[0001] The present invention relates to stain-resistant polyamide or polyamide blend carpets.
More particularly, it relates to stain-resistant polyamide or polyamide-blend carpets
according to the precharacterising part of claim 1 and having improved after-wash
stain performance due to the incorporation of a stainblocker into the adhesive that
is used to anchor the yarn tufts into the primary backing.
[0002] Polyamide substrates, such as carpeting, upholstery, fabric and the like, are subject
to staining by a variety of foodstuffs containing acid-dye colorants. The treatment
of polyamide substrates with acid-dye-resist, levelling, or wet-fastness agents in
order to render them resistant to staining by acid dyestuffs, including food dyes
such as FD&C Red Dye No. 40, is well known in the art.
[0003] Stain-resist agents comprising sulfonated naphthol- or sulfonated phenol-formaldehyde
condensation products and methods for treating polyamide carpets or carpet yarn with
these compositions to render the carpets resistant to staining by acid dyes are disclosed
in Ucci and Blyth US-A-4,501,591, Blyth and Ucci US-A-4,592,940, Blyth and Ucci US-A-4,680,212,
and Greschler, Malone, and Zinnato US-A-4,780,099.
[0004] Stain-resist compositions comprising mixtures of sulfonated phenol-formaldehyde condensation
products with a hydrolyzed polymer of maleic anhydride and one or more ethylenically
unsaturated aromatic monomers are described in Fitzgerald, Rao, Vinod, and Alender,
US-A-4,883,839. Processes for applying these stain-resist compositions to polyamide
substrates are also described in Fitzgerald, et. al. US-A-5032136 which is a divisional
application of the above-mentioned patent. An alternate process for applying these
stain-resist compositions is disclosed in Fitzgerald, Materniak, Moores, Openstone,
and Rivet in their US-A-5,087,121.
[0005] Olson, Chang, and Muggli, US-A-4,822,373 discloses treatment of fibrous polyamide
substrates to render them resistant to staining by acid dyestuffs by applying thereto
(a) a partially sulfonated novolak resin and (b) polymethacrylic acid, copolymers
of methacrylic acid, or combinations of polymethacrylic acid and copolymers of methacrylic
acid.
[0006] Chang, Olson, and Muggli, EP-A-332,342 discloses a method for imparting stain resistance
to fibrous polyamide materials that involves contacting the materials with an aqueous
solution comprising polymethacrylic acid, copolymers of methacrylic acid, or combinations
thereof.
[0007] Blyth and Ucci, US-A-4,619,853 discloses polyamide carpets comprising a primary backing
and a pile coated with a sufficient amount of sulfonated phenol- or naphthol-formaldehyde
condensation product to render the carpet stain resistant, wherein the underside of
the primary backing is coated with a carpet backing adhesive composition containing
a fluorochemical in an amount sufficient to render the primary backing substantially
impervious to water. Ucci, US-A-4,579,762 discloses similar carpets wherein the carpet
fibers are shaped from nylon 6,6 or nylon 6 polymer modified to contain as an integral
part of its polymer chain aromatic sulfonate units in an amount sufficient to improve
the acid dye-resist properties of the fibers. The fluorochemical which is added to
the carpet adhesive composition renders the carpets impervious to water so that soil
and stains may be washed from the carpet without wetting the carpet underpad.
[0008] GB-A-2,129,841 discloses tufted nylon carpets having an adhesive backing composition
containing fixing agents for anionic dyestuffs, at least some of which are also stain-resist
agents of the type described herein. The purpose of the addition of those agents is
to prevent water spotting.
[0009] In order to maintain the aesthetic appearance of carpets, it is necessary to clean
them periodically. The stain-resist properties of polyamide carpets that have been
prepared using the stain-resist compositions and procedures referenced above may be
degraded when the carpet is cleaned with various detergents. When this occurs, the
carpet is no longer sufficiently resistant to re-staining in the areas where washing
has occurred, and subsequent stains resulting from spills containing acid-dyestuffs
will leave a stained area that cannot be completely cleaned, leaving an undesirable
visible stain. In some instances, this problem may be overcome by applying more stain-resist
composition to the carpet pile in the initial treatment process. However, this may
lead to yellowing problems with certain stain-resist compositions upon exposure of
the treated carpet to nitrogen oxides or ultraviolet radiation due to the increased
amount of stain-resist compositions on the carpet pile. Further, this increase in
the amount of stain-resist agent used to treat the carpet can lead to effluent-treatment
problems due to the increased amount of stain-resist chemicals remaining in the used
treatment bath. Alternatively, the afterwash stain performance of the carpet can also
be improved by topically applying a stainblocker to the installed carpet as taught
by Vinod in US-A-4,925,707 or by Moore et al. in US-A-4,908,149. Such processes, however,
may be expensive for the carpet owner, and the results can be variable depending on
the application methods used.
[0010] The present invention provides stain-resistant polyamide or polyamid carpets which
exhibit improved stain-resist performance after washing with a detergent, through
addition of a stain-resist composition, suitable for rendering polyamide fibers resistant
to staining by acid dye stuffs, to the adhesive used to anchor the carpet tufts in
the primary backing. The present invention also makes it possible to apply less of
the stain-resist composition to the carpet pile than is normally required. In some
instances, the stain-resist agent may be applied to the carpet pile under milder pH
conditions than would have been necessary to achieve acceptable afterwash performance
when using standard adhesives that do not contain a stain-resist composition, thus
increasing the life of the equipment used to apply the stain-resist compositions.
[0011] It has also been found that the present invention increases the "tuft-bind" which
is the term used to describe the force necessary to completely remove a yarn tuft
from the carpet. The invention, therefore, serves to more securely anchor the carpet
yarns into the primary backing.
[0012] The carpets of the current invention are constructed using methods well known in
the art, except that a modified adhesive composition containing a stain-resist composition
is used. A typical tufted carpet has a primary backing of polypropylene or jute which
may be woven or nonwoven, stitched with tufts which generally are loops and/or cut
loops of polyamide carpet yarn which extend upward from the backing to form the carpet
pile. The underside of the primary backing is coated with an adhesive composition
which serves to anchor the tufts in the primary backing. The carpet pile may be comprised
exclusively of polyamide yarns or of polyamide-blend yarns in which polyamide fibers
are blended with fibers of one or more other types commonly used in carpeting, i.e.
wool, polypropylene, acrylic, etc. A secondary backing of woven jute or polypropylene
is usually applied to the underside of the carpet following application of the adhesive.
The adhesive typically is a latex emulsion, which is dried and heated in a separate
curing step. Normally the weight of the dry latex as applied to the carpet ranges
from about (20-32 ounces/square yard) 0.68-1.05 kg/m², with (24 ounces/sq. yard) 0.81
kg/m² being most common. The carpet is typically installed with an underpad between
the floor and the carpet. Alternately, a foam may be applied to the primary backing
which serves to anchor the tufts as well as to replace the secondary backing and padding.
According to the current invention, an adhesive is considered to be any composition
which is used to anchor the carpet tufts in the primary backing. Examples include
the latex emulsions and foam compositions described above. The specific adhesive used
depends on the type of carpet construction and end use (for example, residential,
commercial, carpet tile, automotive carpet, etc.).
[0013] Examples of adhesive compositions which may be used in the present invention comprise
latex emulsions which are known in the art for binding tufts of fiber in primary carpet
backings. Examples of adhesive polymers useful in these emulsions are disclosed in
Ucci US-A-4,579,762 and include, but are not limited to, polyvinyl acetates, polyacrylates,
ethylene-vinylacetate copolymers, styrene-butadiene copolymers and carboxy styrene-butadiene
copolymers. Typical foams include urethane and latex compositions.
[0014] The amount of stain-resist agent required in the adhesive composition to provide
a carpet having improved afterwash performance will depend on the particular stain-resist
composition being used. It will also depend on the nature of the carpet pile fibers,
including the specific polyamide polymer, the type of heatsetting process used, the
amount of stain-resist composition originally on the carpet pile and the process used
to apply the stain-resist agent to the carpet pile fibers. The same stain-resist agent
that was used to treat the carpet pile fibers may be used in the adhesive. Alternatively,
a different stain-resist agent may instead be used.
[0015] In a preferred aspect of the invention, the latex contains from 0.04 to 3.0 weight
percent of the active stain-resist agent, the agents typically being supplied in the
trade in the form of aqueous stain-resist compositions having concentrations from
20-30%. It is most preferred to use compositions containing from 0.04 weight percent
to 0.9 weight percent of the stain-resist agent based on the weight of the latex.
[0016] The stain-resist agents are polymeric in nature and are either condensation polymers,
addition polymers derived from one or more monomers having ethylenic carbon-carbon
unsaturation, or mixtures of such condensation and addition polymers. Generally, the
condensation polymers are derived from formaldehyde and either a sulfonated phenol
or a sulfonated naphthol, and preferably a monosulfonated phenol. Generally, the addition
polymers contain repeating units derived from maleic acid or methacrylic acid and
up to 70 weight percent of a comonomer having ethylenic unsaturation and containing
from 2 to 20 carbon atoms. More specifically, they include those such as the type
described in EP-A-0329899, published August 30, 1989, or in the aformentioned US-A-4,883,839
to Fitzgerald et al., the disclosure of each of which is incorporated herein by reference.
These polymers contain repeating units derived from a hydrolyzed polymer of maleic
acid and one or more ethylenically unsaturated aromatic comonomers. Examples of such
comonomers are styrene, alphamethyl styrene, and stilbene. The maleic acid generally
is derived from maleic anhydride, that is, maleic anhydride is polymerized to form
either a homopolymer or a copolymer such as with styrene. The polymerized maleic anhydride
can be hydrolyzed to maleic acid which, in turn, can be partially or wholly converted
to its stereoisomer fumaric acid, such as by treating at an elevated temperature.
Other types of addition polymers include those of the type disclosed in the aforementioned
EP-A-332,342 to Chang et al. and US-A-4,822,373 to Olson et al., each of which is
also incorporated herein by reference. Examples of these include the homopolymer polymethacrylic
acid and copolymers of methacrylic acid with up to 70 weight percent of an ethylenically
unsaturated monomer such as alkyl acrylates having 1-4 carbon atoms, itaconic acid,
and sodium sulfostyrene. The alkali metal salts of both the condensation and addition
polymers may also, of course, be used.
[0017] Additionally a soil-resist composition may also be added to the adhesive in combination
with the stain-resist. Generally, the soil-resist compositions contain organic compounds
having a plurality of fluorine atoms which tend to repel foreign materials, i.e.,
soil. Soil-resist compositions may also, of course, be topically applied to the fibers
in the tufts in the conventional manner.
[0018] The polyamides used to form the fibers in the tufts are aliphatic or cycloaliphatic
in nature. Generally, they have the formula
where -R-, -R₁-, and -R₂- are divalent aliphatic or cycloaliphatic radicals containing
4 to 20 carbon atoms. Such polyamides include polyhexamethylene adipamide, polyhexamethylene
dodecamide, polycaprolactam, 6,6/6 copolyamide, polyaminoundecanoic acid, etc. The
subscripts n and m represent integers large enough to ensure fiber forming characteristics
of the polyamide. Generally, the number average molecular weight of the polymer will
be from 10,000 to 500,000.
[0019] In typical stain-resistant carpets made with standard, unmodified latex adhesives,
stain-resist compositions containing from as little as 0.2 to as much 1.5 weight percent
active stain-resist agent (on weight of fiber) are directly applied to the fibers
in the tufts to provide satisfactory stain-resistance both before and after washing.
The amount actually used will, of course, vary depending on such factors as the specific
stain-resist being applied, the fiber polymer, heat-setting method, pH and other application
conditions. By use of the modified latex compositions described herein, comparable
performance can be achieved with as much as about 10% less stain-resist, i.e. by treating
the carpet pile with about 0.18 to 1.35 wt.% of the active agent.
Test Methods
[0020] In the test procedures and examples described below, all percentages are by weight
unless otherwise indicated.
Stain Test 1
[0021] Stain Test 1 used herein consists of two parts: 1) a 24 hour stain test on "As Is",
i.e. tufted, dyed, and latexed, but unwashed carpet; and 2) a 24 hour stain test on
a carpet which has been subjected to a wash prior to staining (referred to as "After
Wash"). The staining agent for both the "As Is" and "After Wash" evaluations is a
solution containing 0.054 g/l of Red Dye No. 40 prepared from comercially-sold, cherry-flavored,
sugar-sweetened "Kool-Aid" (TM) premix. The solution is made by dissolving 45 grams
of this "Kool-Aid" premix powder in 500 ml of water, and it is allowed to reach room
temperature, i.e. (75°F ( ±5°F) 24°C (±3°C), before using.
"As Is" Evaluation
[0022] For the "As Is" evaluation, a carpet sample tufted from approximately 15 grams of
fiber is prepared. Half of this sample is immersed in 40 cm³ of the staining agent.
The staining agent is worked into the tufts for uniform staining. The sample is then
placed on a flat non-absorbent tray or surface. The sample is left undisturbed for
24 hours ( ± 4). Then the stained sample is rinsed thoroughly with cool tap water,
extracted to remove excess liquid, and dried.
[0023] The stain resistance of the carpet is visually determined by the amount of color
left in the stained area of the carpet. This is referred to as the stain rating, and
is herein determined according to the Stain Rating Scale (a copy of which is currently
used by and available from the Flooring Systems Division of E.I. du Pont de Nemours
and Company, Wilmington, DE 19898). These colors can be categorized according to the
following standards:
5 = no staining
4 = slight staining
3 = moderate staining
2 = considerable staining
1 = heavy staining
In other words, a stain-rating of 5 is excellent, indicating good stain-resistance,
whereas 1 is a poor rating, indicating persistence of heavy staining.
"After Wash" Evaluation
[0024] For the "After Wash" evaluation, a 15 gram sample of carpet is prepared. A detergent
solution is made by adding 57 grams of "Dupanol WAQE" (TM), an aqueous composition
containing about 30 weight percent of a surfactant made by neutralizing the reaction
product of chlorosulfonic acid and lauryl alcohol (predominantly sodium lauryl sulfonate),
to 3.8 liters of water and adjusting the pH to 10.0 with an aqueous solution of about
0.2% trisodium phosphate, and allowing the solution to reach room temperature, i.e.
(75°F ( ± 5°)) 24°C ( ± 3°), before using. The carpet sample is completely immersed
in the detergent solution for 5 minutes, the detergent solution being discarded after
each wash. Then the sample is rinsed thoroughly with cool tap water, extracted to
remove excess liquid, and dried.
[0025] The staining agent is then applied and evaluated in the same manner as described
above in the "As Is" evaluation.
[0026] For a carpet to be considered to have a commercially acceptable level of stain-resistance,
it should have a rating of at least 4 on the above-described Stain Rating Scale for
both the "As Is" and "After Wash" evaluations.
Stain Test 2
[0027] The procedure followed in Stain Test 2 is identical to that described for Stain Test
1, both for "As Is" and "After Wash" evaluation, except that a different method is
used for staining the carpet sample. Instead of immersing half of the carpet sample
in the staining agent, the specimens are placed on a flat non-absorbent surface and
20 ml of the staining agent is poured on each specimen through a cylinder ((1-1/2
to 2 inches) 3.8 to 5.1 cm diameter) to form a (1-1/2 to 2 inch) 3.8 to 5.1 cm circular
stain. The cylinder is removed and the solution worked into the tufts for uniform
staining. The samples are left undisturbed for 24 ± 4 hours, rinsed thoroughly with
cool tap water, squeezed dry and an extractor used to remove excess solution.
Tuft-Bind Measurement
[0028] Tuft-bind is measured using ASTM D 1335.
EXAMPLE 1
[0029] BCF (bulked continuous filament) nylon 6,6 yarns of 1150 total denier and comprised
of 68 filaments (of trilobal cross-section) were produced by a conventional process.
Two of these yarns were plied and twisted to provide a yarn having a balanced twist
of 3.5 turns per inch (tpi). The resulting yarn was then conventionally heat-set in
a Superba heat-set apparatus at (270 degrees F) 132°C. A cut pile tufted carpet was
constructed from the heat set yarn to the following specifications: (40 oz/sq.yd.)
1.36 kg/m², (3/4 inch) 1.9 cm pile height, (1/8 inch gauge) 31.5 tufts/decimeter,
(8 1/4 stitches per inch) 3.25 stitches/cm. This carpet was dyed to a light blue shade
using a Kusters "Fluidyer" TM on a continuous dye line. A conventional continuous
dye process (at 400% wet pick up) and dye auxiliaries were used (color formula was
the following and base on the weight of carpet: 0.0200% Tectilon Biue 4R-200 (TM)
(C.I. Acid Blue 277), 0.0060% Tectilon Red 2B-200 (TM) (C.I. Acid Red 361), and 0.0045%
Tectilon Orange 3G-200 (TM) (C.I. Acid Orange 156), pH = 6.0). After dyeing, the carpet
was rinsed and extracted.
[0030] The carpet was then treated with a bath containing a stain-resist composition on
a Kusters "Flex-Nip" (TM) dyeing apparatus. The specific stain-resist composition
used was an aqueous mixture of a hydrolyzed styrene/maleic anhydride copolymer and
a sulfonated phenol-formaldehyde condensate, as described in the previously referenced
US-A-4,883,839. (The molar ratio of the copolymer was 1:1 styrene:maleic anhydride,
and the copolymer had a number average molecular weight of 1600). The stain-resist
composition was 75.3 wt% of a 30 wt% solution of the styrene:maleic anhydride copolymer,
13.3 wt% of a 30 wt% solution of the phenol-formaldehyde condensate, and 11.4% of
the anionic surfactant "Alkanol ND" (TM), which contains 45 wt% of the disodium salt
of dodecyldiphenyl oxide disulfonic acid as its active ingredient. The bath was prepared
by water dilution of the stain-resist composition to contain 5.4 wt% of the composition
owf (on the weight of fiber) or 1.2% owf based on active ingredient of the hydrolyzed
styrene/maleic anhydride copolymer, 0.22% owf based on active ingredient of the sulfonated
phenol-formaldehyde condensation product, and 0.28% based on active ingredient owf
of the anionic surfactant "Alkanol ND" (TM). The carpet sample was treated by adjusting
the pH of the stain-resist bath to 2.3 using sulfamic acid. The bath was applied to
the carpet samples in a Kusters "Flex-Nip" (TM) at about (80 degrees F) 26.7°C and
400% wet pick-up on weight of fiber, followed by steaming in a vertical steamer for
a residence time of 3 minutes. After the steamer, the carpet was rinsed and extracted.
The carpet was subsequently treated with a commercial fluorochemical in a conventional
spray application and the carpet was dried in an oven. This carpet sample is designated
as Sample A.
[0031] Additional carpet samples were processed using the same procedure as for Sample A
except that the pH was adjusted to 3.0, 3.5, and 4.0. These samples are referred to
as Samples B, C, and D respectively.
[0032] A commercially available styrene-butadiene latex composition (Latex-V 9370 (TM) made
by Colloids Inc., 207 Telegraph Ave. Gastonia, N.C. 28054) was hand applied to sections
of the carpet samples A-D and the carpets were oven-cured at (250 degrees F) 121°C
for 5-7 minutes. Another set of samples was prepared using carpet Samples A-D except
that the latex composition was modified to contain 1 wt% on the weight of latex (owl)
of the same stain-resist solution that was applied to the carpet pile. In terms of
the nonaqueous components, this corresponds to 0.23 wt% owl of the styrene-maleic
anhydride copolymer, 0.04 wt% owl of the phenol-formaldehyde condensate, and 0.05
wt% owl of the anionic surfactant, with the copolymer and the condensation product
being considered as the active ingredients of the stain resist solution. This stain-resist
composition was added to the latex while stirring slowly for about 5 minutes using
a Gifford Wood (TM) mixer, Model 76-IL, made by J. W. Greer, Inc. The modified latex,
which contained the stain-resist composition, was hand applied to the carpet and oven-cured
using the same conditions as described above. This set of carpet samples is designated
by sample numbers A' - D' in TABLE 1 below. The dried latex weight on the carpet both
for these samples and for all the carpets described in these Examples was approximately
(30 oz/sg.yd.) 1.02 kg/m². The carpet was tested for stain resistance by Stain Test
2. The results from the Table 1 show that the samples with modified latex containing
the stain-resist composition exhibited improved "after wash" stain performance versus
samples with standard latex for all the samples regardless of the application pH of
the stain-resist composition. The "as is" performance was almost equal for all the
samples. This demonstrates that it is possible to apply the stain-resist composition
to the carpets at a higher pH (i.e. milder conditions) and to achieve acceptable afterwash
performance through the addition of stain-resist to the latex.
EXAMPLE 2
[0033] The dyed carpet and the stain-resist composition as described in Example 1 were used
for this experiment. Two samples were prepared, one at 4.5% owf and the other at 3.75%
owf of the stain-resist composition, and are designated as Samples E and F, respectively.
The stain-resist bath was adjusted to a pH of 2.3 with sulfamic acid. The samples
were finished with the standard latex and also with the modified latex containing
1% owl of the stain-resist composition as described in Example 1. These samples are
referred to as Samples E' and F' in TABLE 2 below. The samples were tested using Stain
Test 2. This example demonstrates that the use of the stain-resist composition in
the latex improves the staining performance for the samples which are processed with
less stain-resist composition applied to the carpet pile.
EXAMPLE 3
[0034] A mill-processed carpet sample was used in this example. The carpet was made from
a BCF nylon 6,6 yarn of 1410 total denier. Two of these yarns were plied and twisted
to provide a yarn having a balanced twist of 4.0 tpi. The resulting yarn was then
heat-set in a Superba heat-set apparatus with stuffer box attachment at (270 degrees
F) 132°C. A cut-pile tufted carpet was constructed from the heat-set yarn to the following
specification: (28 oz/sq.yd ) 0.94 kg/m², (3/4 inch) 1.9 cm pile height, (3/16 inch
gauge) 21 tufts/decimeter, (7.8 stitches per inch) 3.07 stitches/cm. This carpet was
dyed to an off-white color using levelling acid dyes on a Kusters continuous dye line.
The carpet was then treated in a Kusters "Flex-Nip" (TM) with 6.0% owf of the same
stain-resist composition as described in the Example 1, except that the composition
did not contain the "Alkanol ND" (TM) surfactant. The stain resist composition was
applied at a pH of approximately 2.25.
[0035] Different samples of this carpet were then hand coated with the unmodified standard
latex of Example 1 and the modified latex containing 1.0% owl of the same stain-resist
composition as described in Example 1. The stain performance of the samples was evaluated
using Stain Test 1 and the stain test results are reported in Table 3 below. The results
show that the afterwash stain performance of the commercially processed mill samples
is improved when the samples are finished with the modified latex composition.
EXAMPLE 4
[0036] The same dyed and stain-resist treated carpet samples as described in above Example
3 were used in this example. In addition to using the modified latex of example 3,
two further modified latex compositions were used for this experiment. The first comprised
the commercial latex used in previous examples and 1 wt% owl of a combined stain and
soil resist composition, identified as SRC-1. SRC-1 contains 8.72 wt% based on active
ingredient of the hydrolyzed styrene/maleic anhydride copolymer, 1.74 wt% based on
active ingredient of the sulfonated phenol formaldehyde condensate and 3.8 wt% based
on active ingredient of "Teflon" MF (TM) (a 30% active, anionic fluorochemical commercially
available from E. I. du Pont de Nemours and Company, Wilmington, DE). The second modified
latex contained the commercial latex and 1% owl of the "Teflon" MF fluorochemical
composition.
[0037] The carpet samples were hand latexed, oven-cured and then stain tested according
to Stain Test 1. The results show that the afterwash stain improvement is greatest
where the latex is modified with the stain-resist composition alone, followed by the
one where the latex contains both stain resist and soil resist (fluorochemical). The
sample where the latex is modified with the soil-resist chemical (fluorochemical)
alone did not improve the afterwash stain performance.
EXAMPLE 5
[0038] The dyed BCF carpet sample tufted from Superba-set yarns as described in Example
1 was used in this example, except the carpet was not treated with a stain-resist
composition. One sample was prepared with the standard latex and four others were
prepared with modified latex. The latex of each of these samples was modified to contain
between 1% to 10% owl of the same stain-resist composition as that used for Example
3 (referred to as SRC-2 for identification purpose below). Viewing both the styrene-maleic
anhydride copolymer and the condensation product as active ingredients, the addition
of 1%, 3%, 5%, and 10% owl of this composition corresponds to the addition of 0.27
wt%, 0.81 wt%, 1.35 wt%, and 2.7 wt% respectively of the active components. Another
sample was prepared with the standard latex to which was added 3 wt% owl of a solution
containing 30 wt% active ingredient of a sulfonated phenolic formaldehyde condensate
type stain-resist composition (referred to as SRC-3 for identification purpose below),
i.e. 0.9 wt% owl of the condensation product itself. A jute secondary backing was
applied to all the samples after the latex coating. The samples were then stain-tested
using Stain Test 1. The results reported in Table 5 below show that there is no appreciable
afterwash stain improvement until the modified latex contained 10% owl of the stain-resist
composition SRC-2. Even then, the sample showed some visible stain (stain-rating of
3). However, it is surprising that it is possible to impart some degree of stain-resistance
to a carpet pile that has not been treated with a stain-resist agent simply by incorporating
a stain-resist agent in the latex adhesive.
EXAMPLE 6
[0039] A mill-processed carpet sample made from 4.5 denier, unheatset nylon 6,6 staple was
used in this example. The carpet had the following construction: (16 oz/sq.yd.) 0.54
kg/m², (1/10 inch gauge) 39.4 tufts/decimeter and (1/4 inch) 0.64 cm pile height.
The carpet was dyed to a light yellowish beige color in a beck dyeing process using
premetallized dyes. One sample was prepared by using a standard latex while others
were prepared with a modified latex containing varying percentages of a stain-resist
composition. All samples were hand latexed, and oven-cured, after which a jute backing
was applied. The stain-resist compositions added to the latex were SRC-2 and SRC-3,
as previously described in Example 5. The SRC-2 concentration was varied between 1
wt% and 5 wt% owl, while SRC-3 was used at 3 wt% owl. All the samples were then stain
tested using Stain Test 1. The results reported in Table 6 below show that there is
a marginal improvement in the afterwash performance for the latex samples containing
the stain-resist composition SRC-2 at 5% owl addition (1.35 wt% owl of the active
components) and at 3% owl (0.9 wt% owl of the active component) of stain-resist composition
SRC-3.
[0040] Examples 5 and 6 demonstrate that the degree of improvement in afterwash stain performance
depends upon the nature (i.e. the dye rate) of the pile yarn used. The Superba-set
yarn, being more open in structure, has a higher dye rate than unheatset yarn, and
thus is more susceptible to staining. Thus, the Superba-set yarn requires that more
of the stain-resist agent be used in order to achieve a specified level of stain performance.
Similarly, it is known that Suessen-set yarn is less susceptible to staining than
Superba-set yarn. It can therefore be expected that less stain-resist agent would
be required for effective results on carpets tufted from Suessen-set yarns. Since
it is also known that nylon 6,6 is less vulnerable to staining than other polyamides
such as nylon 6, it can be expected that adjustments in the amount of stain-resist
agent added to the latex will be required depending on the specific polymer type in
the fiber.
EXAMPLE 7
[0041] The dyed carpet as described in the Example 1 was used for this experiment. The carpet
was treated in a Kuester's "Flex-Nip" (TM) whith 6.0% owf (1.62 wt% active components)
of the same stain resist composition as described in Example 1, except that it did
not contain the "Alkanol ND" (TM) surfactant. The stain resist composition was applied
at a pH of approximately 2.5. The samples were finished with the standard latex and
also with modified latex compositions containing 2% owl of three stain-resist compositions
used commercially. Each of these stain-resist compositions is chemically different
from one another as outlined in different patents. The samples, identified as A (standard
latex), and B, C, and D (modified latex), were then tested using Stain Test 1. The
results reported in Table 7 below show that the afterwash stain performance is improved
with the modified latex regardless of the type of the stain resist composition.
EXAMPLE 8
[0042] A carpet prepared and dyed as described in Example 1 was treated in a Kuester's "Flex-Nip"
(TM) with a 5.0 % owf of a stain-resist composition, identified as SRC-4, at a pH
of approximately 2.5. The SRC-4 stain-resist composition was a 25% active solution
of the sodium salt of a hydrolyzed styrene-maleic anhydride copolymer of the type
described in EP-A-0329899, published August 30, 1989. Samples were finished both with
a standard latex and also with modified latex compositions containing 1.0, 2.0, and
3.0 % owl of two different stain-resist agents. Those were SRC-4, which is the same
as that applied on the fiber, and the other one, identified as SRC-5, which is a nominal
30% active solution of "Mesitol" FC40556D (TM), a sulfonated phenolic formaldehyde
condensate product sold by Mobay Corporation. The samples were then stain tested using
Stain Test 1 and evaluated for tuft-bind to determine the force required to pull a
tuft completely out of each carpet sample. The results reported in Table 8 below show
that the "As Is" and the "After Wash" stain performance are both improved by the modified
latex compositions, whether the modification is by SRC-4 or SRC-5. As might be expected,
the results are best for 3.0%, followed by 2.0%, and then 1.0% owl for either of the
stain resist compositions. When compared at equal percent addition of these stain
resist compositions, the overall improvement was better with stain resist SRC-5 than
with SRC-4. It can also be seen that the presence of stain-resist in the latex has
the effect of more securely anchoring the tufts to the carpet's primary backing as
all the samples made with the modified latexes had increased tuft-bind values versus
that of Sample 1 which did not have stain-resist in the latex.
1. A fabric structure comprising a primary backing stitched with closely spaced tufts
of aliphatic polyamide or polyamide-blend fibers which tufts extend upwardly from
the top surface of the primary backing to form a pile, which fibers are coated with
a polymeric stain-resist composition rendering the fibers resistant to staining by
acid dyestuffs, and which tufts are adhered to the primary backing with an adhesive,
characterised in that the adhesive contains a polymeric stain-resist composition suitable
for rendering polyamide fibers resistant to staining by acid dye stuffs
2. The fabric structure of claim 1 wherein the polymeric stain-resist composition in
the adhesive adhering the tufts to the primary backing comprises an active polymeric
stain-resist agent selected from the group consisting of a sulfonated naphthol-formaldehyde
condensation product, a sulfonated phenol-formaldehyde condensation product, a polymer
of methacrylic acid or its alkali metal salts, and up to 70 weight percent of one
or more monomers having ethylenic unsaturation and containing from 2 to 20 carbon
atoms, a polymer of maleic acid or fumaric acid, or alkali metal salts thereof, and
up to 70 weight percent of an ethylenically unsaturated aromatic comonomer containing
2 to 20 carbon atoms, and mixtures thereof.
3. The fabric structure of claim 2 wherein the polymeric stain-resistant composition
coated on the aliphatic polyamide or polyamide-blend fibers comprises an active polymeric
stain-resist agent selected from the group consisting of a sulfonated naphthol-formaldehyde
condensation product, a sulfonated phenol-formaldehyde condensation product, a polymer
of methacrylic acid, its alkali metal salts, and up to 70 weight percent of one or
more monomers having ethylenic unsaturation and containing from 2 to 20 carbon atoms,
a polymer of maleic or fumaric acid, or alkali metal salts thereof, and up to 70 weight
percent of an ethylenically unsaturated aromatic comonomer containing 2 to 20 carbon
atoms, and mixtures thereof.
4. The fabric of claim 3 wherein the polymeric stain-resist composition in the adhesive
adhering the tufts to the primary backing contains from 0.04 to 3.0 weight percent
of active polymeric stain-resist agent on the weight of the adhesive.
5. The fabric of claim 4 wherein the polymeric stain-resist composition coated on the
fibers in the tufts comprises from about 0.18 to 1.35 weight percent of active stain-resist
agent on the weight of the fibers in the tufts.
6. The fabric of claim 3 which is in the form of a carpet.
7. The carpet of claim 6 wherein the adhesive is a latex adhesive.
8. The carpet of claim 7 wherein the latex contains an organic fluorochemical soil-resist
composition.
9. The carpet of claim 7 wherein the stain-resist agent in the latex adhesive is a sulfonated
phenolic formaldehyde condensate.
10. The carpet of claim 7 wherein the stain-resist agent in the latex adhesive is a blend
of a sulfonated phenolic formaldehyde condensate and a hydrolyzed styrene maleic anhydride
copolymer.
11. The fabric of claim 5 which is in the form of a carpet.
12. The carpet of claim 11 wherein the adhesive is a latex adhesive.
13. The carpet of claim 12 wherein the latex contains an organic fluorochemical soil-resist
composition.
14. The carpet of claim 12 wherein the stain-resist agent in the latex adhesive is a sulfonated
phenolic formaldehyde condensate.
15. The carpet of claim 12 wherein the stain-resist agent in the latex adhesive is a blend
of a sulfonated phenolic formaldehyde condensate and a hydrolyzed styrene maleic anhydride
copolymer.
1. Gewebestruktur, welche ein primäres Grundgewebe aufweist, welches mit in engen Abständen
angeordneten Büscheln von Fasern aus aliphatischem Polyamid oder einem Polyamidgemisch
geheftet ist, wobei die Büschel sich von der oberen Fläche des primären Grundgewebes
unter Bildung eines Flors nach oben erstrecken, die Fasern mit einer polymeren, schmutzabweisenden
Zusammensetzung beschichtet sind, welche die Fasern beständig gegen eine Verschmutzung
durch saure Farbstoffe macht, und wobei die Büschel mit dem primären Grundgewebe mittels
eines Klebstoffs haftend verbunden sind, dadurch gekennzeichnet, daß der Klebstoff eine polymere, schmutzabweisende Zusammensetzung enthält, welche
geeignet ist, die Polyamidfasern beständig gegenüber einer Verschmutzung durch saure
Farbstoffe zu machen.
2. Gewebestruktur nach Anspruch 1, bei der die polymere, schmutzabweisende Zusammensetzung
im Klebstoff, welcher die Büschel mit dem primären Grundgewebe haftend verbindet,
ein aktives, polymeres, schmutzabweisendes Mittel aufweist, welches aus der Gruppe
gewählt ist, die ein sulfoniertes Naphthol-Formaldehyd-Kondensationsprodukt, ein sulfoniertes
Phenol-Formaldehyd-Kondensationsprodukt, ein Polymer aus Methacrylsäure oder ihren
Alkalimetallsalzen und bis zu 70 Gewichtsprozent eines oder mehrerer Monomere, welche
ethylenunqesättigt sind und 2 bis 20 Kohlenstoffatome enthalten, ein Polymer aus Maleinsäure
oder Fumarsäure oder Alkalimetallsalzen hiervon und bis zu 70 Gewichtsprozent eines
ethvlenungesättigten, aromatischen Comonomers, welches 2 bis 20 Kohlenstoffatome enthält,
und Mischungen hiervon umfaßt.
3. Gewebestruktur nach Anspruch 2, bei der die polymere, schmutzabweisende Zusammensetzung,
die auf die Fasern aus aliphatischem Polyamid oder einem Polyamidgemisch aufgetragen
ist, ein aktives, polymeres, schmutzabweisendes Mittel aufweist, welches aus der Gruppe
gewählt ist, welche ein sulfoniertes Naphthol-Formaldehyd-Kondensationsprodukt, ein
sulfoniertes Phenol-Formaldehyd-Kondensationsprodukt, ein Polymer aus Methacrylsäure
oder ihren Alkalimetallsalzen und bis zu 70 Gewichtsprozent eines oder mehrerer Monomerer,
welche ethylenungesättigt sind und 2 bis 20 Kohlenstoffatome enthalten, ein Polymer
aus Maleinsäure oder Fumarsäure oder Alkalimetallsalzen hiervon und bis zu 70 Gewichtsprozent
eines ethylenungesättigten, aromatischen Comonomers, welches 2 bis 20 Kohlenstoffatome
enthält, und Mischungen hiervon umfaßt.
4. Gewebe nach Anspruch 3, bei dem die polymere, schmutzabweisende Zusammensetzung in
dem Klebstoff, welcher die Büschel haftend mit dem primären Grundgewebe verbindet,
von 0,04 bis 3,0 Gewichtsprozent aktives, polymeres, schmutzabweisendes Mittel, bezogen
auf das Gewicht des Klebstoffs, enthält.
5. Gewebe nach Anspruch 4, bei dem die polymere, schmutzabweisende Zusammensetzung, die
auf den Fasern in den Büscheln aufgetragen ist, etwa 0,18 bis 1,35 Gewichtsprozent
aktives, schmutzabweisendes Mittel, bezogen auf das Gewicht der Fasern, in den Büscheln
ausmacht.
6. Gewebe nach Anspruch 3, welches in Form eines Teppichs vorliegt.
7. Teppich nach Anspruch 6, bei dem der Klebstoff ein Latexklebstoff ist.
8. Teppich nach Anspruch 7, bei dem der Latex eine organische, fluorchemische, schmutzbeständige
Zusammensetzung enthält.
9. Teppich nach Anspruch 7, bei dem das schmutzabweisende Mittel im Latexklebstoff ein
sulfoniertes Phenol-Formaldehyd-Kondensat ist.
10. Teppich nach Anspruch 7, bei dem das schmutzabweisende Mittel im Latexklebstoff ein
Gemisch aus einem sulfonierten Phenol-Formaldehyd-Kondensat und einem hydrolisierten
Styrol-Maleinsäure-Anhydrid-Copolymer ist.
11. Gewebe nach Anspruch 5, welches in Form eines Teppichs vorliegt.
12. Teppich nach Anspruch 11, bei dem der Klebstoff ein Latexklebstoff ist.
13. Teppich nach Anspruch 12, bei dem der Latex eine organische, fluorchemische, schmutzbeständige
Zusammensetzung enthält.
14. Teppich nach Anspruch 12, bei dem das schmutzabweisende Mittel im Latexklebstoff ein
sulfoniertes Phenol-Formaldehyd-Kondensat ist.
15. Teppich nach Anspruch 12, bei dem das schmutzabweisende Mittel im Latexklebstoff ein
Gemisch aus einem sulfonierten Phenol-Formaldehyd-Kondensat und einem hydrolisierten
Styrol-Maleinsäure-Anhydrid-Copolymer ist.
1. Une structure de tissu comprenant un fond piqué à l'aide de touffes de fibres de polyamides
aléphatiques ou mélanges de polyamides extroitement serrées, ces touffes constituant
la surface supérieure du premier fond et formant une fourrure, lesdites fibres étant
revêtues d'une composition polymère résistant aux taches qui rend les fibres résistantes
aux taches produites par des colorants acides, et lesdites touffes adhèrant au premier
fond grâce à un agent adhésif, ladite structure étant caractérisée en ce que l'agent
adhésif contient une composition polymère résistant aux taches qui permet de rendre
les fibres de polyamides résistantes aux taches produites par des colorants acides.
2. Une structure de tissu selon la revendication 1, caractérisée en ce que la composition
polymère résistante aux taches contenue dans l'agent adhésif qui permet l'adhésion
des touffes au premier fond comprend un agent polymère actif résistant aux taches
sélectionné dans le groupe consistant en produit de condensation formaldéhyde-naphtol
sulfoné, produits de condensation formaldéhyde-phénol sulfoné, un polymère de l'acide
méthacrylique ou de ses sels de métaux alcalins, et jusqu'à 70% en poids d'un ou de
plusieurs monomères présentant une insaturation éthylénique et contenant de 2 à 20
atomes de carbone, un polymère d'acide maléique ou d'acide fumarique, ou les sels
de métaux alcalins de ces éléments, et jusqu'à 70% en poids d'un co-monomère aromatique
éthyléniquement insaturé contenant de 2 à 20 atomes de carbone, et les mélanges de
ces composés.
3. Une structure de tissu selon la revendication 2, caractérisée en ce que la composition
polymère résistant aux taches qui recouvre les fibres constituées d'un mélange polyamides
ou polyamides aliphatiques comprend un agent polymère actif résistant aux taches sélectionné
dans le groupe consistant en produits de condensation formaldéhyde-naphtol sulfoné,
produits de condensation formaldéhyde-phénol sulfoné, un polymère de l'acide méthacrylique
ou de ses sels de métaux alcalins, et jusqu'à 70% en poids d'un ou de plusieurs monomères
présentant une insaturation éthylénique et contenant de 2 à 20 atomes de carbone,
un polymère d'acide maléique ou d'acide fumarique, ou de leurs sels de métaux alcalins
de ces éléments, et jusqu'à 70% en poids d'un co-monomère aromatique éthyléniquement
insaturé contenant de 2 à 20 atomes de carbone, et les mélanges de ces composés.
4. Le tissu selon la revendication 3, caractérisé en ce que la composition polymère résistant
aux taches contenue dans l'agent adhésif permettant l'adhésion des touffes au premier
fond contient entre 0,04 et 3,00% en poids de l'agent actif polymère résistant aux
taches par rapport au poids de l'agent adhésif.
5. Le tissu selon la revendication 4, caractérisé en ce que la composition polymère résistant
aux taches qui recouvre les fibres dans les touffes comprend d'environ 0,18 à 1,35%
en poids d'agents actifs résistant aux taches par rapport au poids des fibres dans
les touffes.
6. Le tissu selon la revendication 3 qui se présente sous la forme tapis.
7. Le tapis selon la revendication 6, caractérisé en ce que l'agent adhésif est un latex-ciment.
8. Un tapis selon la revendication 7, caractérisé en ce que le latex contient une composition
organique fluorochimique résistant aux salissures.
9. Un tapis selon la revendication 7, caractérisé en ce que l'agent résistant aux taches
présent dans le latex dans le latex-ciment est un condensat de formaldéhyde phénolique
sulfoné.
10. Un tapis selon la revendication 7, caractérisé en ce que l'agent résistant aux taches
présent dans le latex-ciment est un mélange de condensat de formaldéhyde phénolique
sulfoné et d'un copolymère d'anhydride et de styrène hydrolysé.
11. Le tissu selon la revendication 5 qui se présente sous la forme d'un tapis.
12. Un tapis selon la revendication 11, caractérisé en ce que l'agent adhésif est un latex-ciment.
13. Un tapis selon la revendication 12, caractérisé en ce que le latex contient une composition
organique résistant aux salissures fluorochimiques.
14. Un tapis selon la revendication 12, caractérisé en ce que l'agent résistant aux taches
présent dans le latex-ciment est un condensat de formaldéhyde phénolique sulfoné.
15. Un tapis selon la revendication 12, caractérisé en ce que l'agent résistant aux taches
présent dans le latex-ciment correspond à un mélange de condensat de formaldéhyde
phénolique sulfoné et de copolymères d'anhydride maléique et styrène hydrolysé.