METHODS OF ENHANCING PRINTING QUALITY OF DYE COMPOSITIONS ONTO COTTON FABRICS

Abstract: Disclosed are methods for enhancing the quality of printing on cotton-containing fabrics. Specifically, these methods disclosed herein recite the pretreatment of cotton-containing fabrics with cellulase prior to printing with a dye in order to enhance printing characteristics on the fabric such as dye uptake, enhanced clarity, reduced dye bleeding, and the like. The methods disclosed herein generally entail treating cotton-containing fabrics with an aqueous cellulase formulation and preferably with an aqueous cellulase solution under agitating conditions.

Description: METHODS OF ENHANCING PRINTING QUALITY OF DYE COMPOSITIONS ONTO COTTON FABRICS BACKGROUND OF THE INVENTION 1. Field of the Invention. This invention is directed to methods for enhancing the quality of printing on resinated and non-resinated cotton fabrics using colorant compositions containing a dye. Specifically, this invention is directed to methods of pretreating resinated and non-resinated cotton fabrics with an aqueous cellulase formulation prior to printing an image onto the fabric with a dye composition so as to enhance printing qualities on the fabric such as reduced dye bleeding. The methods disclosed herein generally entail treating cotton fabrics with an aqueous cellulase formulation followed by drying the fabrics and then printing on the fabrics with a dye composition. 2. State of the Art. Aesthetic and/or informational images are often placed on cotton fabrics with dye or pigment (i.e., colorant compositions) compositions by methods such as silk screening, painting, etc. While such methodology is well known in the art, these methods entail numerous problems which must be overcome in order to impart and retain quality images on cotton fabrics. Specifically, the placement of an image onto a cotton fabric can result in bleeding of the colorant composition into the fabric. Bleeding occurs because of diffusion of the colorant composition beyond its intended boundary and leads to blurring of the image and loss of resolution. In order to overcome this problem, the colorant composition to be used will generally incorporate an additive which minimizes bleeding. Specifically, with dye compositions, a thickener is generally employed whereas, with pigment compositions, a binder/extender is generally employed. One of the functions of these additives is to provide sufficient viscosity to the colorant composition so that, upon application to cotton fabrics, the composition is resistant to bleeding. A problem with this approach is that the optimum level of thickener or binder for one type of cotton fabric (e.g. , knits) is often different from the optimum level of thickener or binder for another type of cotton fabric (e.g., wovens) . Moreover, some cotton fabrics are more susceptible to bleeding than others and accordingly, even when a thickener or binder is employed at an optimum level, the colorant composition may still exhibit some bleeding. This problem of colorant bleeding is a particular problem with dye compositions and imparts a significant impediment to providing high quality cotton fabrics having images painted or silk-screened thereon using such a dye composition. The present invention is directed to the discovery that pretreating cotton fabrics with an aqueous cellulase formulation, preferably under conditions of agitation, prior to printing an image on the fabric with a dye composition, results in significant and unexpected improvements in reducing the extent of bleeding into the fabric. Additionally, when so treated, other benefits can be imparted to certain fabrics (e.g., dye uptake is improved when resinated fabrics are first treated with cellulase and when non-resinated fabrics are treated with a high concentration of cellulase) . While treatment of cotton fabrics with an aqueous cellulase formulation (including treatment under agitation) has heretofore been suggested in the art, there appears to be no suggestion in the art of using such conditions as a pre-treatment for printing processes, such as silk-screening and painting, using a dye composition. SUMMARY OF THE INVENTION This invention is directed to printing methods for imparting an image onto a cotton-containing fabric which methods enhance the quality of printing with a dye composition on such cotton-containing fabrics. The methods of this invention entail the pretreatment of a cotton-containing fabric with an aqueous cellulase formulation prior to printing an image onto the fabric with a dye composition. Accordingly, in one of its method aspects, the present invention is directed to a method for printing an image onto a cotton-containing fabric with a dye composition which method comprises the steps of: (a) contacting a cotton-containing fabric with an aqueous formulation comprising at least about 50 ppm of cellulase proteins at a temperature of from about 25*C to about 70*C for at least 0.1 hours wherein the aqueous formulation is maintained at a pH where the cellulase has activity; (b) drying the fabric; and (c) printing an image on the fabric with a dye composition. The improvements in print quality seen in the examples of this invention include, for example, reduced dye bleeding and, in some cases, improved dye uptake. In a preferred embodiment, the aqueous cellulase formulation is an aqueous cellulase solution which is agitated during contact with the cotton-containing fabric. In another preferred embodiment, cellulase, including cellulase proteins, is inactivated on the cotton-containing fabric before printing an image on the fabric. Inactivation of the cellulase can be accomplished either in a step separate from the drying step or the cellulase can be inactivated during the drying step by employing drying conditions sufficient to inactivate the cellulase. In one of its composition aspects, the present invention is directed to cotton-containing fabrics prepared in the methods described herein. DETAILED DESCRIPTION OF THE INVENTION As noted above, the present invention is directed to methods which enhance the quality of printing on cotton-containing fabrics using a dye composition. The methods of this invention entail the pretreatment of the fabric with an aqueous cellulase formulation, preferably in an aqueous cellulase solution under conditions which agitate the fabric in solution. However, prior to discussing this invention in further detail, the following terms will first be defined: 1. Definitions As used herein, the following terms will have the following meanings: The term "cotton-containing fabric" refers to resinated and non-resinated fabrics made of pure cotton or cotton blends including cotton woven fabrics, cotton knits, cotton denims, cotton yarns and the like. When cotton blends are employed, the amount of cotton in the fabric should be at least about 40 percent by weight cotton; preferably, more than about 60 percent by weight cotton; and most preferably, more than about 75 percent by weight cotton. When employed as blends, the companion material employed in the fabric can include one or more non-cotton fibers including synthetic fibers such as polyamide fibers (for example, nylon 6 and nylon 66) , acrylic fibers (for example, polyacrylonitrile fibers), and polyester fibers (for example, polyethylene terephthalate) , polyvinyl alcohol fibers (for example, Vinylon) , polyvinyl chloride fibers, polyvinylidene chloride fibers, polyurethane fibers, polyurea fibers, aramid fibers, and the like. The term "resin" or "resinous finish" employed herein refers to those commonly employed and well known resin finishes which impart desirable improvements to cotton fabrics including cotton fabrics made of pure cotton or cotton blends. Such resins generally employ formaldehyde and include, by way of example, methylol urea (which is a mono eric condensation product of urea and formaldehyde) , melamine formaldehyde, and the like. When employed on cotton fabrics, such resins impart one or more desirable properties to the fabric including wrinkle resistance, shrinkage control, durable embossing, durable glazing, and the like. Cotton fabrics which include such a resin are referred to as "resinated cotton-containing fabrics" whereas cotton fabrics which do not include such a resin are referred to as "non-resinated cotton-containing fabrics". The term "cellulase" as employed herein refers to an enzyme composition derived from a microorganism which acts on cellulose and/or its derivatives (e.g., phosphoric acid swollen cellulose) to hydrolyze cellulose and/or its derivatives and give primary products, including glucose and cellobiose. Such cellulases are synthesized by a large number of microorganisms including fungi, actinomycetes, gliding bacteria (mycobacteria) and true bacteria. Some microorganisms capable of producing cellulases useful in the methods recited herein are disclosed in British Patent No. 2 094 826A, the disclosure of which is incorporated herein by reference. Most cellulases generally have their optimum activity against cellulose and/or its derivatives in the acidic or neutral pH range. On the other hand, alkaline cellulases, i.e., cellulases showing optimum activity against cellulose and/or its derivatives in neutral or alkaline media, are also known in the art. Microorganisms producing alkaline cellulases are disclosed in U.S. Patent No. 4,822,516, the disclosure of which is incorporated herein by reference. Other references disclosing alkaline cellulases are European Patent Application Publication No. 269,977 and European Patent Application Publication No. 265,832, the disclosures of which are also incorporated herein by reference. Cellulase produced by a microorganism is sometimes referred to herein as a "cellulase system" to distinguish it from the classifications and components isolated therefrom. Such classifications are well known in the art and include exo-cellobiohydrolases ("CBH") , endoglucanases ("EG") and 3-glucosidases ("BG") . Additionally, there can be multiple components in each classification. For example, in the cellulase obtained from Trichoderma reesei, there are at least two CBH components, i.e., CBH I and CBH II, and at least three EG components, EG I, EG II and EG III. The different classifications are known in the art to synergistically interact with each other to provide enhanced activity against cellulose. Thus, while a cellulase system derived from any microorganism can be employed herein, it is preferred that the cellulase system contain at least one CBH component and at least one EG component so that enhanced cellulase activity is achieved. A preferred cellulase composition for use in this invention is one produced from a fungal source. A particularly preferred fungal cellulase composition for use in this invention is one produced by a naturally occurring fungal source and which comprises one or more CBH and EG components wherein each of these components is found at the ratio produced by the fungal source. Such compositions are sometimes referred to herein as complete fungal cellulase systems or complete fungal cellulase compositions to distinguish them from the classifications and components of cellulase isolated therefrom, from incomplete cellulase compositions produced by bacteria and some fungi, or from a cellulase composition obtained from a microorganism genetically modified so as to overproduce, underproduce or not produce one or more of the CBH and/or EG components of cellulase. The use of such complete fungal cellulase compositions appears to provide for optimal results in improving the quality of printing on cotton-containing fabrics with a dye composition. On the other hand, it is contemplated that some components or combination of components of cellulase may provide for improvements in the treatment of cotton- containing fabrics. For example, CBH type deficient/EG enriched cellulase compositions can be used so as to provide reduced strength loss in the cotton-containing fabric while also providing for the improvements recited herein. See, for example, U.S. Serial Nos. 07/677,385 and 07/678,865 which are incorporated herein by reference in their entirety. Additionally, it appears that CBH type enriched cellulase compositions may provide for improved dye uptake as compared to the dye uptake in a non-cellulase treated fabric. Methods for preparing CBH deficient and CBH enriched cellulases from Trichoderma reesei are recited in U.S. Serial No. 07/770,049 filed on October 4, 1991 as Attorney Docket No. 010055-076 and entitled "TRICHODERMA REESEI CONTAINING DELETED AND/OR ENRICHED CELLULASE AND OTHER ENZYME GENES AND CELLULASE COMPOSITIONS DERIVED THEREFROM". This application is incorporated herein by reference in its entirety. Similarly, methods to genetically manipulate Asperσillus nidulans which methods can be employed to prepare CBH deficient and CBH enriched cellulases in Asperσillus nidulans are disclosed by Miller et al., Molecular and Cellular Biology, Vol. 5, No. 7, pp. 1714-1721 (1985) which is incorporated herein by reference in its entirety. Such CBH deficient and CBH enriched cellulases can be used as cellulase compositions in the methods described herein. It is also contemplated that treatment of cotton- containing fabrics with cellulase as per this invention may be enhanced by use of a cellulase composition con- taining enhanced or deficient amounts of / S-glucosidase. Methods of modifying a microorganism to provide for enhanced or deficient amounts of 3-glucosidase are disclosed in U.S. Serial No. 07/807,028 filed on December 10, 1991 as Attorney Docket No. 010055-077 and entitled "IMPROVED SACCHARIFICATION OF CELLULASE BY CLONING AND AMPLIFICATION OF THE 0-GLUCOSIDASE GENE OF TRICHODERMA REESEI". This application is incorporated herein by reference in its entirety. The fermentation procedures for culturing cellulolytic microorganisms for production of cellulase are known per se in the art. For example, cellulase systems can be produced either by solid or submerged culture, including batch, fed-batch and continuous-flow processes. The collection and purification of the cellulase systems from the fermentation broth can also be effected by procedures known per se in the art. Preferred fungal cellulases for use in this invention are those obtained from Trichoderma reesei, Trichoderma koninσii. Pencilium sp. , Humicola insolens. and the like. Certain cellulases are commercially available, i.e., CELLUCAST (available from Novo Industry, Copenhagen, Denmark) , RAPIDASE (available from Gist Brocades, N.V. , Delft, Holland) , CYTOLASE 123 (available from Genencor International, Inc., Rochester, New York) and the like. Other cellulases can be readily isolated by art recognized fermentation and isolation procedures. The term "cellulase proteins" refer to any and all exo-cellobiohydrolase (CBH) proteins, endoglucanase (EG) proteins and β-glucosidase (BG) proteins contained in the cellulase composition. Accordingly, cellulase proteins do not include other proteins such as xylanases, proteases, amylases, etc. This invention is further directed to the discovery that it is the amount of cellulase proteins which are active on cotton fabric and not their specific activities on synthetic substrates which provide the improvements to the cotton-containing fabrics with regard to printing. The term "surface active agent or surfactant" refers to anionic, non-ionic and ampholytic surfactants well known in the art. The term "buffer" refers to art recognized acid/base reagents which stabilize the cellulase solution against undesired pH shifts during the cellulase treatment of the cotton-containing fabric. The term "aqueous cellulase formulation" means an aqueous formulation containing cellulase and optional additives such as surfactants, buffers, and the like. Such aqueous cellulase formulations include aqueous cellulase solutions, gels, pastes, and the like. In general, the aqueous cellulase formulation will contain a sufficient amount of cellulase proteins so as to provide enhancements in printing with dye compositions onto a cotton-containing fabric. Preferably, the aqueous cellulase formulation will contain at least about 50 ppm cellulase proteins, preferably, from about 50 ppm to about 2,000 ppm of cellulase proteins, and more preferably, from about 100 ppm to about 1000 ppm of cellulase proteins. In all cases where a ppm concentration of cellulase proteins is recited in this application, the ppm of cellulase proteins is based on the total amount of cellulase proteins in the aqueous formulation which amount is determined by first precipitating protein in trichloroacetic acid followed by the Lowry assay as provided by Sigma in Order No. 690-A. The term "dye" refers to any known dye useful with cotton-containing fabrics and includes, by way of example, reactive dyes, direct dyes, azoic dyes, and the like. The particular dye employed is not critical and is chosen relative to its color and its properties such as waterfastness, lightfaεtneεs, etc. Certain dyes which possess poor waterfastness properties can be used with a resin so as to improve their waterfastness. The term "dye composition" means an aqueous composition comprising a dye which is suitable for imparting an image onto cotton-containing fabrics. Such dye compositions additionally comprise materials generally incorporated into such compositions in order to improve or impart one or more of the properties of the composition. For example, a dye composition will generally include a thickener in order to provide suitable viscosity to the composition. Other additives for inclusion within such compositions include by way of examples, emulsifiers, fillers, etc. Dye compositions for use in this invention are well known in the art and are either commercially available or can be prepared by methods known per se in the art. Such dye compositions per se form no part of this invention. The term "printing" refers to methods for imparting an image on cotton-containing fabrics by dye composi¬ tions and include, by way of example, silk-screening, painting, and the like. Such methods are well known in the art and have been commercially employed. 2. Methodoloσy In the methods of the present invention, cotton- containing fabrics are pretreated with an aqueous cellulase formulation, preferably in an aqueous cellulase solution under conditions which result in the agitation of the cellulase solution with the fabric, prior to printing an image onto the fabric with a dye composition. Surprisingly, if the cotton-containing fabric is merely incubated in an aqueous cellulase formulation without agitation but under otherwise identical conditions, the resulting fabric will show some improvements in the quality of the printed images but not as much as when an aqueous cellulase solution is employed under agitation. Agitation suitable for use in this invention can be achieved by any mechanical and/or physical force which interacts with the cellulase solution so as to result in movement of the solution relative to the cotton- containing fabric. Such agitation can also result in fabric to fabric contact. Agitation suitable for use in the preferred ' methods of this invention can be achieved, for instance, by employing a laundrometer, a rotary drum, a jig, a jet, a ercerizer, a beck, a paddle machine, a Terg-O-tometer, a continuous bleach range, continuous wash range, a washing machine (both front and top load) , and the like. Other methods for achieving such agitation are well known in the art. The agitation employed herein is either repetitive (e.g., intermittent) or continuous agitation. For example, the cellulase solution can be continuously agitated by employing a laundrometer, a jet, a Terg-0- tometer, a top loaded washing machine and the like. In a laundrometer, the cotton-containing fabric is loaded into stainless steel water-tight canisters along with an aqueous cellulase solution. Continuous agitation is achieved by rotation of the fixed canisters on a frame within a temperature adjustable water bath. The degree of agitation is defined by the speed at which the canisters rotate. In a preferred embodiment, canisters rotated at a speed of at least about 40 revolutions per minute (rpms) achieve the agitation effect required in the herein described methods. Laundrometers are well known in the textile art and are generally employed as laboratory equipment. Suitable laundrometers are commercially available from, for example, Custom Scientific Instruments, Inc., Cedar Knolls, N.J. In a jet, the cotton-containing fabric, in a rope form, continuously rotates through and with the cellulase solution. Specifically, jets are based on a venturi tube in which the circular movement of liquor carries the fabric with it in a totally enclosed tubular chamber, annular in shape. The tubular chamber is filled in part with the aqueous cellulase solution and the fabric is rotated through the chamber via a lifter roller so that at any given time a portion of the fabric is being lifted upward. The venturi tube is a constriction in the annular passage through which the speed of the flow of the liquor must be increased, thus causing suction which imparts movement to the fabric. The primary flow is given by a centrifugal pump, but it is usual to incorporate also a few inclined steam jets to boost the movement of both the fabric and the liquor. The movement of the fabric through the jet, preferably at a rate of at least about 6 ft/sec, provides the agitation required in the herein described methods. A jet is a well known apparatus found in textile mills and is generally used for the purpose of dyeing and after treating fabrics. A Terg-O-tometer is a laboratory scale washing machine which provides accelerated results and which duplicates the action of an agitator type home washer. During operation, the washing solution can be maintained at any temperature between 25 * C and 70*C and the speed of the agitator can be varied from approximately 80 cycles per minute (CPM) to about 200 CPM. With such speeds, the agitator will agitate the solution. Preferably, the agitator is operated at a speed of about 100 to about 150 CPM. The Terg-O-tometer can also be used for rinsing the fabric by employing a rinse solution in the beaker, placing the fabric in this rinse solution and then operating the Terg-O-tometer. Terg-O-tometers are commercially available from United States Testing Co., Inc., 1415 Park Avenue, Hoboken, New Jersey, 07030. Repetitive agitation can be achieved by employing a jig, a mercerizer, a beck, a front load washing machine, and the like. A jig is a well known apparatus found in mills manufacturing cotton-containing fabrics and is generally used for the purpose of scouring fabrics prior to dyeing. In a jig, a defined length of cotton- containing fabric, in its open width position, is maintained on and between two rollers wherein the fabric is passed from one roller which is in the unwinding stage to a second roller which is in the winding stage. Once the unwinding/winding process is completed, the process is reversed so that the previous unwinding roll becomes the winding roll and the previous winding roll becomes the unwinding roll. This process is continuously conducted during the entire cellulase treatment time. A trough containing the cellulase solution is placed between the two rollers and the rollers are adjusted so that the cotton-containing fabric becomes immersed in the cellulase solution as it passes from one roller to the other. Repetitive agitation is achieved in the jig by continuously rolling and unrolling the cotton-containing fabric from the rolls, preferably at a rate of speed of at least about 1 yd/sec and more preferably at least about 1.5 yd/sec so that at any given time, part of the length of the fabric is moving through the cellulase solution at this defined rate of speed. The net result of such rolling and unrolling is that at any given time a portion of the cotton-containing fabric found on the rolls is immersed in the cellulase solution and over a given period of time, all of the fabric (except for the very terminal portions found at either end of the fabric—these terminal ends are often, composed of leader fabric, i.e., fabric sewn to the terminal portions of the treated fabric and which is not intended to be treated) has been immersed into the cellulase solution. Moving the fabric, preferably at a rate of speed of at least about 1 yd/sec, through the cellulase solution provides the agitation required in the herein described methods. A mercerizer unit is similar to a jig in that the cotton-containing fabric, in its open width position, is passed through a trough of solution, e.g., cellulase solution, at a set speed. Passing the cotton-containing fabric through the trough, preferably at a speed of at least 1 yd./sec, and more preferably at a rate of at least 1.5 yd/sec, provides the agitation required in the herein described methods. The mercerizer unit operates in only one direction and the length of time the fabric is exposed to the cellulase solution can be varied by modifying the mercerizer so as to contain more than one trough. In this embodiment, the length of time the fabric is exposed in such a modified mercerizer depends on the number of troughs and the speed the fabric is moving through the troughs. When repetitive agitation is employed, each portion of the cotton-containing fabric is preferably exposed to the cellulase solution under agitating conditions at least once every minute on average, and more preferably at least 1.5 times every minute on average. For example, when a jig is employed, this required degree of repetitive agitation can be achieved by limiting the length of the fabric so that when conducted at the requisite speed, each portion of the cotton-containing fabric is exposed to the cellulase solution under agitating conditions at least once every minute on average. When a modified mercerizer is employed, the desired degree of repetitive agitation can be achieved by adding a sufficient number of troughs appropriately spaced so that the fabric repetitively passes through different troughs. The reaction conditions employed to treat the cotton-containing fabric include applying an aqueous cellulase formulation to the fabric, preferably by immersing the fabric in an aqueous cellulase solution, and maintaining the fabric at an elevated temperature, i.e., about 25*C to about 70'C and preferably about 35*C to about 60*C, for a period of time at least about 0.1 hours and preferably from about 0.25 to 2.5 hours and most preferably from about 0.33 hours to 1 hour. When an aqueous cellulase solution is employed, the reaction employs liquor ratios of at least about 2:1 weight of liquor to weight of fabric (dry) to be treated; preferably, at least about 5:1; and most preferably, from about 5:1 to about 20:1 weight of liquor to weight of fabric. As noted above, when an aqueous cellulase solution is employed, the fabric is generally immersed into the solution and is preferably agitated. Additionally, the aqueous cellulase formulation is generally maintained at a pH where the cellulase possesses cellulolytic activity. In this regard, it is art recognized that cellulase activity is pH dependent. That is to say that, with all other factors being equal, a specific cellulase composition will exhibit significant cellulolytic activity within a defined pH range with optimal cellulolytic activity generally being found within a small portion of this defined range. The specific pH range for cellulolytic activity will vary with each cellulase composition. As noted above, while most cellulases will exhibit cellulolytic activity within an acidic to neutral pH profile, there are some cellulase compositions which exhibit cellulolytic activity in an alkaline pH profile. During treatment of the cotton-containing fabrics as per this invention, it is possible for the pH of the initial cellulase formulation to be outside the range required for cellulase activity. It is further possible for the pH to change during treatment of the cotton- containing fabric, for example, by the generation of a reaction product which alters the pH of the formulation. In either event, the pH of an unbuffered cellulase solution could be outside the range required for cellulolytic activity. When this occurs, undesired reduction or cessation of cellulolytic activity in the cellulase formulation occurs. For example, if a cellulase having an acidic activity profile is employed in a neutral/alkaline unbuffered aqueous solution, then the pH of the solution will result in lower cellulolytic activity and possibly in the cessation of cellulolytic activity. On the other hand, the use of a cellulase having a neutral or alkaline pH profile in a neutral unbuffered aqueous formulation should initially provide significant cellulolytic activity. In view of the above, the pH of the cellulase formulation should be maintained within the range required for cellulolytic activity and preferably, is maintained within ±1 pH unit of the pH maximum for the particular cellulase employed as determined by its activity against phosphoric acid swollen carboxymethyl- cellulose at 40 * C. One means of accomplishing this is by simply adjusting the pH of the formulation as required by the addition of either an acid or a base. However, in a preferred embodiment, the pH of the formulation is preferably maintained within the desired pH range by the use of a buffer. In general, a sufficient amount of buffer is employed so as to maintain the pH of the formulation within the range wherein the employed cellulase exhibits activity or preferably within ±1 pH unit of the pH performance maximum for the particular cellulase employed. Insofar as different cellulase compositions have different pH ranges for exhibiting cellulase activity, the specific buffer employed is selected in relationship to the specific cellulase composition employed. The buffer(s) selected for use with the cellulase composition employed can be readily determined by the skilled artisan taking into account the pH range and optimum for the cellulase composition employed as well as the pH of the cellulase formulation. Preferably, the buffer employed is one which is compatible with the cellulase composition and which will maintain the pH of the cellulase formulation within the pH range required for optimal activity. Suitable buffers include sodium citrate, ammonium acetate, sodium acetate, disodium phosphate, and any other art recognized buffers. In general, such buffers are employed in concentra¬ tions of at least 0.005 N and greater. Preferably, the concentration of the buffer in the cellulase formulation is from about 0.01 to about 0.5 N, and more preferably, rom about 0.02 to about 0.15 N. In general, increased buffer concentrations in the cellulase formulation may cause enhanced rates of tensile strength loss of the treated cotton-containing fabric. Additionally, in order to improve the wettability of the formulation, the aqueous cellulase formulation to be employed on the cotton fabric may contain from about 0.001 to about 5 weight percent of a surfactant. Cotton-containing fabrics which are exposed to agitation generally develop "pills" which are small balls of cotton-containing material attached to the surface of the fabric. One of the advantages in using an aqueous cellulase solution in the methods of this invention is that agitation in an aqueous cellulase solution results in significantly reduced numbers of pills as compared to agitation in a similar solution but which does not contain cellulase. Without being limited to any theory, we believe that the pilling is indirectly related to broken surface fibers on the fabric and that during treatment of the fabric, these fibers are removed by the cellulase. After pretreatment of the cotton-containing fabric is complete, the fabric is optionally but preferably treated in a manner to inactivate the cellulase. The so-treated fabric is then dried, generally in a conventional dryer. In one embodiment, the step to inactivate the cellulase is a separate step from the drying step. In this embodiment, cellulase inactivation can be achieved by heating the fabric at elevated temperatures (at least 75'C) to inactivate the enzyme. Alternatively, the fabric can be washed with hot water or other.cellulase free aqueous solution at a temperature of at least about 75'C and preferably from about 90*C to about 100*C to inactivate the cellulase. In still another alternative embodiment, inactivation of the cellulase can be coupled with the drying step by employing a drying temperature and drying time sufficient to inactivate the enzyme and to dry the fabric. When the inactivation step is coupled to the drying step, the fabric is generally heated at a temperature of at least 75*C for a period of at least 10 minutes. In this embodiment, the fabric is then usually thoroughly rinsed and dried. In either case, after drying, the fabric can then be used in printing processes such as silk-screening, painting and the like. Silk-screen processes are well known in the art and are described in, for example, Biegeleiεen, The Complete Book of Silk Screen Printing Production, Dover Publications, Inc., N.Y., N.Y. (1963) which is incorporated herein by reference in its entirety. 3. Utility The methods of this invention provide for cotton- containing fabrics with reduced dye bleeding as compared to the level of dye bleeding exhibited in the same cotton-containing fabrics which were not pretreated with cellulase. Additional! treatment of certain cotton- containing fabrics with llulase can also result in improved dye uptake in fabrics. The improvement in dye bleeding is noticeable after printing on the fabric as well as after the fabric has been washed one or more times in an aqueous detergent composition. In regard to the above, U.S. Serial No. , filed concurrently herewith as Attorney Docket No. 010055-024 and entitled "METHODS OF ENHANCING PRINTING QUALITY OF PIGMENT COMPOSITIONS ONTO COTTON FABRICS" discloses improvements in printing pigment compositions onto cotton-containing fabrics by pretreating the fabrics with a cellulase composition. This application is incorporated herein by reference in its entirety. The following examples are offered to illustrate the present invention and should not be construed in any way as limiting its scope. EXAMPLES The cellulase treated fabrics employed in the following examples were all treated with the described cellulase solution in a Terg-O-tometer. During treatment, the cellulase solution containing 20 mM citrate buffer was maintained at a temperature of about 50*C; the fabric was maintained in the Terg-O- tometer for about 120 minutes; and the speed of the agitator was approximately 200 cycles per minute (CPM) . Specifically, the Terg-O-tometer is operated by filling the bath with the desired amount of water and then adjusting the temperature of the bath by use of the thermostat. Solutions having the desired concentration of cellulase proteins and other optional ingredients (e.g., buffers, surfactants, etc.) are prepared and generally heated to a temperature of about 3*C higher than the temperature of the bath. One liter of this solution is then placed into the stainless steel container which is the washing receptacle. The container is placed in position in the wash bath. The agitator is place in the container and connected to the chuck. The machine is operated for a minute or two to bring the temperature of the solution in the container to that of the bath. The fabric to be treated is then added while the machine is in motion. The operation of the machine is continued for the desired length of time. At that point, the machine is stopped and the agitator and fabric removed. The fabric is then generally squeezed out by hand or passed through a wringer. Terg-O-tometers are commercially available from United States Testing Co., Inc., 1415 Park Avenue, Hoboken, New Jersey, 07030. EXAMPLE 1 This example ascertains reductions in dye bleeding by pre-treating cotton-containing fabrics with cellulase. The fabric employed was a resinated or non- resinated 100% cotton-knit fabric. The fabric was separated into swatches of about 12 inches by 12 inches. All swatches were treated with either 1000 ppm of CYTOLASE 123 cellulase (available from Genencor International, Inc., South San Francisco, CA) in 20 mM citrate phosphate buffer or with a control (i.e., a 20 mM citrate phosphate buffer containing no cellulase) . The solutions were maintained at about pH 5 for 2 hours. During treatment, the swatches were agitated by use of Terg-O-tometer in the manner described above. Each of the swatches were then used for printing using an identical dye composition under identical conditions. The dye composition contained water; sequestering agent (e.g., Calgon—available from Calgon Corp.); urea; and sodium algamate. After printing, the fabrics were washed in an aqueous solution containing a detergent composition and dried. After drying, the swatches were evaluated by 3 panelists (without knowledge of the fabric treatment conditions) for the extent of dye bleeding based on the extent dye traversed beyond its intended boundary and uniformity of bleeding across the entire boundary. The fabric were ranked seriatim and that fabric with the most amount of bleeding was given the lowest number (1) and the fabric with the least amount of bleeding was given the highest number (7) . The results of this evaluation are set forth in Tables I and II below. In these tables, all of the fabrics, resinated and non-resinated were evaluated together without knowledge by the evaluators as to the fabric origin. In all, seven fabrics were evaluated and ranked seriatim from 1 to 7 based on the above criteria. After evaluation, the fabric ratings were separated into either resinated or non-resinated fabrics. TABLE I WASHED, RESINATED 100% COTTON KNIT RATING ASSIGNED TO AMT OF CELLULASE PROTEIN BLEEDING IN A WASHED, IN AQUEOUS SOLUTION (PPmi RESINATED 100% COTTON KNIT 1000 3.5* 0 1.5" TABLE II WASHED, NON-RESINATED 100% COTTON KNIT RATING ASSIGNED TO AMT OF CELLULASE PROTEIN BLEEDING IN A WASHED, IN AQUEOUS SOLUTIONSPPm) NON-RESINATED 100% COTTON KNIT 1000 7 0 5.5" a = average of two runs. The above results demonstrate that pre-treatment of cotton-containing fabrics with an aqueous cellulase solution prior to printing an image onto the fabrics with a dye composition provides for reduction in the extent of dye bleeding into the fabric. As noted above, in some cases, pretreatment of certain cotton-containing fabrics with an aqueous cellulase solution can provide for improvements in dye uptake. Example 2 below illustrates the degree of dye uptake into different cotton-containing fabrics. EXAMPLE 2 This example evaluates the degree of dye uptake in resinated and non-resinated cotton fabrics (i.e., a washed, non-resinated or resinated 100% cotton-knit fabric) . In this example, each of the cotton-containing fabrics was treated under identical conditions with an aqueous solution containing 20 mM of citrate phosphate buffer and optionally containing the specified amount of cellulase (i.e., Cytolase 123 cellulase available from Genencor International, Inc., South San Francisco, CA 94080) . After drying, images were then printed onto each of the so-treated fabrics with the same dye composition using the same printing methodology (i.e., silkscreening) . The dye composition contained water; sequestering agent (e.g., Calgon—available from Calgon Corp.); urea; and sodium alganate. The resulting fabrics were then evaluated by three individuals (without knowledge of the fabric origin) who rated each fabric for its degree of dye uptake based on the depth of dye uptake into the fabric and intensity of color. Fabrics exhibiting a deeper degree of dye uptake throughout the fabric were evaluated as having more dye uptake. Likewise, fabrics having a more intense color were also evaluated as having more dye uptake. Each fabric was evaluated and compared to similar fabrics based on these factors and all of the fabrics were ranked seriatim. The fabric with the most dye uptake was given the lowest number and the fabric with the least dye uptake was given the highest number. The results of this evaluation are set forth in Tables III and IV below. In these tables, all of the fabrics, resinated and non-resinated were evaluated together without knowledge by the evaluators as to the fabric origin. In all, eight fabrics were evaluated and rated from 1 to 8 based on the above criteria. A second set of fabrics were treated under identical conditions so as to provide a duplicate set of results. This second set of fabrics were similarly evaluated and rated from 1 to 8. After evaluation, the fabric ratings were separated into either resinated or non-resinated fabrics and the results from the two sets of fabrics averaged. The results of this evaluation are as follows: TABLE III WASHED, NON-RESINATED 100% COTTON KNIT RELATIVE RATING ASSIGNED TO AMT OF CELLULASE PROTEIN DYE UPTAKE IN A NON- IN AQUEOUS SOLUTION(ppm) RESINATED 100%COTTON KNIT" 1000 2 0 6 100 6.5 500 7 TABLE IV NON-WASHED NON-RESINATED 100% COTTON KNIT RATING ASSIGNED TO AMT OF CELLULASE PROTEIN DYE UPTAKE IN A RESINATED IN AQUEOUS SOLUTIONfPPmi 100% COTTON KNIT* 100 2.5 500 3 1000 3.5 0 5.5 a — average-..of 2 runs The above results indicate that with a non-washed non-resinated 100% cotton knit, improvements in dye uptake are seen with fabrics treated with an aqueous cellulase solution as compared to the control (i.e., 0 ppm cellulase) and that all fabrics treated with an aqueous cellulase solution gave approximately similar results. The above results also indicate that with a washed, non-resinated, 100% cotton knit, improvements in dye uptake are seen only with fabrics treated with an aqueous cellulase solution containing 1000 ppm of cellulase proteins and that treatment with either 500 ppm or 100 ppm of cellulase proteins provided approximately equivalent dye uptake results as fabrics treated with control (i.e., 0 ppm cellulase).

Claims: WHAT IS CLAIMED IS: 1. A method for printing an image onto a cotton- containing fabric with a dye composition which method comprises the steps of: (a) contacting a cotton-containing fabric with an aqueous formulation comprising at least about 50 ppm of cellulase proteins at a temperature of from about 25'C to about 70*C for at least about 0.1 hours wherein the aqueous formulation is maintained at a pH where the cellulase has activity; (b) drying the fabric; and (c) printing an image on the fabric with a dye composition. 2. A method as described in Claim 1, wherein the cellulase protein concentration in said aqueous formulation is from about 100 ppm cellulase to about 2,000 ppm. 3. A method as described in Claim 1 wherein the temperature of the aqueous cellulase formulation is maintained at from about 35* to 60*C for a period of time of from about 0.25 to 2.5 hours. 4. A method as described in Claim 1 wherein the cellulase solution is agitated during contact with the cotton-containing fabric. 5. A method as described in Claim 1 wherein the cellulase is derived from a fungal source. 6. A method as described in Claim 1 wherein the cellulase is a complete fungal cellulase composition. 7. A method as described in Claim 1 wherein the aqueous cellulase composition is maintained at a pH within ±1 pH unit of the pH at which the cellulase composition possesses maximal activity. 8. A method as described in Claim 1 wherein the aqueous cellulase formulation is an aqueous cellulase solution and the liquor ratio of the weight of aqueous cellulase solution to the weight of the fabric to be treated is at least 2:1. 9. A method as described in Claim 1 which further comprises an enzyme deactivation step prior to or during said drying step. 10. A method as described in Claim 9 wherein the drying step is conducted at a temperature of at least 75*C for a period of at least 10 minutes so as to inactivate the cellulase on said fabric. 11. A method as described in Claim 1 wherein said cellulase is deficient in CBH type components and enriched in EG type components. 12. A cotton-containing fabric having an image placed thereon with a dye composition which fabric is prepared in the method described in Claim 1.

Inventors: ASHIZAWA EUNICE C, CLARKSON KATHLEEN A, LAD PUSHKARAJ J, LARENAS EDMUND, ASHIZAWA, EUNICE, C., CLARKSON, KATHLEEN, A., LAD, PUSHKARAJ, J., LARENAS, EDMUND
Applicants: GENENCOR INT, GENENCOR INTERNATIONAL, INC.
Application year: 1993
Main classification: D06P5
IPC codes: C11D3, C11D7, D06M16, D06P3, D06P5