of 28 seconds and tufted into ⅛″ gage, 9 / 16″ pile height carpet with a weight of 45-46 ounces / square yard. The carpet was then dyed using the dye mixture below to a wool beige color. Stain blocker and anti-soil were not added. The control carpet had an initial stain rating of 1, a stain rating of 1 after 1 WAQE wash and a stain rating of 1 after 3 WAQE washes.

[0041]Sample carpets were prepared similar to above, except that a Suessen heat set at 195° C., instead of Superba heat set, was performed on the yarn for 60 seconds residence time.

[0042]A tri-component composition was prepared as follows: A mixture of dyes (Yellow 3G, Red 2B, and Blue 4R to obtain a wool b...

example 2

[0045]Sample carpets were prepared as discussed above, except that the yarn was heat set in a Superba heat setting machine at 265° F. , with a residence time of 28 seconds. The carpet was treated on a range continuous dyer as described in Table 2 below. The dye was the wool beige color described above. The carpets were tested for stain resistance. The tri-component composition was prepared as above without the salt, with the variations disclosed in Table 2. The stain blocker in all cases was S-801 at 4.0% and 2.1 pH, unless otherwise stated. Samples 8 and 9 used MgSO4 in the concentrations disclosed above.

TABLE 2InitialStain13ConductivitySampleDescriptionAnti-soilRatingWAQEWAQE(micromhos)1Standard separateCapstone1097.5265processRCP at250 ppmOWF2Dye + SB appliedCapstone9.57.574806togetherRCP at250 ppmOWF3Dye + SB appliedCapstone975.54721together withRCP atDOWFAX 2A1 at250 ppm0.5%OWF4Dye + SB appliedCapstone97.564903together withRCP atDOWFAX 2A1 at 1%250 ppmOWF5Dye + SB appliedCapsto...

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Abstract

Disclosed is composition comprising an aqueous dispersion containing a dye, a stain blocker component, and an anti-soil component. The composition provides uniform dyeing, and superior stain blocking and anti-soil characteristics to fibers, carpets, and fabrics by adjusting the conductivity and pH of the dispersion. Alternatively, the composition can comprise an aqueous dispersion containing a dye, a stain blocker component, and a retarder for slowing down the rate of dye reaction. Also disclosed is a method of applying the compositions and dispersions to fibers, carpets, and fabrics.

Description

FIELD OF THE INVENTION[0001]This disclosure relates to the carpet industry in general and to the application of carpet dyeing and finishing chemistry in particular. The disclosed aqueous dispersion of dye, stain-blocker, and fluorochemical and application thereof relates especially to the treatment of carpet fiber to maintain carpet appearance after extended use. The aqueous dispersion and processes disclosed herein provide superior appearance retention via stain and soil protection while using far less water and energy than processes of the prior art. The aqueous dispersion and processes are applicable to various fibers, including nylon 6,6 and copolymers and blends thereof.BACKGROUND OF THE TECHNOLOGY[0002]The carpet industry today uses large quantities of fresh water in the course of dyeing and treating carpets. However, fresh water is becoming increasingly valuable for other uses, and that the continued growth of such water usage is unacceptable. Means of reducing water consumpt...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D06P5/04
CPCD06P5/04D01F1/10D01F1/103D01F6/70D01F6/94
Inventor RAO, SUNDAR MOHAN
Owner INVISTA NORTH AMERICA R L
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