Treatment of solvent-spun cellulosic fibres to reduce their fibrillation tendency

Abstract: A process for treating a solvent-spun cellulose fibre to reduce its fibrillation tendency is disclosed which is characterised in that a chemical reagent having two to six functional groups reactive with cellulose is applied from an aqueous system to never-dried solvent-spun cellulose fibre and is caused to react therewith under alkaline conditions.

Description: This invention is concerned with the treatment of solvent-spun cellulose fibres to reduce their tendency to fibrillation. Proposals have been made to produce cellulose fibres by spinning a solution of cellulose in a suitable solvent. An example of such a process is described in GB-A-2043525, the contents of which are incorporated herein by way of reference. In such a solvent-spinning process, cellulose is dissolved in a solvent for the cellulose such as a tertiary amine N-oxide, for example N-methylmorpholine N-oxide. The resulting solution is then extruded through a suitable die to produce a series of filaments, which are washed in water to remove the solvent and subsequently dried. Such cellulose fibres are referred to herein as "solvent-spun" cellulose fibres and are to be contrasted with fibres produced by chemical regeneration of cellulose compounds, such as viscose fibres, cuprammonium fibres, polynosic fibres and the like. The present invention is particularly concerned with the treatment of such solvent-spun cellulose fibres so as to reduce the tendency of the fibres to fibrillate. Fibrillation is the breaking up in a longitudinal mode ofa fibre to form a hairy structure. A practical process to reduce fibrillation tendency needs not only to inhibit fibrillation but also to have a minimal effect on subsequent processability of the fibre and to have as little as possible effect on tenacity and extensibility of the fibre. Some processes which have been investigated by the applicants and which will reduce the fibrillation tendency have the unwanted side effects either of reducing the tenacity and the extensibility of the fibre or of embrittling the fibre so as to make it unprocessable. Cellulose fabrics have been treated with resins to give improved crease resistance. This type of treatment is described in an article entitled "Textile Resins" in Encyclopaedia of Polymer Science and Technology, Volume 16 (1989, Wiley-Interscience) at pages 682-710. The resins used are generally polyfunctional materials which react with and crosslink cellulose. Resin treatment may reduce breaking strength and tearing strength as well as abrasion resistance. Fabrics are usually dyed before crosslinking because the dye cannot penetrate the crosslinked fibre. The literature on the dyeing of fibres, including natural cellulosic fibres such as cotton and artificial cellulosic fibres such as cuprammonium and viscose rayon, is extensive. Representative examples of this literature include: Man-Made Fibres, R.W. Moncrieff, 6th Edition (Newnes-Butterworth, 1975), Chapter 49 (pages 804-951); an article entitled "Dyeing" in Encyclopaedia of Polymer Science and Engineering, Volume 5 (Wiley-Interscience, 1986), pages 214-277; and Textile Dyeing Operations, S.V. Kulkami et al. (Noyes Publications, 1986). Common types of dye for cellulose include direct dyes, azo dyes, fibre-reactive dyes, sulphur dyes and vat dyes. The choice of dye for any particular application is governed by various factors including but not limited to the desired colour, levelness of dyeing, effect on lustre, wash-fastness, lightfastness and cost. Reactive dyes are described in an article entitled "Dyes, Reactive" in Kirk-Othmer, Encyclopaedia of Chemical Technology, 3rd edition, Volume 8 (1979, Wiley-Interscience) at pages 374-392. Reactive dyes are coloured compounds that contain functional groups capable of forming covalent bonds with active sites in fibres such as hydroxyl groups in cellulose. These dyes contain a chromophore system attached directly or indirectly to a unit which carries one or more functional groups reactive with the material to be dyed. Reactive dyes for cellulosic materials are particularly described at pages 380-384 of the above-mentioned article. The reactive functional groups tend to hydrolyse in the dye bath, and reactive dyes containing several reactive groups have been used to provide higher fixation efficiency. GB-A-878655 describes a process in which a synthetic resin is incorporated in a regenerated cellulose fibre. Never-dried conventional viscose rayon fibre has a water imbibition of 120-150% and is squeezed to reduce the water imbibition to 100%. (Water imbibition is defined as the weight of water retained per unit weight of bone-dry fibre.) The squeezed fibre is then treated with a crosslinking agent, for example a formaldehyde resin precondensate, squeezed again to reduce the water imbibition to 100%, dried, and heated to cure the resin. The cured resin crosslinks the fibre, and the treated fibre has improved processability into yarn and cloth. GB-A-950073 describes a similar process. Such processes do, however, embrittle the fibre and reduce extensibility. FR-A-2273091 describes a method of manufacturing polynosic viscose rayon fibre with reduced fibrillation tendency. The fibre is treated in the primary gel state characteristic of polynosic viscose rayon manufacture with a crosslinking agent containing at least two acrylamido groups and an alkaline catalyst. This primary polynosic gel is a highly swollen gel having a water imbibition of 190-200%, which is only found in polynosic viscose rayon that has never been dried. The fibres may be dyed after having been crosslinked and dried. EP-A-118983 describes a method of treating natural textile fibres, for example wool and cotton, and synthetic polyamide fibres to enhance their affinity for disperse or anionic dyestuffs. The fibres are treated with an aqueous solution or dispersion of an arylating agent. The arylating agent contains both a hydrophobic benzene or naphthalene ring and a reactive group such as a halotriazine group. EP-A-174794 describes a method of treating natural textile fibres, for example wool and cotton, and synthetic polyamide fibres with an arylating agent. This treatment provides cellulose fibres and fabrics with improved dye affinity and crease recovery. The arylating agent preferably contains at least one functional group which is a vinyl sulphone or a precursor thereof. GB-A-950,073 discloses a process in which regenerated cellulose fibre in the gel state (i.e., never-dried fibre) prepared by the viscose process is treated with a permanently soluble cross-linking agent of known type and of molecular weight not greater than 1000 and then pressed to reduce the liquid content of the treated fibre to a figure below the normal water imbibition of the fibre in the gel state. After curing, the treated fibres are said to exhibit good processability without fibre breakage, good handle, even dyeability (after spinning/weaving) and improved tensile properties in comparison with fibres treated by other impregnation processes. A paper entitled "Precipitation and Crystallisation of Cellulose from Amine Oxide Solutions" by M Dubé & R H Blackwell in Proceedings of the Technical Association of the Pulp and Paper Industry, 1983 Dissolving and Specialty Pulps Conference, TAPPI Press (1983), pages 111-119, discloses cellulose fibres prepared by solvent-spinning a solution of cellulose in a tertiary amine oxide such as N-methylmorpholine N-oxide. The fibres can be treated with a textile resin of the glyoxal resin type. The resin acts as a cross-link between fibrillar elements in the fibres; and because the resin is cured when the sample is dried, the fibrils are cross-linked in the compacted state. Upon rewetting, swelling is restricted and no regular fibril separation takes place. This accords with the teaching of the article entitled "Textile Resins" discussed hereinabove, that resin-finishing reduces the accessibility of cellulose fibres to dyestuffs. WO-A-92/19807 in the name of the applicant has a filing date of 24th April 1992 and was published on 12th November 1992, both dates being after the filing date of the present application, although its priority date is 25th April 1991. It is therefore prior art only by virtue of Article 54(3) EPC. It discloses the dyeing of never-dried solvent-spun cellulose fibre with at least one cationic direct dye. However, these dyes are not polyfunctional fibre-reactive dyes and no mention is made in that application of any change in fibrillation tendency. WO-A-92/07124 in the name of the applicant was published on 30th April 1992, after the filing date of the present application, although its priority date is 12th October 1990 and its filing date is 11th October 1991. It, too, is therefore prior art only by virtue of Article 54(3) EPC. It discloses the reduction of fibrillation tendency of solvent-spun cellulose fibre by treatment of never-dried fibre with an aqueous dispersion or solution of a polymer having a plurality of cationic ionisable groups, such as imidazoline or azetidinium groups. However, there is no reference to treatment with polyfunctional fibre-reactive dyes. The wet fibre may be crosslinked with glyoxal. The fibres may subsequently be dyed (after spinning). The present invention addresses the need for a process which not only reduces the fibrillation tendency of solvent-spun cellulose fibres, but also produces no significant reduction in tenacity and extensibility and has no significant deleterious effect on processability. Maintaining a balance between all of the required properties of the solvent-spun fibre is extremely difficult because it is not sufficient to produce a fibre which will not fibrillate but which has a very low tenacity or a very low extensibility or a very poor processability. In some cases it would also be unsatisfactory to produce a fibre which would he unsuitable for subsequent dyeing. According to the present invention, for providing a solvent-spun cellulose fibre with a reduced fibrillation tendency a process is provided which is characterised in that the fibre is treated with a chemical reagent which is a fibre-reactive dyestuff having two to six functional groups reactive with cellulose which reagent is applied from an aqueous system to never dried solvent-spun cellulose fibres and is caused to react therewith under alkaline conditions. Fibrillation of cellulose fibres as herein described is believed to be due to mechanical abrasion of the fibres whilst being processed in a wet and swollen form. Solvent-spun fibres appear to be particularly sensitive to such abrasion and are consequently more susceptible to fibrillation than other types of cellulose fibres. Higher temperatures and longer times of wet processing tend to lead to greater degrees of fibrillation. Wet treatment processes such as dyeing processes inevitably subiect fibres to mechanical abrasion. Reactive dyes generally demand the use of more severe dyeing conditions than other types of dyes, for example direct dyes, and therefore subject the fibres to correspondingly more severe mechanical abrasion. It was therefore both remarkable and unexpected to find that the selection as chemical reagent in accordance with the invention of polyfunctional reactive dyes from the class of dyes suitable for dyeing cellulose should produce a lower degree of fibrillation than for example monofunctional reactive dyes or direct dyes. The treated fibre is suitable for dyeing in any manner known for cellulose fibres, yarns or fabrics. The functional groups reactive with cellulose may be any of those known in the art. Numerous examples of such groups are given in the above-mentioned article entitled "Dyes, Reactive". Preferred examples of such functional groups are reactive halogen atoms attached to a polyazine ring, for example fluorine, chlorine or bromine atoms attached to a pyridazine, pyrimidine or sym-triazine ring. Other examples of such functional groups include vinyl sulphones and precursors thereof. Each functional group in the reagent may be the same or different. The chemical reagent preferably contains at least one ring with at least two, in particular two or three, reactive functional groups attached thereto. Examples of such rings are the polyhalogenated polyazine rings hereinbefore mentioned. Such reagents have been found to be more effective at reducing the fibrillation tendency than reagents in which the functional groups are more widely separated, for example reagents in which two monohalogenated rings are linked together by an aliphatic chain. One preferred type of reagent contains one ring having two reactive functional groups attached thereto. Other types of reagent, which may also be preferred, contain two or three rings linked by aliphatic groups and having two reactive functional groups attached to each ring. Preferred types of reagent include reagents containing a dichlorotriazinyl, trichloropyrimidinyl, chlorodifluoropyrimidinyl, dichloropyrimidinyl, dichloropyridazinyl, dichloropyridazinonyl, dichloroquinoxalinyl or dichlorophthalazinyl group. Other preferred types of dye include dyes having at least two vinyl sulphone, beta-sulphatoethyl sulphone or beta-chloroethyl sulphone groups attached to a polyazine ring. The chemical reagent is applied to the fibre in an aqueous system, preferably in the form of an aqueous solution. The chemical reagent may contain one or more solubilising groups to enhance its solubility in water. A solubilising group may be an ionic species, for example a sulphonic acid group, or a nonionic species, for example an oligomeric poly(ethylene glycol) or poly(propylene glycol) chain. Nonionic species generally have less effect on the essential dyeing characteristics of the cellulose fibre than ionic species and may be preferred for this reason. The solubilising group may be attached to the chemical reagent by a labile bond, for example a bond which is susceptible to hydrolysis after the chemical reagent has reacted with the cellulose fibre. The known processes for the manufacture of solvent-spun cellulose fibres include the steps of: (i) dissolving cellulose in a solvent to form a solution, the solvent being miscible with water; (ii) extruding the solution through a die to form a fibre precursor; (iii) passing the fibre precursor through at least one water bath to remove the solvent and form the fibre; and (iv) drying the fibre. The wet fibre at the end of step (iii) is never-dried fibre, and typically has a water imbibition in the range 120-150%. The dried fibre after step (iv) typically has a water imbibition of around 60-80%. In the invention, the fibre is treated with the chemical reagent in its never dried state, that is to say, during or after step (iii) but before step (iv). The fibre may be in the form of staple fibre or tow, depending on the configuration of the equipment. An aqueous solution of the chemical reagent may for example be applied to the never-dried fibre by means of a circulating bath, spray or bubbler. The method of treatment of the invention may be carried out using conventional techniques for reactive dyestuffs, in which the chemical reagent is used in the same or similar manner as a reactive dyestuff. In this embodiment, the method may be carried out on tow or staple fibre. If the treatment is performed before or after dyeing, the fibre is preferably not dried between the treatment and dyeing processes. The method of treatment may be carried out using a dye bath which contains both a monofunctional reactive dyestuff and the chemical reagent, which is itself a reactive dyestuff. The method of treatment may be carried out using a bath containing more than one type of chemical reagent, for example one or more dyestuffs and one or more substantially colourless reagents. The functional groups in any such dyestuffs and reagents may be the same or different chemical species. The functional groups reactive with cellulose in reactive dyes as well as in the chemical reagents used in the present invention may react most rapidly with cellulose under alkaline conditions. Examples of such functional groups are the halogenated polyazine rings hereinbefore mentioned. Such chemical reagents may therefore be applied from weakly alkaline solution, for example from a solution made alkaline by the addition of sodium carbonate (soda ash), sodium bicarbonate or sodium hydroxide. Alternatively, the fibre may be made alkaline by treatment with mild aqueous alkali in a first stage before treatment in a second stage with the solution of the chemical reagent. The first stage of this two-stage technique is known in the dyeing trade as presharpening. It has the advantage that hydrolysis of the functional groups in the solution of the reagent is reduced, since hydrolysis of such groups is more rapid under alkaline conditions. The solution of the chemical reagent used in the second stage of the two-stage technique may or may not contain added alkali. If the two-stage technique is used then preferably substantially all the alkali is applied in the first stage. Fibre treated in this manner has generally and surprisingly been found to have a lower fibrillation tendency than in the case when alkali is applied in both of the stages. It has surprisingly also been found that the fibrillation tendency of the treated fibre may be less after a two-stage treatment in which substantially all the alkali is added in the first stage than after a single stage treatment, although the reason for this is not known. This two-stage technique is accordingly a preferred method of putting the invention into practice. The functional groups of the chemical reagent may react with cellulose at room temperature, but it is generally preferable to apply heat to induce a substantial degree of reaction. For example, the reagent may be applied using a hot solution, or the fibre wetted with the reagent may be heated or steamed, or the wetted fibre may be heated to dry it. Preferably, the wetted fibre is steamed because this method of heating has generally been found to yield fibre with the lowest fibrillation tendency. Low-pressure steam is preferably used, for example at a temperature of 100 to 110°C, and the steaming time is typically 4 seconds to 20 minutes, more narrowly 5 to 60 seconds or 10 to 30 seconds. In chemical reagents carrying more than one of a particular type of functional group, it is often found that the functional groups have different reactivities. This is true for example for the polyhalogenated polyazines hereinbefore mentioned. The first halogen atom reacts more rapidly with cellulose than a second or subsequent halogen atom. The method of the invention may be carried out under conditions such that only one such functional group reacts during the treatment stage, and the remaining functional group or groups is or are caused to react subsequently, for example by the application of heat during steaming or drying or by the application of alkali during subsequent fabric wet processing. The fibre may be rinsed with a mildly acidic aqueous solution, for example a weak solution of acetic acid, after reaction of the chemical reagent with the cellulose in order to neutralise any added alkali. The fibre may be treated with 0.1 to 10%, preferably 0.2 to 5%, further preferably 0.2 to 2%, by weight of the chemical reagent, although some of the reagent may be hydrolysed and so not react with the fibre. In the preferred form of the invention the chemical reagent may be reacted with the cellulose fibre so that less than 20%, and preferably less than 10% and further preferably 5% or less, of the dye sites on the cellulose fibre are occupied, so as to permit subsequent further colouration of the fibre with coloured dyes which may or may not be reactive dyes. The treated cellulose fibres, particularly in the form of fabrics made from such fibres, may be further treated with a cellulase enzyme to remove surface fibrils. The cellulase enzyme may be in the form of an aqueous solution, and the concentration may be in the range 0.5% to 5%, preferably 0.5% to 3%, by weight. The pH of the solution may be in the range 4 to 6. There may be a nonionic detergent in the solution. The fabric may be treated at a temperature in the range 20°C to 70°C, preferably 40°C to 65°C, further preferably 50°C to 60°C, for a period in the range 15 minutes to 4 hours. This cellulase treatment may be utilised to remove fibrils from solvent-spun fibres, yarns and fabrics which have been treated with a chemical reagent according to the method of the invention. Solvent-spun cellulose fibre is commercially available from Courtaulds Fibres Limited. The invention is illustrated by the following Examples. Fibre was assessed for degree of fibrillation using the method described below as Test Method 1 and assessed for fibrillation tendency using the techniques described below as Test Methods 2-4. Test Method 1 (Assessment of Fibrillation) There is no universally accepted standard for assessment of fibrillation, and the following method was used to assess Fibrillation Index. A series of samples of fibre having nil and increasing amounts of fibrillation was identified. A standard length of fibre from each sample was then measured and the number of fibrils (fine hairy spurs extending from the main body of the fibre) along the standard length was counted. The length of each fibril was measured, and an arbitrary number, being the product of the number of fibrils multiplied by the average length of each fibril, was determined for each fibre. The fibre exhibiting the highest value of this product was identified as being the most fibrillated fibre and was assigned an arbitrary Fibrillation Index of 10. The wholly unfibrillated fibre was assigned a Fibrillation Index of zero, and the remaining fibres were evenly ranged from 0 to 10 based on the microscopically measured arbitrary numbers. The measured fibres were then used to form a standard graded scale. To determine the Fibrillation Index for any other sample of fibre, five or ten fibres were visually compared under the microscope with the standard graded fibres. The visually determined numbers for each fibre were then averaged to give a Fibrillation Index for the sample under test. It will be appreciated that visual determination and averaging is many times quicker than measurement, and it has been found that skilled fibre technologists are consistent in their rating of fibres. Test Method 2 (Scour, Bleach, Dye) (i) Scour 1 g fibre was placed in a stainless steel cylinder approximately 25 cm long by 4 cm diameter and having a capacity of approximately 250 ml. 50 ml of a conventional scouring solution containing 2 g/l Detergyl (an anionic detergent) (Detergyl is a Trade Mark of ICI plc) and 2 g/l sodium carbonate was added, a screw cap fitted, and the capped cylinder tumbled end-over-end at 60 tumbles per minute for 60 minutes at 95°C. The scoured fibre was then rinsed with hot and cold water. (ii) Bleach 50 ml of a bleaching solution containing 15 ml/l 35% hydrogen peroxide, 1 g/l sodium hydroxide, 2 g/l Prestogen PC as a peroxide stabiliser (Prestogen is a Trade Mark of BASF AG) and 0.5 ml/l Irgalon PA as a sequestrant (Irgalon is a Trade Mark of Ciba Geigy AG) was added to the fibre and a screw cap fitted to the cylinder. The cylinder was then tumbled as before for 90 minutes at 95°C. The bleached fibre was then rinsed with hot and cold water. (iii) Dye 50 ml of a dyeing solution containing 8%, on weight of fibre, Procion Navy HER 150 (Procion is a Trade Mark of ICI plc) and 55 g/l Glauber's salt was added, the cylinder capped, and tumbled as before for 10 minutes at 40°C. The temperature was raised to 80°C and sufficient sodium carbonate added to give a concentration of 20 g/l. The cylinder was then capped once more and tumbled for 60 minutes. The fibre was rinsed with water. 50 ml of a solution containing 2 ml/l Sandopur SR (an anionic detergent) (Sandopur is a Trade Mark of Sandoz Ltd) was then added and the cylinder capped. The cylinder was then tumbled as before for 20 minutes at 100°C. The dyed fibre was then rinsed and dried. It was then assessed for fibrillation using Test Method 1. Test Method 3 (Ball Bearing) 1 g fibre was placed in a 200 ml metal dye pot together with 100 ml of a solution containing 0.8 g/l Procion Navy HER 150 (Procion is a Trade Mark of ICI plc), 55 g/l Glauber's salt and a 2.5 cm diameter ball bearing. The purpose of the ball bearing was to increase the abrasion imparted to the fibre. The pot was then capped and tumbled end-over-end at 60 tumbles per minute for 10 minutes at 40°C. The temperature was raised to 80°C and sufficient sodium carbonate added to give a concentration of 20 g/l. The pot was then capped once more and tumbled for 3 hours. The ball bearing was then removed and the fibre rinsed with water. 50 ml of a solution containing 2 ml/l Sandopur SR (an anionic detergent) (Sandopur is a Trade Mark of Sandoz Ltd) was then added and the cylinder capped. The cylinder was then tumbled as before for 20 minutes at 100°C. The dyed fibre was then rinsed and dried. It was then assessed for fibrillation using Test Method 1. Test Method 3 provides more severe fibrillating conditions than Test Method 2. Test Method 4 (Blender) 0.5 g fibre cut into 5-6 mm lengths and dispersed in 500 ml water at ambient temperature was placed in a household blender (liquidiser) and the blender run for 2 minutes at about 12000 rpm. The fibre was then collected, dried and assessed for fibrillation using Test Method 1. Test Method 4 provides more severe fibrillating conditions than either Test Method 2 or Test Method 3. The following Examples relate to the use of coloured chemical reagents (dyestuffs) for the treatment of solvent-spun cellulose fibre. Example 1 (not according to invention) In a first series of tests using dyes solvent-spun cellulose staple fibre was dyed, the dyed fibre processed into yarn by conventional spinning techniques, and the yarn woven into fabric for evaluation of the effect of the different dyes on fibrillation. The details of the dyeing of the fibre sample were as follows:- In each case the fibre was pretreated before dyeing as follows: 2g of fibre was first placed in a stainless steel cylinder approximately 25 cm high by 4 cm diameter. The cylinder had a capacity of approximately 250 ml, and at each step in the treatment 50 ml of solution was added to the 2 g of fibre. The first step was to scour the fibre to remove the spinning lubricant. A conventional scouring solution of anionic detergent and Na 2 CO 3 at 94°C was added to the fibre, a screw cap was applied, and the capped cylinder was tumbled end-over-end for 45 minutes at about 60 tumbles per minute. The scouring solution was then removed and the fibres were washed in water and bleached for 1 hour at 95°C. Again the cylinder was capped and tumbled at 60 tumbles per minute. The bleaching solution used contained:- 7.5 ml/l H 2 O 2 (at 35% concentration) 1 g/l NaOH solid 1 g/l of a peroxide stabiliser and heavy metal sequestrant ("Contovan SNF" available from CHT Products Limited) After bleaching, the fibres were washed and dyed using the dyes listed below. The dyeing procedures for each dye are also set out below. Dyes Used Dye Colour Index Reactive Group(s) Procion Red MX-5B Reactive Red 2 Dichlorotriazine Drimarene Red K-4BL Reactive Red 147 Fluorochloropyrimidine Sumifix Supra Red 3BF Reactive Red 195 Vinyl sulphone/monochlorotriazine Procion Red H8BN Reactive Red 58 Monochlorotriazine Solar Red BA Direct Red 80 None (Procion is a Trade Mark of ICI plc. Drimarene and Solar are Trade Marks of Sandoz Ltd. Sumifix is a Trade Mark of Sumitomo Corporation.) The application method for dyeing the fibre differed as to whether the fibres were dyed with reactive dyes or the direct dye. In the case of reactive dyes, the stainless steel cylinder containing the fabric was partially filled with a solution of dyestuff at a temperature in the range 25 to 30°C. 4% by weight dyestuff (on the weight of dry fibre used) was incorporated into the bath. The cylinder was then capped and tumbled end-over-end at about 60 tumbles per minute for 10 minutes. The cylinder was then stopped and uncapped and sodium chloride was added at the rate of 50 to 80 g/l. The cylinder was again capped and tumbled at 60 tumbles per minute for 10 minutes. The cap on the cylinder was loosened and the cylinder heated at a rate of 2°C per minute until the dyeing temperature was reached. In the case of the Procion MX dye the temperature was raised to 30°C, in the case of Drimarene K the temperature was raised to 40°C, in the case of Procion H the temperature was raised to 80°C and in the case of Sumifix Supra the temperature was raised to 60°C. After the specified temperature had been reached 5 to 20 g/l of sodium carbonate was added to the solution in the cylinder and the cylinder was again capped. The cylinder was then tumbled at 60 tumbles per minute for 60 minutes. The fibre was then removed from the cylinder and rinsed in clear water. The fibre was then replaced in the cylinder and washed with an anionic detergent for 15 minutes at 95°C. 2 g/l of anionic detergent was used. After the treatment with the detergent the fibre was rinsed with running water until the water ran clear. In the case of the direct dye the cylinder was filled with a solution of dyestuff having 4% dyestuff by weight of dry fibre at a temperature of 40°C. The fibre was added, the cylinder capped and tumbled at 60 tumbles per minute for 10 minutes. The cylinder was then loosely uncapped and heated to 95°C at 2°C per minute. The cylinder was recapped and tumbled for 10 minutes at 60 tumbles per minute after which 20 g/l of sodium chloride was added. After recapping, the cylinder was again tumbled at a rate of 60 tumbles per minute for 60 minutes. The fibre was then removed from the cylinder and simply rinsed until the rinse water ran clear. After dyeing and washing, the fibres were dried. The fibres were then assessed for the amount of fibrillation, fibre tenacity, fibre extensibility and water imbibition (W.I.). Tenacity (in centiNewton/tex) and extensibility (in per cent) were measured using conventional equipment, and again several samples (usually ten) were measured and an arithmetic mean calculated. Results Dye Tenacity cN/tex Extensibility % W.I.% Fibrillation Index Procion Red MX-5B 41.4 13.3 63.8 1.2 Drimarine Red K-4BL 41.8 14.0 63.5 0.9 Sumifix Supra Red 3BF 40.6 13.4 65.1 1.8 Procion Red H8BN 42.0 13.6 66.0 2.7 Solar Red BA 41.7 14.1 66.4 3.0 Undyed Control 40-42 13-15 63-65 3 The control sample was treated using the conditions described above for Direct Red 80, but without the use of any dyestuff in the dye bath. From Table I it can be seen that three of the reactive dyes, namely Procion Red MX-5B, Drimarene Red K-4BL and Sumifix Supra Red 3BF, are bireactive dyes in the sense that each of these three dyes has two functional groups reactive with cellulose. In the case of the Procion Red MX-5B dye there are two chlorine atoms on a triazine ring. In the case of the Drimarene Red dye there is one fluorine atom and one chlorine atom on a pyrimidine ring. In the case of the Sumifix Supra Red dye there is one chlorine atom and one vinyl sulphone group on the triazine ring. In the case of the Procion Red H8BN dye, however, there is only one reactive functional group, namely a single chlorine atom on the triazine ring. In the case of the Solar Red BA Direct dye there is, of course, no reactive functional group at all. Reviewing the figures in Table II, it can be seen that the all five dyes had very little effect on the tenacity, extensibility or water imbibition of the fibre compared to the undyed control fibre. Considering, however, the effect of the dyes on the fibrillation characteristics of the fibre it can be seen that the Direct dye gave effectively no reduction in fibrillation tendency at all compared to the undyed fibre. The Reactive Red 58 dye Procion Red H8BN - having a single reactive group - had very little effect on the fibrillation tendency of the fibre. In contrast, the three reactive dyes which are bireactive, namely Reactive Red 2 (Procion Red MX-5B), Reactive Red 147 (Drimarene Red K-4BL) and Reactive Red 195 (Sumifix Supra Red 3BF), all gave significant improvements in the resistance of the fibre to fibrillation. These improvements were, however, obtained as mentioned above without any significant effect on the other measured properties of the fibre. Example 2 (not according to invention) Rather than being dyed in fibre form (whether in the dried or never dried state), solvent-spun cellulosic fibre may be spun into yarn, formed into fabric and then dyed as fabric. Alternatively, the yarn may be dyed as yarn. The following dyeing trials were carried out on undyed fabric. Dyes Used Dye Colour Index Reactive Group(s) Procion Blue MX-R Reactive Blue 4 Dichlorotriazine Drimarene Blue K-BL Reactive Blue 114 Fluorochloropyrimidine Procion Blue H-4R Reactive Blue 74 Monochlorotriazine Solophenyl Blue A-GFL Direct Blue 212 None After dyeing by the same method as used for the corresponding Red dyes listed in Example 1, the fabrics were subjected to five cycles of a domestic wash at 60°C each followed by tumble drying. The degree of fibrillation was then assessed and the samples ranked in order:- Drimarene Blue K-BL - No fibrillation Procion Blue MX-R - No fibrillation Procion Blue H-4R - High fibrillation Solophenyl Blue A-GFL - High fibrillation Because the samples were in fabric form rather than in fibre form it was not possible to produce fibrillation indexes for the material. However, the two samples dyed with bireactive dyes, namely Drimarene Blue K-BL and Procion Blue MX-R, showed no fibrillation. The sample dyed with a monoreactive dye, namely Procion Blue H-4R, had a frosted appearance associated with a highly fibrillated material. Similarly, the fabric dyed with the direct dye Solophenyl Blue A-GFL was also highly fibrillated. Example 3 (partly according to invention) In a yet further series of tests, the same dyes and same conditions as in Example 2 were used to dye never-dried cellulosic fibres. Test results for tenacity, extensibility, water imbibition (W.I.) and Fibrillation Index are given in Table IV. Test Results Dye Tenacity cN/tex Extensibility % W.I.% Fibrillation Index Reactive Blue 4 41.1 13.1 64.3 1.3 Reactive Blue 114 39.9 13.3 65.1 0.8 Reactive Blue 74 40.7 13.9 63.8 2.4 Direct Blue 212 42.0 13.8 65.7 2.9 Again, it can be seen that the two samples dyed with the bireactive dyes Reactive Blue 4 and Reactive Blue 114 (according to the invention) were very lightly fibrillated. The fibre dyed with the monoreactive dye Reactive Blue 74 (comparative) was heavily fibrillated and the fibre dyed with the direct dye Direct Blue 212 (comparative) was a so heavily fibrillated. No significant differences in tensile properties or water imbibition were observed. To further improve the appearance and handle of the fabric obtainable, it may preferably be further treated with cellulase enzymes, as illustrated below. Cellulase enzymes work by cleaving the beta-1,4-glycoside bond in the cellulose converting it to soluble glucose. As a result of this hydrolytic effect, the fabric becomes smooth due to loss of the surface fibre and the handle becomes softer. This hydrolytic effect will also result in a negative effect on fabric strength. On solvent-spun cellulose fabrics, cellulase enzymes have been found to be extremely effective at removing fibrillation that has occurred during the dyeing process. A number of cellulase enzymes were tested on a badly fibrillated solvent-spun cellulose woven fabric. The effectiveness of each enzyme was numerically assessed by carrying out a colour difference measurement before and after treatment. The higher the total colour difference (DE) the more effective the treatment due to removal of the apparently white surface fibrils. The system is most applicable on a batchwise system as the mechanical agitation of a winch or jet machine is beneficial at removing loose fibres. Standard process: x% by weight cellulase 0.75 g/l Rucogen SAS (nonionic detergent) pH set as required 60 mins 55-60°C Enzyme pH Max Conc DE Manufacturer Cytolase 123 4.8 1.5% 1.4 Genencor Rucolase CEL 4.8 1.0% 1.3 Rudolf Celluclast 4.8 1.0% 1.0 Novo All the above enzymes are-acid activated. The maximum concentrations quoted are maximum percentages by weight of enzyme that have been found to be able to be used without resulting in a strength loss of greater than 10%. Strength losses of up to 30% can occur with high enzyme concentration and extended treatment times, but this may make the fabric unacceptably weak for many applications. Two neutral activated systems were also evaluated. These have the advantage that strength losses are very low (less than 5%) even at high concentrations of cellulase enzymes but the effectiveness at removing fibrillation is reduced. Enzyme Conc(wt) DE Manufacturer Deltazyme 3% 0.9 Rexodan Denimax 3% 0.85 Novo The following characteristics of the process have been determined by these trials:- i) Acid-activated enzymes display much higher activity than their neutral counterparts. ii) Concentrations and times should be carefully controlled to prevent excessive strength losses. iii) Every fabric will be affected to a lesser or greater degree; preliminary trials should be carried out to define the degree of fibre loss that will yield a smoother, softer product and still maintain adequate strength. iv) Inclusion of a nonionic detergent assists action. Enzyme treatment is preferably carried out as a discrete step, which makes the control of pH, time and temperature easier to achieve. The cellulase enzyme treatment may also be carried out (not according to the invention) on undyed solvent-spun material, or on solvent-spun material not treated with a chemical reagent having two to six functional groups per molecule reactive with cellulose.

Claims: A process for treating a solvent-spun cellulose fibre to reduce its fibrillation tendency, characterised in that a chemical reagent which is a fibre-reactive dyestuff having two to six functional groups reactive with cellulose is applied from an aqueous system to never-dried solvent-spun cellulose fibre and is caused to react therewith under alkaline conditions. A process according to claim 1, further characterised in that the chemical reagent contains at least one ring having at least two functional groups reactive with cellulose attached thereto. A process according to claim 2, further characterised in that the chemical reagent contains one ring having two or three functional groups reactive with cellulose attached thereto. A process according to either of claims 2 and 3, further characterised in that the or each ring is a polyazine ring. A process according to claim 4, further characterised in that the or each ring is selected from pyridazine, pyrimidine and sym-triazine rings. A process according to either of claims 4 and 5, further characterised in that at least one of the functional groups reactive with cellulose is a fluorine, chlorine or bromine atom attached directly to the ring. A process according to claim 6, further characterised in that the chemical reagent contains a dichlorotriazinyl, tri- chloropyrimidinyl, chlorodifluoropyrimidinyl, dichloropyrimidinyl, dichloropyridazinyl, dichloropyridazinonyl, dichloroquinoxalinyl or dichlorophthalazinyl group. A process according to any of claims 2 to 5, further characterised in that at least one of the functional groups reactive with cellulose is a vinyl sulphone group or precursor thereof. A process according to any preceding claim, further characterised in that the chemical reagent contains a solubilising group to enhance its solubility in water. A process according to claim 9, further characterised in that the solubilising group is a sulphonic acid group or an oligomeric poly(ethylene glycol) or poly(propylene glycol) chain. A process according to any preceding claim, further characterised in that the fibre is treated with 0.1 to 10% by weight of the chemical reagent. A process according to claim 11, further characterised in that the fibre is treated with 0.2 to 5% by weight of the chemical reagent. A process according to claim 12, further characterised in that the fibre is treated with 0.2 to 2% by weight of the chemical reagent. A process according to any preceding claim, further characterised in that the chemical reagent is applied to the fibre in the form of an aqueous solution. A process according to any precding claim, further characterised in that the never-dried fibre after reaction with the chemical reagent is first dried and is subsequently dyed with a conventional dyestuff for cellulose. A process according to claim 14, further characterised in that the solution of the chemical reagent is applied to the fibre, and the fibre without having been dried is then dyed with a conventional dyestuff for cellulose. A process according to any of claims 14 to 16, further characterised in that the fibre is treated with the aqueous solution of the chemical reagent under mildly alkaline conditions. A process according to any of claims 14 to 17, further characterised in that the fibre is treated with a mildly alkaline aqueous solution before treatment with the solution of the chemical reagent. A process according to claim 18, further characterised in that the solution of the chemical reagent contains no added alkali. A process according to any preceding claim, further characterised in that the treated fibre is heated to induce a substantial degree of reaction between the cellulose and the functional groups reactive with cellulose. A process according to claim 20, further characterised in that the treated fibre is heated using steam. A process according to claim 21, further characterised in that the treated fibre is heated using steam at a temperature of 100 to 110°C for 4 seconds to 20 minutes. A process according to any preceding claim, further characterised in that the treated fibre is subsequently treated with an aqueous solution of a cellulase enzyme.

Inventors: TAYLOR JAMES MARTIN, TAYLOR, JAMES MARTIN
Applicants: TENCEL LTD, TENCEL LIMITED
Application year: 1992
Main classification: D06M13
IPC codes: D06M13, D01F11, D01F2, D06P1, D06M16, D06M11, D06P3