Classifications

• • 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
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/643—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain
  • D06M15/647—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain containing polyether sequences
• • 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
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/643—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds containing silicon in the main chain
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31652—Of asbestos
  • Y10T428/31667—Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31855—Of addition polymer from unsaturated monomers
  • Y10T428/31938—Polymer of monoethylenically unsaturated hydrocarbon
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
  • Y10T442/2311—Coating or impregnation is a lubricant or a surface friction reducing agent other than specified as improving the "hand" of the fabric or increasing the softness thereof
  • Y10T442/2328—Organosilicon containing
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
  • Y10T442/2861—Coated or impregnated synthetic organic fiber fabric
  • Y10T442/291—Coated or impregnated polyolefin fiber fabric
  • Y10T442/2918—Polypropylene fiber fabric

Definitions

• a typical continuous dyeing process comprises the steps of 1) application of about 100 percent wet pickup of a prepad solution to wet all carpet face fibers; 2) application of about 400 percent of a dye solution which is metered onto the carpet face by doctoring the solution from a roll rotating in the dye solution; 3) steaming the carpet at 100C. for about minutes; 4) scouring the carpet; 5) removing excess water with suction; and 6) drying the carpet in an oven.
• the prepad solution generally contains a pH adjustor and a thickener to keep the solution on the carpet face fibers.
• the dye solution contains dyes, foaming agent, pH adjustors, and a thickener.
• the steaming operation is probably the most critical of the entire process. In this operation, condensation of water vapor on the carpet causes a large generation of foam on the carpet surface. This foam distributes the dyestuff evenly throughout the face yarn and helps ensure uniform dyeing. If the foam generation is too low, the surface fibers will not be dyed and the carpet surface will have a frosty appearance. When the foam is uneven, spots of undyed fibers will result.
• the scouring and drying operations are well known in the art.
• the first step in the production of tufted carpets usually involves tufting the face yarns into a primary carpet backing, which is a relatively slow operation. When sufficient yardage of a given style has been produced, the material is stored until dyeing facilities are available. The time elapsed between tufting and dyeing, lag time, of the primary carpet backing may range from l-2 days to 34 weeks. When carpet produced from a primary carpet backing lubricated with a polymethylhydrogensiloxane is lagged more than two to three days before dyeing, poor dyeing performance is obtained in continuous dyeing processes, this typically being characterized by a frosty appearance in the dyed carpet.
• Polydialkylsiloxanes appear to present much less problem than the polyalkylhydrogensiloxanes when applied to carpet backings destined for continuous dyeings; but the dialkyl products present another problem; these products give carpets which are scroopy underfoot, i.e., the carpet pile has an annoying crunchy feel when walked upon.
• the invention provides a bonded nonwoven sheet of synthetic organic fibers having applied thereon a lubricating composition comprising 3-50 percent by weight of a liquid polysiloxane and 50-97 percent by weight of defined liquid polyoxypropylene compound in an amount such that the quantity of polysiloxane present on the sheet is in the range of about 0.06-0.8 percent by weight.
• This lubricated, nonwoven fabric is suitable as a primary carpet backing which has high strength after tufting and performs acceptably in continuous dyeing operations.
• the preferred nonwoven sheets which are lubricated in accordance with this invention are of the type disclosed and claimed in Petersen U.S. Pat. No. 3,502,538.
• the sheets comprise continuous filaments of isotactic polypropylene which have been segmentally drawn by passage over a heated roll adapted with an axially slotted surface to heat only segments of the filaments, followed by passage over unheated draw rolls.
• Other polypropylene filaments for example drawn at a single draw ratio, or at two or more different draw ratios, may be used, as can filaments from other spinnable polymers such as polyesters, polyamides, etc.
• the most preferred lubricated nonwoven sheets of this invention are made from continuous polypropylene filaments which are preferentially aligned in the length and width directions, as disclosed in Edwards U.S. Pat. No. 3,563,838. These sheets, which are particularly suited for use as primary carpet backings due to their high dimensional stability and strength after tufting, may be prepared by the process described in Troth U.S. Pat. No. 3,477,103. In this process, a primary fluid stream containing a plurality of electrostatically charged continuous filaments is forwarded toward a laydown zone on a receiver surface moving away from the laydown zone.
• Two secondary fluid streams are alternately impinged on opposite sides of the primary fluid stream thereby deflecting said primary stream and the contained filaments in opposite directions, the filaments being laid down in swaths on the receiver, aligned in the direction of deflection.
• a plurality of filament deflecting devices can be used and disposed so as to provide filament alignment in the machine (length) and in the cross-machine (width) direction.
• the nonwoven sheets of this invention may be bonded by methods known in the art but are preferably self-bonded by exposure to saturated steam to provide bond-strength distributions as described in Petersen U.S. Pat. No. 3,502,538. Suitable apparatus for effecting this steam-bonding is described in Wyeth U.S. Pat. No. 3,313,002. In the following examples, bonding was accomplished in this manner.
• the lubricating compositions used in accordance with this invention consist of mixtures comprising 3-50 percent and preferably 5-20 percent by weight of liquid polymonoalkyl or polydialkylsiloxane with 50-97 percent and preferably 80-95 percent by weight of liquid polyoxypropylene compound having a viscosity of at least 100 centipoise at 25C.
• the polyoxypropylene component may either have two hydroxy end groups, i.e., the glycol, or may have one hydroxy end group and one alkoxy (preferably from one to six carbon atoms) end group, i.e., the monoalkyl ether.
• the specified polysiloxanes and polyoxypropylene compounds form relatively stable emulsions when combined and other additives are not needed unless the emulsions are expected to stand for several hours before use.
• the emulsion of the invention can be applied to the nonwoven sheets by spraying, gravure coating or other techniques.
• a preferred emulsion for providing high tufted tongue tear strength while avoiding frostiness in continuous dyeing is prepared from a polymethylhydrogensiloxane (available from Dow-Corning Corp. as DC1107) and a polyoxypropylene glycol (a dihydroxy material available from Wyandotte Chemical Corp. as Pluracol P1010).
• a preferred emulsion for high tufted tear strength without development of scroopiness in carpet is a mixture of polydimethylsiloxane (available from Dow- Corning Corp. as DC-200) and the monobutylether of polyoxypropylene glycol (available from Union Carbide Chemical Corp. as Ucon LB385).
• the effectiveness of a tufting lubricant may be determined by tufting the lubricated sheet and measuring the tear strength of the tufted sheet, the more effective the lubricant, the higher the tear strength.
• lubricant effectiveness was measured by tufting the lubricated sheets on a table-top tufter with 3700 denier bulked continuous filament nylon yarn, at 7 tufts/inch (in the machine or length direction) the tufts being spaced three-sixteenths inch apart in the width direction and having a height of sevensixteenths inch.
• the machine direction tufted tongue tear strength was measured in the following manner.
• the tufted nonwoven sheet is cut into a sample 6 inches wide (crossmachine direction, across tufting rows) and 8 inches long (machine direction along tufting rows).
• the sample is cut in the center of the width 4 inches in the machine (tufting) direction.
• the sample is mounted in an Instron" tester using 1.5 inch by 2 inch serrated clamps. With a jaw separation of 3 inches, one side of the sample cut is mounted in the upper jaw and the other side of the sample cut is mounted in the lower jaw.
• the sample is uniformly spaced between the jaws.
• the full scale load is adjusted to a value greater than the tear strength expected for the sample.
• the Instron is started and the sample is torn. An average of the three highest stresses during tearing is taken. The tongue tear strength in pounds is reported as this average divided by 100 and multiplied by the full scale load. In general several determinations are made and the average reported.
• the dyeing tests were carried out in continuous dyeing equipment developed by the Kusters Co., Germany (distributed in the U. S. by Zima Corporation, Spartanburg, S.C.). Most of the tests were carried out in semiworks type equipment capable of continuously dyeing tufted goods about 36 inches wide, but some tests were carried out in commercial size equipment capable of handling tufted goods up to 15 feet wide.
• Emulsions were formed from different amounts of polymethylhydrogensiloxane (DC1107) and polyoxypropylene glycol (Pluracol" P- l 010) described above, the latter having a viscosity of about 155 centipoise at 25C. These were sprayed in an amount of about 2 percent by weight onto a 3.5 oz./yd. bonded nonwoven sheet from segmentally drawn continuous polypropylene filaments, in which the filaments were preferentially aligned in the machine and cross-machine direction, the sheet being prepared by the process described in Troth U.S. Pat. No. 3,477,103. The samples were tufted and the tear strength measured in the manner described above.
• EXAMPLE II A 3.0 oz./yd. nonwoven sheet, produced from continuous polypropylene filaments in the manner generally described in Example I was lubricated with various amounts of an emulsion formed from 95 percent by weight of the polyoxypropylene glycol (Pluracol" P-10l0) and 5 percent by weight of polymethylhydrogensiloxane (DC-1107). Samples of these lubricated sheets were tufted and the tufted tongue tear measured. The results, summarized in Table II, again indicate that the tufted tongue tear starts to decrease sharply when the amount of polysiloxane on the sheet drops below about 0.06 percent.
• Pluracol polyoxypropylene glycol
• DC-1107 polymethylhydrogensiloxane
• DuPonol FAB Foaming Agent E. I. du Pont de Nemours & Co., Inc.
• Polygum 260 Thickener Polymer Industries Incorporated 6 g/l Monosodium Phosphate (PI-I buffer): 2 g/l Color Index Direct Yellow 44 3 g/l Color Index Acid Red 337 0.28 g/l Color Index Acid Blue 40 0.95 g/l Prepad Bath (Pickup 100 percent) Merpol WF (Wetting Agent E. I. du Pont de Nemours & Co., Inc.): 5 g/] DuPonol FAB (Foaming Agent E. I.
• du Pont de Nemours & Co., Inc. 2 g/l All the samples were dyed under essentially the same conditions using a steaming time of about 8 minutes at 100C. After drying, the dyed samples were subjectively evaluated for appearance, dye uniformity, lack of frostiness, etc., the criterion for acceptability being that the product should be free of dyeing defects when dyed at least three weeks and preferably four weeks after tufting.
• EXAMPLE V Additional tests were carried out using a 3 or/yd. nonwoven polypropylene primary carpet backing to which was applied various amounts of an emulsion containing 95 percent polyoxypropylene glycol and 5 percent polymethylhydrogensiloxane previously described. After tufting, the continuous dyeing performance of the various samples was tested every week, for a number of weeks, to determine how many weeks each sample could be lagged and still obtain acceptable dyeing performance.
• Formulations of the baths used in the dyeing operation are listed in Table VI and the dye-quality results are given in Table VI]. These results indicate that acceptable performance is obtained with up to 0.72 percent of polysiloxane on the sheet and that the lag time for acceptable performance increases as the amount of polysiloxane on the sheet decreases.
• Example II produced in the manner generally described in Example I were lubricated (a) with an amount of an emulsion of a polysiloxane and a polyoxypropylene compound, (b) with the polyoxypropylene compound alone and (c) with the polysiloxane alone, the respective amounts of the components in items (b) and (c) being about the same as those present in combination in item (a).
• the actual materials used and the amount of finish by weight are listed in Table VIII which also gives the results of the tufted tongue tear measurements. In each case, it is seen that the tear strength is significantly higher in samples lubricated with the two component emulsion than with either component separately.
• Example VIa The carpet of Example VIa was allowed to stand for three weeks and was then subjected to a continuous dyeing operation as described in previous examples. Dyeing was uniform and acceptable.
• a bonded nonwoven synthetic organic fiber sheet to which has been applied a lubricating composition consisting essentially of 3-50 percent by weight of a liquid polysiloxane selected from the group of polymethyl hydrogen siloxane and polydimethyl siloxane and 50-97 percent by weight of a liquid polyoxypropylene compound having a viscosity of at least 100 centipoises at 25C. and selected from the group of polyoxypropylene glycol and the monobutyl ether thereof, said composition being present in an amount such that the quantity of polysiloxane on the sheet is in the range of about 0.06 and 0.8 percent by weight.
• the sheet of claim 3 wherein the lubricating composition comprises 5-20 percent by weight of polysiloxane and 80-95 percent by weight of polyoxypropylene compound.

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• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (1)

Publications (1)

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Family Applications (1)

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Cited By (14)

Citations (6)

• 1971
  • 1971-03-17 US US00125355A patent/US3772069A/en not_active Expired - Lifetime
• 1972
  • 1972-03-08 CA CA136,728A patent/CA972911A/en not_active Expired
  • 1972-03-16 BE BE780773A patent/BE780773A/fr unknown
  • 1972-03-17 GB GB1265472A patent/GB1360524A/en not_active Expired
  • 1972-03-17 DE DE19722213074 patent/DE2213074A1/de active Pending
  • 1972-03-22 NL NL7203627A patent/NL7203627A/xx unknown

Patent Citations (6)

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