Dye-leveling agent and dyeing method

Abstract: 1. A method for dyeing a cloth with a reactive dye, an alkali­ ne substance and a leveling agent, said leveling agent being selected from the group consisting of phospholipids obtained from animals or plants and phospholipid-like compounds having the formula (I) or (II): (where R₁ and R₃ each denote an alkyl group, alkenyl group, hydroxyalkyl group, or M (but both of them do not denote M si­ multaneously); R₂ denotes and alkylene group having 2. to 4 car­ bon atoms; ℓ and m each denote 0 or an integer of 1 or above; and M denotes an alkali metal or hydrogen.) (where R₄ denotes an alkyl group, alkenyl group, hydroxyalkyl group, or linear or side chain unsaturated OH-containing alkoxy group; X and Y each denote hydrogen, alkoxy group, alkyl group, or phosphate group represented by - (OM)₂ M denotes an alkali metal or hydrogen; and n denotes an integer of 1 or above.) The invention also includes the dyeing composition whiche com­ prises the leveling agent described in the above-mentioned method.

Description: The present invention relates to a leveling agent for reactive dyes. More particularly, it is concerned with a leveling agent which simplifies the sophisticated dyeing process and permits the uniform reproducible dyeing in the dyeing with reactive dyes. Natural fibers vary in their properties depending on locality and climate and other factors, and this makes it difficult to dye natural fibers uniformly with good reproducibility. For this reason, there has been a demand for technology that permits one to control dyeing and reactions at will, especially in the case where reactive dyes are used. In dyeing with reactive dyes, the rate of dyeing is typically controlled by adding alkaline substances. This dyeing method is required to be performed according to a quadratic curve representing the relationship between the time and the amount of alkali added which is established for individual reactive dyes. Therefore, this dyeing method needs complex controls according to the combination of the dyeing machine, substrate, and reactive dye. Other known dyeing methods include S.A.S. method and all-in method; but they are useful only for limited combinations of reactive dyes and fibers. In dyeing with reactive dyes, it is necessary to control the rate of alkali addition and the temperature for each reactive dye because the reactivity and adsorption to fibers differ from one reactive dye to another. Therefore, it is difficult to perform dyeing in the case where reactive dyes having different reactivity are used in combination with one another. On the other hand, natural fibers vary in dyeability depending not only on the kind and locality but also on their chemical treatment such as bleaching. For natural fibers to be dyed uniformly, it is necessary to establish complex conditions for the dyeing steps; and this in turn makes it difficult to maintain good reproducibility and uniform quality. FR-A-1396294 discloses a wetting bath having a reduced foaming and containing between its different compounds, phosphates of medium molecolar weight aliphatic alcohols, preferably tributylphosphate, and polysiloxanes as main compounds. This bath is usable with suitable dyes to effect an even dyeing of fibres and clothes. JP-A-7943111 discloses a dyeing bath suitable to give a higher colour deepness and containing phosphatidylcoline, an anionic surface active agent and Na₂SO₄. In summary, the immediate problem to be solved in the dyeing industry is to develop a leveling agent which simplifies the dyeing steps, ensures uniformity and reproducibility of dyeing, permits dyeing with different types of dyes in combination, and reduces the limitations on dyeing conditions for individual fibers and blended products. Such a leveling agent will improve the productivity and cost reduction of dyeing and also increases the versatility of colors that can be selected, which are the most important subjects in the dyeing industry. Unfortunately, no leveling agent has so far been proposed which meets such requirements. It is an object of the present invention to provide a leveling agent which solves the above-mentioned problems. To achieve the above-mentioned object, the present inventors carried out a series of researches which led to the finding that the above-mentioned problems can be solved if dyes are used in combination with the leveling agent of the present invention. The present invention was completed on the basis of this finding. Accordingly, the present invention relates to a leveling agent for reactive dyes and also to a dyeing method which employs said leveling agent, said leveling agent comprising containing therein one or more than one kind of substances selected from phospholipids obtained from plants and phospholipid-like compounds represented by the formula (I) or (II). The invention provides a method for dyeing a cloth with a reactive dye, an alkaline substance and a leveling agent, said leveling agent incorporating a substance selected from the group consisting of phospholipids obtained from plants and phospholipid-like compounds having the formula (I) or (II): where R₁ denotes an alkyl group, alkenyl group or hydroxyalkyl group; R₃ denotes an alkyl group, alkenyl group, hydroxyalkyl group or M; R₂ denotes an alkylene group having 2 to 4 carbon atoms; l denotes an integer of 1; m denotes 0 or an integer of 1; and M denotes an alkali metal or hydrogen, where; R₄ denotes an alkyl group, alkenyl group or hydroxyalkyl group; X and Y each denote hydrogen, alkyl group, or phosphate group represented by M denotes an alkali metal or hydrogen; and n denotes 0 or an integer of 1 or above, and a polycarboxylic acid or salt thereof. According to the invention it is possible that the alkaline substance is added to the dyeing solution at a time. The invention further provides a dyeing composition which comprises a reactive dye an alkaline substance and a leveling agent as defined above and then a dyeing solution which comprises the dyeing composition and water. The dyeing solution may further comprise a hydrophilic surfactant. The dyeing solution comprises 0.1 to 5 g/l of the leveling agent. The solution is intended to include also a dispersion of a dye and one in the form of micelle. The phospholipids that can be used in the present invention are those which originate from plants. They include oil-containing crude lecithins, purified lecithins, and their hydrogenated products and enzymatically decomposed products. They also include phytic acid. The phospholipid-like substances include alkyl phosphate esters and polyalkyleneoxide alkyl phosphate esters represented by the formula (I) and alkyl polyglycerin ether phosphate ester salt and polyglycerin fatty ester phosphate ester salt represented by the formula (II). These compounds should preferably contain alkyl chains having 8 or more carbon atoms. They can be used as such or in combination with a hydrophilic surface active agent or in the form of liposome-like dispersion. The leveling agent of the present invention readily disperses or dissolves in water. It produces its effect when added in an amount of 0.1 to 5 g/liter, preferably 0.5 to 3 g/liter. The leveling agent of the present invention is incorporated with one or more than one kind of polycarboxylates in addition to the above-mentioned substances. Examples of the polycarboxylates include salts of organic acid such as oxalic acid, maleic acid, and succinic acid, and salts of polymeric carboxylic acids such as polyacrylic acid, carboxymethylcellulose, and polystyrenemaleic acid copolymer. The leveling agent of the present invention may also be incorporated with one or more than one kind of anionic surface active agent in addition to the above-mentioned substances. Examples of the anionic surface active agent include carboxylates such as fatty acid salts and an alkylpolyethylene glycolether methyl carboxylic acid salt; sulfate ester salts such as alkyl sulfate and polyoxyethylenealkylether sulfate; and sulfonates such as alkylbenzenesulfonate and alkylsulfonate. Furthermore, the leveling agent of the present invention may be used in combination with a polyoxyethylene alkylether-type nonionic surface active agent and a water-soluble alcohol such as ethanol and ethylene glycol, in addition to the above-mentioned substances, for the improvement of mutual dissolution or dispersion into water of the components. The leveling agent of the present invention is completed by properly selecting and formulating the above-mentioned components according to the kind of dyes used and the dyes' reactivity toward fibers. The present inventors also found a new dyeing method which, owing to the leveling agent of the present invention, permits uniform dyeing even though an alkaline substance is added all at once. This dyeing method simplifies and shortens the dyeing steps and improves the dyeing productivity. According to this dyeing method, an alkaline substance is added all at once, as shown in Fig. 1, unlike the conventional dyeing method, in which case an alkaline substance is added in a controlled manner. The amount of an alkaline substance to be added can be increased or decreased according to the reactivity toward fibers of the reactive dye used. Likewise, the reaction time can also be adjusted. The leveling agent of the present invention makes the following improvements when used in dyeing with reactive dyes. (1) It permits uniform dyeing with good reproducibility. (2) It permits an alkaline substance to be added all at once without any adverse effect on the uniformity and reproducibility of dyeing. This simplifies the dyeing steps, making in-process sampling unnecessary and giving more chances of achieving the desired dyeing by a single pass. All this leads to the streamlining and cost reduction of the dyeing process. (3) It permits simultaneous dyeing and scouring by one-bath method. (4) It gives an extremely bright color. (5) It permits the use of dyes having different reactivities. In addition to the above-mentioned advantages, the leveling agent of the present invention produces the effect of imparting soft feel and wrinkle resistance to the dyed products. The leveling agent of the present invention is also useful for direct dyes as well as reactive dyes. Moreover, it facilitates the soaping to be performed after dyeing. Figs. 1 and 2 are the dyeing programs used in the present invention. The invention will be described with reference to the following examples. Examples 1 to 4 and Comparative Examples 1 to 4 Dyeing tests were performed according to the dyeing program shown in Fig. 1 by shaking a 500-ml Erlenmeyer flask containing a folded sample cloth (100 × 300 mm) and 75 ml of deionized water, at a constant speed (100 rpm) in a water bath. The results are shown in Table 1. Composition A (leveling agent) Crude soybean lecithin 30% Sodium polyacrylate 30% Sodium L-dodecylbenzenesulfonate 40% Dye Fiber Composition A Results Comparative Example 1 Levafix Blue E-RN Mercerized cotton None Uneven Example 1 -ditto- -ditto- 1 g/L Even Comparative Example 2 Remazol Rriel. Blue R-KN Mercerized cotton None Uneven Example 2 -ditto- -ditto- 1 g/L Even Comparative Example 3 Cibacron Red FB Mercerized cotton None Uneven Example 3 -ditto- -ditto- 1 g/L Even Comparative Example 4 Levafix Yellow E-2RN Levafix Brown E-RN Levafix Blue E-RN Mercerized cotton None Uneven Example 4 -ditto- -ditto- 1 g/L Even Examples 5 to 8 and Comparative Examples 5 to 8 Dyeing tests were performed in the same manner as in Examples 1 to 4 according to the dyeing program shown in Fig. 2. The results are shown in Table 2. Composition B (leveling agent) Dilaurin phosphate 20% Sodium polystyrenemaleate 30% Polyoxyethyleneoleyl ether 10% Sodium laurylsulfonate 40% Dye Fiber Composition B Results Comparative Example 5 Levafix Royal Blue E-FR Mercerized cotton None Uneven Example 5 -ditto- -ditto- 2 g/L Even Comparative Example 6 Reactive Blue ZE-GN Linen None Uneven Example 6 -ditto- -ditto- 2 g/L Even Comparative Example 7 Sumifix Supra Navy Blue 2GF Cotton-linen blend None Uneven Example 7 -ditto- -ditto- 2 g/L Even Comparative Example 8 Remazol Black B Bleached cotton None Uneven Example 8 -ditto- -ditto- 2 g/L Even Examples 9 to 13 Dyeing tests were performed in the same manner as in Examples 1 to 4, using Levafix Brown E-RA dye, mercerized cotton, and leveling agents in the percentages shown in Table 3. The results are shown in Table 3. Example No. 9 10 11 12 13 Soybean lecithin 10 - - - 60 Na laurylglycerylether phosphate 10 20 60 60 1 Sodium polyacrylate 40 - - 40 - Sodium carboxymethylcellulose - 20 40 - - Polyoxyethylene (20 mol) soybean oil 20 10 - - 40 Sodium laurate 20 50 - - - Results Even Even Even Even Even

Claims: A method for dyeing a cloth with a dyeing composition comprising a reactive dye and an alkaline substance characterized in that said dyeing composition further comprises a dye-leveling agent incorporating: a substance selected from the group consisting of phospholipids obtained from plants and phospholipid-like compounds having the formula (I): where R₁ denotes an alkyl group, alkenyl group or hydroxyalkyl group; R₃ denotes an alkyl group, alkenyl group, hydroxyalkyl group or M; R₂ denotes an alkylene group having 2 to 4 carbon atoms; l denotes an integer of 1; m denotes 0 or an integer of 1; and M denotes an alkali metal or hydrogen; or the formula II where R₄ denotes an alkyl group, alkenyl group or hydroxyalkyl group; X and Y each denote hydrogen, alkyl group, or phosphate group represented by M denotes an alkali metal or hydrogen; and n denotes 0 or an integer of 1 or above; and a polycarboxylic acid or a salt thereof. A method as claimed in claim 1), in which the alkaline substance is added to the dyeing solution at a time. A dye-leveling agent characterized in that it comprises: a substance selected from the group consisting of phospholipids obtained from plants and phospholipid-like compounds having the formula (I): where R₁ denotes an alkyl group, alkenyl group or hydroxyalkyl group; R₃ denotes an alkyl group, alkenyl group, hydroxyalkyl group or M; R₂ denotes an alkylene group having 2 to 4 carbon atoms; l denotes an integer of 1; m denotes 0 or an integer of 1; and M denotes an alkali metal or hydrogen; or the formula (II) where R₄ denotes an alkyl group, alkenyl group or hydroxyalkyl group; X and Y each denote hydrogen, alkyl group, or phosphate group represented by M denotes an alkali metal or hydrogen; and n denotes 0 or an integer of 1 or above; and a polycarboxylic acid or a salt thereof. A dye-leveling agent as claimed in Claim 3, which further comprises a hydrophilic surfactant. A dyeing composition comprising a reactive dye, an alkaline substance and a dye-leveling agent as claimed in claim 3) or 4). A dyeing solution which comprises 0.1 to 5 g/l of a dyeing composition as defined in Claim 5) and water.

Inventors: NAGATOMI TATEYUKI, OHBA NORIAKI, TABATA YUJIN, NAGATOMI, TATEYUKI, OHBA, NORIAKI, TABATA, YUJIN
Applicants: NIHON SURFACTANT KOGYO KK, NIHON SURFACTANT KOGYO K.K.
Application year: 1988
Main classification: D06P1
IPC codes: D06P1, D06P3