PROCESS FOR IMPARTING FLAME RESISTANCE TO A POLYESTER/COTTON BLEND FABRIC

Abstract: A process for imparting flame resistance to a polyester/cotton blend fabric containing at least 20% by weight polyester comprises the successive steps of: (1) applying to a polyester/cotton blend fabric a flame-retarding amount of a cyclic phosphonate ester represented by the formula: in which x is 0 or 1 or a flame-retarding amount of hexabromocyclododecane, that fixes onto the polyester fibres; (2) optionally applying to the fabric a flame-retarding amount of a prepolymer condensate of urea and a tetrakis(hydroxymethyl)phosphonium (THP) salt flame retardant that fixes to the cotton fibres, exposing the prepolymer condensate-containing fabric to a source of ammonia to form an ammoniated prepolymer to form a flame-retardant polymer network within the cotton fibre structure; and (3) applying a flame-retarding amount of THP salt and urea to the fabric, heating the fabric to form an insoluble phosphorus-containing polymer in and on the cotton fibres and oxidizing the fabric to further improve the flame resistance imparted by the phosphorus.

Description: This invention relates to processes for imparting flame resistance to polyester/cotton blend fabrics and to fabrics so prepared. The process employs multiple flame-retardant systems, one specific to the polyester component of the polyester/cotton blend fabric and two specific to the cotton component thereof. Fabrics having improved hand and increased durability through multiple launderings may thus be obtained. Prior attempts to achieve acceptable flame-retarded polyester/cotton blends have not met with commercial success. None of the treatments are practical from the consumer point of view, producing fabrics that have a very stiff hand. This is because in order to achieve the requisite flame-resistant properties, a high chemical add-on is required. This add-on makes the fabric stiff, masks the color of the underlying fabric, and often imparts an acrid or unacceptable odor to the fabric. In addition, the performance of the flame-resistant fabrics is often unreliable. Most of the previous work conducted on flame-retardant polyester/cotton blends used a single chemical system that was targeted for the cotton component of the blend. The approach was to "load" the fabrics with a fire-retardant specific for cotton, for instance THPS [tetrakis-(hydroxymethyl)phosphonium sulphate]. It was not unusual with these earlier products to use from 30 to 35% of fixed chemical add-on in order for the polyester/cotton blend fabric to pass a bottom vertical flame test. Regrettably, however, the aesthetics of the finished fabrics were poor, as they had a very stiff hand and the appearance of a coated fabric. The add-ons used for these products were far in excess of the theoretically required amounts. The application of THP/urea-precondensate/ammonia or THPOH/ammonia has been used commercially for a number of years. The process consists of applying the precondensate to cotton fabric and drying the fabric to about 10 weight percent moisture. The precondensate is insolubilized by the ammonia inside the cotton fibres. Fixation of the precondensate must take place inside of the cotton fibre to be durable through multiple launderings. However, attempts made in the past to use this process to finish polyester/cotton fabric have not been successful when the polyester fibre content was greater than about 10 weight percent. While there is an upper limit for the amount of the flame-retardant chemical that can be packed in the cotton fibre, techniques can be used to maximize that amount. It is generally believed that approximately 3 weight percent phosphorus in the form of the THP/urea-precondensate/ammonia complex can be fixed inside of the cotton fibre; however, the actual amount will depend on the prior history of the cotton fibre. Fixation of the flame-retardant polymer inside the cotton fibres provides no protection to the polyester fibres. Therefore, the polyester fibres still need an additional chemical treatment to provide adequate flame resistance to the polyester/cotton fabric. The hand and durability of polyester/cotton blend fabrics can be further improved according to another aspect of the invention by applying the THP/urea-precondensate/ammonia treatment after the application of a flame retardant specific to the polyester component, which protects the polyester fibres, and prior to the application of THPS/urea which is also used to protect the cotton fibre. When THPS is applied to a polyester/cotton blend, it is generally believed that about 3% of fixed phosphorus in the form of the THP/urea-precondensate/ammonia complex is required to achieve flame-resistance results. Since the THPS is specific to the cotton, it does not react with the polyester content of the fabric but simply physically coats the polyester. As a result, after multiple launderings, that portion of the flame-retardant surrounding the polyester fibre is partially lost. In consequence, it was not unusual to use as much as 5.5% phosphorus add-on for a polyester/cotton blend, at least initially, in order to result in the target 3% of fixed phosphorus after 50 launderings in hot water. In the 1970's, polyester/cotton blends were flame retarded using tris-2,3-dibromopropyl phosphate ("Tris") in combination with THPS. However, "Tris" was found to be a carcinogen and was withdrawn from the market, so that there is no predominantly-polyester blend of polyester and cotton sold today that has been treated with flame-retardant chemicals. The textile literature contains references generally describing the use of two specific flame retardants for a blend of fibres, one for each component of the blend. It is reported that various approaches to the treatment of polyester/cotton blend fabrics have not been commercially accepted. A flame-resistant-treated polyester/cotton fabric according to the present invention exhibits an improved hand and increased durability over multiple launderings. The present invention seeks to produce a flame-resistant polyester/cotton blend fabric having improved durability and hand by means of a multiple step application process, an intermediate step to maximize the location of the flame-resistant chemicals inside the cotton fibres in order that enough total phosphorus for good flame resistance and durability can be added to the polyester/cotton blend while, at the same time, producing a flame-retardant polyester/cotton fabric which has a greatly improved hand over the prior art. The present invention also seeks to produce acceptable flame-resistant polyester/cotton blends using multiple flame-retardant chemicals or chemical systems in a specific sequence, and to employ processing conditions or adjuvants that produce a commercially acceptable, attractive product having good color, acceptable hand and commercially acceptable durability through multiple launderings. According to one aspect of the present invention there is provided a process for imparting flame resistance to a polyester/cotton blend fabric containing at least 20% by weight polyester, characterised by comprising the successive steps of: (1) applying to a polyester/cotton blend fabric a flame-retarding amount of a cyclic phosphonate ester represented by the formula: in which x is 0 or 1 or a flame-retarding amount of hexabromocyclododecane, that fixes onto the polyester fibres; (2) optionally applying to the fabric a flame-retarding amount of a prepolymer condensate of urea and a tetrakis(hydroxymethyl)phosphonium (THP) salt flame retardant that fixes to the cotton fibres, exposing the prepolymer condensate-containing fabric to a source of ammonia to form an ammoniated prepolymer to form a flame-retardant polymer network within the cotton fibre structure; and (3) applying a flame-retarding amount of THP salt and urea to the fabric, heating the fabric to form an insoluble phosphorus-containing polymer in and on the cotton fibres and oxidizing the fabric to further improve the flame resistance imparted by the phosphorus. According to yet another aspect of the present invention there is provided a flame-resistant polyester/cotton blend fabric containing more than 60% by weight of polyester, characterised by having at least 2.6% phosphorus fixed to the fibres after 50 launderings. The invention will now be described merely by way of example, in the accompanying drawing which is a flow chart illustrating the sequential operating steps, and the procedures for certain steps, of a process according to the invention for imparting flame resistance to a polyester/cotton blend fabric. Abbreviations, chemicals, processing times, conditions and the like are described in the detailed information that follows. The object of a particular subcombination of steps is given in the horizontal line below the flow chart. A process according to the present invention for imparting flame resistance to a polyester/cotton blend fabric employs two or preferably three flame-retardant (FR) systems, one specific to the polyester component and one, preferably two, specific to the cotton component of the polyester/cotton blends in order to maximize the amount of flame retardant inside the cotton fibres. With this approach, the amount of the individual flame-retardants required to satisfy flame-resistant standards can be reduced significantly, and the resulting fabrics have not only better flame-resistant characteristics, but also better aesthetics. The polyester/cotton fibrous materials which can be provided with a flame-retardant finish according to the present invention can be in any desired stage of processing, i.e., they can be treated as woven or knitted fabrics, dyed or undyed, or as textiles which have already been further processed. The present invention disclosed herein has several aspects which, for convenience, are illustrated in the drawing and are summarized according to the following scheme: Treating the Polyester Component of the Blend -- Flame-resistant properties are first imparted to the polyester component of the blend using a cyclic phosphonate ester or hexabromocyclododecane as a flame-retardant. Processing conditions, especially temperatures and humidities, are carefully controlled in order to optimize the use of the FR chemicals and to ensure good fixation to the polyester/cotton blends, even after several launderings. Flame-resistant polyester/cotton blend fabrics are prepared in a series of operations conducted in the order or sequence stated. In overview, they are: A. attaching a phosphorus-containing flame retardant to the polyester fibres, B. positioning a predetermined minimum amount of a phosphorus flame retardant inside of the cotton fibres, and C. increasing the flame resistance of the cotton fibres by fixing an additional quantity of phosphorus onto the cotton fibres. Each of these procedures is known individually, but they have not been combined in the three-step sequence herein discussed, prior to this invention. Similarly, flame-resistant polyester/cotton blend fabrics containing at least 20% polyester exhibiting both good hand and sufficient durability to withstand at least 50 wash and dry cycles together with the requisite flame-retardant properties, have not been available. The polyester/cotton blends treated in accordance with the present invention contain between 20% and 85% of polyester, the balance being cotton. The term "polyester" is used in its usual sense to mean highly polymeric, essentially linear polyester resins made by the reaction of a dicarboxylic acid or ester with a diol in the presence of an esterification or ester interchange catalyst. Illustrative dicarboxylic acids are malonic, succinic, adipic, azelaic, maleic, fumaric, hydromuconic, isophthalic, terephthalic, and cyclohexane-dicarboxylic acids. Representative diols are ethylene glycol, propylene glycol, butylene glycol and 1,6-hexanediol. (See US-A-2,465,319 and US-A-2,901,446.) The common commercial polyester resins are polyethylene terephthalate and polyethylene terephthalate modified by including minor proportions of a different glycol or dicarboxylic acid during the polyesterification process. The polyester used in the working examples that follow was polyethylene terephthalate. Flame-resistant properties are imparted to the fabric in three distinct steps, one for the synthetic (polyester) component of the blend and one, preferably two, additional steps for the cotton component of the blend. The order in which these steps are conducted is critical to achieve optimum results. With this in mind, the specific procedures of this process are now described. Treating the Cotton Component of the Synthetic/Cotton Blend. Flame-resistant properties are imparted to the cotton component of the synthetic/cotton blend in a two step procedure first in an "ammonia cure" process by impregnating the fabric with a carefully measured quantity of a tetrakis-(hydroxymethyl) phosphonium salt/urea precondensate, referred to as THPS when the salt is in the sulphate [(HOCH₂)₄P⁺]₂SO₄̿ or THPC when the salt is the chloride; the oxalate and phosphate salts are also known. The THP salt/urea precondensate is applied to the fabric typically as an aqueous solution and dried to a specific moisture level. It is then reacted on the fabric with ammonia, usually ammonia gas, under controlled conditions to form an ammoniated flame retardant which, to achieve additional fixation, is oxidized, usually with hydrogen peroxide, to form a three-dimensional flame-retardant polymer network within the cotton fibre structure. Currently there are two THP-based flame-retardant systems marketed for this type of treatment. Pyroset TPO is a THPS/urea precondensate of tetrakis-(hydroxymethyl)phosphonium sulphate and urea available from American Cyanamid Co., while Retardol AC is a THPC/urea prepolymer condensate of tetrakis-(hydroxymethyl)phosphonium chloride and urea available from Albright & Wilson. Pyroset TPO is recommended by its manufacturer for treating cellulosic fabric or blends containing at least 65% cellulosic fibre. The process of imparting flame resistance to 100% cotton fabrics using THPC/urea precondensate (Retardol AC) is known as the PROBAN process as licensed by Albright & Wilson. The process itself is described in the following US-A-4,078,101; US-A-4,145,463; US-A-4,311,855; US-A-4,494,951; and US-A-4,346,031. This process is considered effective and is widely promoted by at least two companies for imparting flame resistance to 100% cotton fabrics; it is not promoted or advertised for polyester/cotton blends or nylon/cotton blends. The THP salt/urea precondensate process by itself is ineffective to adequately protect polyester/cotton blends containing more than about 35 to 40% polyester. Placement of the flame retardant into and onto the cotton fibres is maximized and durability to multiple launderings improved with a second flame-retardant system also specific to the cotton component of the blend. This second system employs a mixture of tetrakis(hydroxymethyl) phosphonium sulphate (THPS, as in the previous step) mixed with urea which mixture, when heated, forms an insoluble polymer, containing both phosphorus and nitrogen, inside of the cotton fibres and around the cotton and synthetic fibres. The insolubility of this polymer is increased further by oxidizing the phosphorus with hydrogen peroxide. THPS is sold by Albright & Wilson as Retardol S (Trade Mark). The hand of the treated fabrics can be improved by conducting the curing operation in a moist, high-humidity environment. This procedure not only imparts an improved hand to the treated fabric, but it also causes better fixation of the FR chemicals so that the desirable FR properties are retained even after multiple launderings. Among the fire-retardant materials used in accordance with the present invention are thermally stable cyclic phosphonate esters prepared by reacting alkyl-halogen-free esters with a bicyclic phosphite. As a class, these cyclic phosphonate esters are represented by one of the formulas: where a is 0 or 1; b is 0, 1 or 2, c is 1, 2 or 3 and a+b+c is 3; R and R′ are the same or different and are alkyl (C₁-C₈), phenyl, halophenyl, hydroxyphenyl, tolyl, xylyl, benzyl, phenethyl, hydroxyethyl, phenoxyethyl, or dibromophenoxymethyl; R² is alkyl (C₁-C₄); and R³ is lower alkyl (C₁-C₄) or hydroxyalkyl (C₁-C₄) or where d is 0, 1 or 2; e is 1, 2 or 3; R² is alkyl (C₁-C₄); R³ is lower alkyl (C₁-C₄) or hydroxyalkyl (C₁-C₄); R⁴ is alkyl C₁-C₄) phenyl, halophenyl, hydroxyphenyl, hydroxyethyl, phenoxyethyl, dibromophenoxyethyl, tolyl, xylyl, benzyl, or phenethyl; and R⁵ is monovalent alkyl (C₁-C₆), chlorophenyl, bromophenyl, dibromophenyl, tribromophenyl, hydroxyphenyl, naphthyl, tolyl, xylyl, benzyl, or phenethyl; divalent alkylene (C₁-C₆), vinylene, o-phenylene, m-phenylene, p-phenylene, tetrachlorophenylene (o, m, or p), or tetrabromophenylene (o, m, or p); or trivalent phenenyl. The preferred compounds (see below) are represented by the formula: in which X is 0 or 1, and usually a 50:50 mixture of the mono- and di-esters. The preparation of these cyclic phosphonate esters and their use as flame retardants are described in US-A-3,789,091 and US-A-3,849,368. The use of these cyclic phosphonate esters as flame retardants for treating polyester/cotton and polyester/cellulose triacetate blends is described in US-A-4,066,812. This patent indicates (column 5, lines 42-47) that the phosphonate esters have little or no effect on the cellulose or cotton portion of the blend but do have an effect on the flame resistance of the blend as a whole, particularly when the blend contains 75% or more by weight of polyester. Antiblaze 19T, as described by the supplier Albright & Wilson Inc., of Richmond, Virginia, is a cyclic phosphonate ester, available as an odorless viscous liquid (viscosity 6000 m²/s at 38°C (100°F)) with a flashpoint of 170°C (340°F) (ASTM D-93). Hexabromocyclododecane, as described by its supplier Great Lakes Chemical Corporation of West Lafayette, Indiana, is a cyclic alkyl bromide, empirical formula C₁₂H₁₈Br₆, CAS registry number 25637-99-4, composed of hexabromocyclododecane and related bromocycloalkanes. It is an odorless, water-insoluble, off-white powder having a melting point range of 142-182°C (288-360°F). Tetrakis-(hydroxymethyl)phosphonium sulphate (THPS), also available from Albright & Wilson, Inc., under the name Retardol S, is a pale, straw-colored liquid that is miscible with water and has a pungent odor. Flame-Resistance Testing Methods -- the following testing procedures were used: FR Federal (USA) Test Method 5903 is intended for use in determining the resistance of cloth to flame and glow propagation and tendency to char. A rectangular cloth test specimen (70mm x 120mm) with the long dimension parallel to the warp or fill direction is placed in a holder and suspended vertically in a cabinet with the lower end 1.9cm (0.75 inch) above the top of a Fisher gas burner. A synthetic gas mixture consisting primarily of hydrogen and methane is supplied to the burner. After the specimen is mounted in the cabinet and the door closed, the burner flame is applied vertically at the middle of the lower edge of the specimen for 12 seconds. The specimen continues to flame after the burner is extinguished. The time in seconds the specimen continues to glow after the specimen has ceased to flame is reported as afterglow time; if the specimen glows for more than 30 seconds, it is removed from the test cabinet, taking care not to fan the glow, and suspend in a draft-free area in the same vertical position as in the test cabinet. Char length, the distance (in inches) from the end of the specimen, which was exposed to the flame, to the end of a lengthwise tear through the center of the charred area to the highest peak in the charred area, is also measured. Five specimens from each sample are usually measured and the results averaged. FR Federal (USA) Test Method 5905, flame contact test -- a measurement of the resistance of textiles and other materials to flame propagation that exposes the specimen to the flame source for a longer period of time than test method 5903. A test specimen the same size as in the above method is exposed to a high temperature butane gas flame 7.5 cm (3 inch) in height by vertical suspension in the flame for 12 seconds, the lowest part of the specimen always 3.8cm (1.5 inch) above the centre of the burner. At the end of 12 seconds, the specimen is withdrawn from the flame slowly, and any afterflaming is timed. Then the specimen is re-introduced into the flame and again slowly withdrawn after 12 seconds and any afterflame timed. For each 12-second exposure the results are reported as: ignites, propagates flame; ignites but is self-extinguishing; is ignition resistant; melts; shrinks away from the flame; or drops flaming pieces. Limiting Oxygen Index (LOI) is a method of measuring the minimum oxygen concentration needed to support candle-like combustion of a sample according to ASTM D-2863-77. A test specimen is placed vertically in a glass cylinder, ignited, and a mixture of oxygen and nitrogen is flowed upwardly through the column. An initial oxygen concentration is selected, the specimen ignited from the top and the length of burning and the time are noted. The oxygen concentration is adjusted, the specimen is reignited (or a new specimen inserted), and the test is repeated until the lowest concentration of oxygen needed to support burning is reached. EXAMPLE 1 A flame-retardant finish solution containing THPS for the cotton component and a dispersion of hexabromocyclododecane for the polyester was padded onto a yarn-dyed 50/50 polyester/cotton blend fabric at approximately a 72% wet pickup. The padded fabric was cured under different conditions as specified below, oxidized with hydrogen peroxide (30:1 liquid-to-fabric ratio, 1% H₂O₂, 71°C (160°F) for 2 minutes), and then laundered 50 times. Curing was at two humidity levels, namely, 0.008 kg water/kg air and 0.08 kg water/kg air (0.008 lb. water/lb. air and 0.08 lb. water/lb. air), seven temperature levels, and four residence times in a Benz oven; see Table 1. Another humidity level curing test was performed by drying samples at 177°C (350°F), with 60 seconds residence time in the Benz oven and subsequently curing at five temperature levels and four residence times in a Werner-Mathis steamer, 100% high-temperature steam; see Table 2. Samples were taken as run for bromine analysis (columns headed "I" in Tables 1 and 2); and for bromine and phosphorus analysis after one oxidative wash (1x) and again after 50 normal washes (50x). The results are presented in Tables 1 and 2. Based on the total phosphorus and bromine content after 50 washes, samples were selected for flammability testing (DOC-FF-3-71). The results of this test on samples washed 50 times are presented in Table 3 along with test results from a modified DOC-FF-3-71 test in which some of the samples were tested under ambient conditions. Curing - Several of the samples cured for low residence times, e.g., 204°C (400°F), 30 s; 193°C (380°F), 30 s; 182°C (360°F), 30 s; and 149°C (300°F), 30 s, were not dry to the touch, indicating an inadequate cure. This observation was later verified by the bromine and phosphorus analyses in Table 3. The bromine content of the sample cured at 149°C (300°F) for 60 s was 2.7% initially, but only 0.11% after 50 washes. While the initial phosphorus content was not determined, it was only 0.15% after 50 washes. Extreme curing conditions, e.g., 204°C (400°F) for 120 seconds, gave visual yellowing and harsh hand. Samples processed through the Werner-Mathis steamer yellowed badly at 193°C (380°F) for 10 minutes and 182°C (360°F) for 10 minutes. The degradation of the cotton portion can be seen in the apparent increase in bromine fixation for 193°C (380° F) for 10 minutes in Table 4. The fixation (2.05%) after 50 washes was greater than the initial deposition (1.86%). Flammability Tests - Samples were selected on the basis of acceptable hand and their % bromine and phosphorus fixation. Of the 12 samples selected (Table 3), three failed the DOC-FF-3-71 test. The sample cured at 171°C (340°F) for 90 s. at low humidity apparently did not contain sufficient fixed bromine (0.77% - Table 1) to prevent burning. The same apparent fixation (0.74%) for the high humidity sample at the same temperature and time was adequate in another flammability sample (Table 3). The difference may be attributed to better diffusion when water is present. Other samples (193°C (380°F), 4 minutes; 182°C (360°F), 10 minutes) selected from the high-temperature steam trials also failed. Table 2 reporting the % bromine in the samples shows a decrease in bromine after one wash but an increase after 50 washes. This can only occur when the cotton is sufficiently degraded by the curing that it washes out of the fabric. These samples lost 9 and 14% of their respective weights between one wash and 50 washes. On the basis of the data analyzed in this example, it was determined that presence of steam in the curing oven improved the hand of the flame-retardant finishes on the polyester/cotton blend. It is believed that the high humidity in curing minimizes migration of the chemicals on the fabric. It thus permits the use of smaller amounts of chemicals, and reduces the tendency of Antiblaze 19T to smoke at higher temperatures, as well as improving the fabric hand. While the process of this invention may be conducted at ambient humidity at the cure stage, a practical upper limit is 22% absolute humidity, with about 10% absolute humidity (that is, 10 kg of water per 100 kg of oven air (10 lb. of water per 100 lb. of oven air)) preferred. EXAMPLE 2 A flame-retardant finish solution containing, by weight, 50% THPS, 15.7% urea and 10% Antiblaze 19T, was padded onto a 65/35 polyester cotton blend fabric (yarn dyed, 237 g/m² (7.0 oz/yd²) at a wet pick-up of 70%. The samples so padded were cured at 182°C (360°F) for 90 s, then oxidized with hydrogen peroxide (30:1 liquid-to-fabric ratio), 1% H₂O₂ actual, at 71°C (160°F) for 2 minutes (as in Example 1), then scoured. Samples so prepared were subjected to the Limiting Oxygen Index test and found to have an LOI value of 0.282. The results of the FTM-5903 test method were as follows. The samples had an average char length of 10cm (4.0 inch) in the warp direction and an average of 10.4cm (4.1 inch) in the fill. All of the samples exhibited 0 afterflame and 0 afterglow. EXAMPLE 3 Improvement in hand for polyester/cotton fabrics is demonstrated in this example. Antiblaze 19 was included in the pad bath and steam was used in the curing environment. Samples of 65/35 polyester/cotton fabric (Indestructible, 203 g/m² (6.0 oz/yd²) were finished with the following formulations, one with, the other without Antiblaze 19: Fabric samples were padded with the above formulas and cured in a Benz oven; wet pick-up was about 60%. Those samples finished with Formula II were cured in an environment of 10% absolute humidity; samples treated with Formula I were cured in an environment of only 1% absolute humidity. The resulting products were examined and subjectively evaluated for hand. Samples finished with Formula I were significantly more stiff than those finished with Formula II. After oxidation and even following machine laundering the hand continued to be significantly better than the samples finished with Formula II. EXAMPLE 4 Seven polyester/cotton fabrics having blend ratios ranging from 40/60 to 65/35 polyester/cotton were selected for a series of tests. Antiblaze 19 (15% solution) was padded onto each fabric at a wet pickup of from 18 to 28.8%, calculated on the weight of the fabric (owf), then cured for 90 seconds at 182°C (360°F) to fix this cyclic phosphonate to the polyester fibres. Following this, the fabric samples were finished with one of two levels of THP/urea-precondensate and one of two levels of THPS/urea. The pad bath in the last step (involving the application of THPS/urea) included 3% of a reactive silicone softener, Ultratex HX-33, a product of the Ciba-Geigy Company. The THPS/urea precondensate was Pyroset TPO (American Cyanamid) which after padding onto the fabric for a wet pickup ranging from 15 to 22% owf was heated at 54°C (130°F) for 48 seconds to reduce the moisture content to a level of about 10%, exposed to ammonia gas at 6:1 ammonia:phosphorus mole ratio, then oxidized with a hydrogen peroxide/sodium silicate solution. Table 4 reports the results in terms of phosphorus fixation and retention after laundering. In this Table, the amounts by weight of polyester/cotton are indicated as a fraction under the name of the fabric. "h.w" indicates heavy weight; "1.w." indicates light weight. The amount of phosphorus fixed to the fabric after the THPS/urea precondensate treatment is indicated in the first column adjacent the sample column; the amount of phosphorus fixed to the fabric following the THPS treatment is indicated in the second column. Four runs were made for each type of fabric; runs were in pairs with equal amounts of the THP/prepolymer in the first pair and a greater amount of THPS in the second run of the first pair. Each sample was laundered 50 times and the amount of phosphorus remaining fixed to the fibre reported. The percentage of phosphorus remaining on the fibre after 50 launderings as compared with the percent phosphorus on the fabric prior to laundering is reported as percent efficiency in the last column. These two columns are a measure of the durability of the flame-retardant finish to multiple launderings. The fabrics were subjected to flame-resistance testing according to FR Federal Test Method 5903. Three different samples of each fabric type were used, laundered 50 times, and samples in the fill (F) and warp (W) direction were subjected to FR 5903. Four samples corresponding to the four of Table I were tested and the results of 12 tests averaged and reported in Table 5. If one or more of the samples burned the entire length, the number of samples is indicated with an integer and reported as the top half of the fraction; the char length of the samples that completed the test was averaged.

Claims: A process for imparting flame resistance to a polyester/cotton blend fabric containing at least 20% by weight polyester, characterised by comprising the successive steps of: (1) applying to a polyester/cotton blend fabric a flame-retarding amount of a cyclic phosphonate ester represented by the formula: in which x is 0 or 1 or a flame-retarding amount of hexabromocyclododecane, that fixes onto the polyester fibres; (2) applying to the fabric a flame-retarding amount of a prepolymer condensate of urea and a tetrakis(hydroxymethyl)phosphonium (THP) salt flame retardant that fixes to the cotton fibres, exposing the prepolymer condensate-containing fabric to a source of ammonia to form an ammoniated prepolymer to form a flame-retardant polymer network within the cotton fibre structure; and (3) applying a flame-retarding amount of THP salt and urea to the fabric, heating the fabric to form an insoluble phosphorus-containing polymer in and on the cotton fibres and oxidizing the fabric to further improve the flame resistance imparted by the phosphorus. A process as claimed in claim 1 characterised in that the cyclic phosphonate ester is used as the flame retardant in step (1). A process as claimed in claim 1 or 2 characterised in that steps (1), (2), and (3) are conducted in the order stated. A process as claimed in any preceding claim characterised in that the fabric contains 20% to 85% by weight polyester, balance substantially entirely cotton. A process as claimed in claim 4 characterised in that the fabric is a 40/60 polyester/cotton blend, or a 65/35 polyester/cotton blend, or a 50/50 polyester/cotton blend. A process as claimed in any preceding claim characterised in that the tetrakis(hydroxymethyl)phosphonium salt is the chloride, sulphate, oxalate or phosphate salt. A process as claimed in any preceding claim characterised in that the curing is conducted in the presence of up to 22% absolute humidity. A flame-resistant polyester/cotton blend fabric containing more than 60% by weight of polyester, characterised by having at least 2.6% phosphorus fixed to the fibres after 50 launderings.

Inventors: JOHNSON, JAMES R., SUJARIT, CHUMPON
Applicants: BURLINGTON INDUSTRIES, INC.
Application year: 1987
Main classification: D06M13
IPC codes: D06M13