LUBRICANT AND SOIL RELEASE FINISH FOR YARNS

Abstract: An improved textile yarn finish is provided having a continuous aqueous phase with a soil release agent incorporated therein and a discontinuous phase of a lubricating oil.

Description: LUBRICANT AND SOIL RELEASE FINISH FOR YARNS Background of the Invention This invention relates to a yam which has been treated with a lubricant and soil release finish composition prior to fabric formation, particularly to a yam which has been treated with an oil-in-water emulsion finish. Prior to fabric formation, synthetic yam and yam blends containing synthetic fibers are typically processed to provide increased strength, stretch and bulk, and to enhance their appearance. The processing steps may include heating and drawing to provide a degree of orientation to the yams, as well as texturing with mechamcal action. After the yams have been modified as desired, a lubricant is applied to reduce friction during subsequent processing steps, such as winding, weaving or knitting. It is well known to improve the washability and moisture transport properties of fabrics made from synthetic fibers by treating the fabric with a "soil release agent". In one example, a soil release agent, which is the condensation product of dimethyl terephthalate, ethylene glycol and polyetiiylene glycol, is added to the bath during jet dyeing of polyester, and the agent is exhausted into the fibers ofthe fabric. Following the dyeing step, the fabric is rinsed, dried and heat set One ofthe shortcomings ofthe prior art process is that the soil release agent is applied to me fabric during the dye cycle. Accordingly, it has been necessary to process the fabric in the dyeing equipment, even if the fabric is not going to be dyed, for the sole purpose of providing the soil release treatment Anomer shortcoming is that it is that the soil release agent is applied after fabric formation. Accordingly, when the yam is sent to different locations to be woven or knitted, or if the yam is sold, each location is required to have its own equipment for applying the soil release agent Summary of the Invention Therefore, one of the objects of the invention is to provide a soil release treatment which need not be exhausted into the fabric. Another object of the invention is to provide a soil release treatment which may be applied to the yams prior to fabric formation. Still another object ofthe invention is to combine application of the lubricant finish and soil release finish in a single step. Accordingly, a finish composition is provided, which incorporates a lubricating oil and a soil release agent and is applied to a yam as an oil-in-water emulsion. The lubricant protects the yam during subsequent processing steps, such as winding and fabric formation. The soil release agent improves the washability and moisture transport properties ofthe yam and fabrics made therefrom. Additionally, the invention may be characterized by one or more ofthe followmg features: • yam to yam friction of 33 to 39 grams of output tension; • yam to metal friction of less man 50 grams of output tension at a contact angle of 180°; and • textured continuous filament polyester yarn. Advantages ofthe present invention include: • a decrease in the amount of lubricant required, as the soil release agent provides lubrication to the yam; and elimination of unnecessary process steps, since the soil release properties may be imparted to a yam by application of a soil release agent under ambient conditions. Detailed Description of he Invention Without limiting the scope ofthe invention, the preferred embodiments and features are hereinafter set forth. Unless otherwise indicated, all parts and percentages are by weight and conditions are ambient i.e. one atmosphere of pressure and 25° C. The terms aryl and arylene are intended to be limited to single and fused double ring aromatic hydrocarbons. Unless otherwise specified, aliphatic hydrocarbons are from 1 to 12 carbon atoms in length, and cycloaliphatic hydrocarbons comprise from 3 to 8 carbon atoms. In the present invention, the soil release agent is applied to a yam, prior to fabric formation, along with a lubricant The ya may be a continuous multifilament yam or spun yam. The yam will typically have a denier ranging from 30-300 and have a filament count ranging from 10-200, preferably 15-100. The denier and the filament count are not deemed to be critical to me practice ofthe invention, and yarns outside the stated ranges may be used. A wide variety of natural and synthetic fibers may be employed. By way of example the fiber substrate may be selected from polyamide fibers, including nylon, such as nylon 6 and nylon 6,6, and aramid fibers; polyester fibers, such as polyethylene terephthalate (PET); polyolefin fibers, such as polypropylene; polyurethane fibers; blends ofthe aforementioned synthetic fibers; and blends of such synthetic fibers with cellulosic fibers, such as cotton, rayon and acetate. Preferably, the fiber has a hydrophobic component and is selected from polyamide fibers, polyester fibers or polyester/cotton blends. The finish composition applied to the yam contains a lubricating oil to facilitate subsequent processing ofthe yam, such as winding, warping and fabric formation, and a soil release agent to enhance the performance ofthe textile article made from the yam. The finish composition is applied to achieve a lubricant add on, including emulsifiers necessary to form a stable emulsion, of from 0.15 to 6 wt% on the weight of the fiber (owf), preferably 0.375 to 2% owf; and a soil release agent add on of from 0.05 to 3.0% owf, preferably 0.075 to 0.75% owf. Satisfactory results are achieved with emulsions containing 45 wt% or greater, preferably, 50 wt% or greater water and compositions having the following ranges may be employed: I to 49.7 wt. % of a lubricating oil; 0.3 to 49 wt. % of a soil release agent; 50 to 95 wt. % water; and up to 5 wt. % auxiliaries. Preferably, the composition is an emulsion having from: 2.5 to 29.5 wt. % of a lubricating oil; 0.5 to 25 wt % of a soil release agent; 70 to 95 wt. % water; and up to 3 wt. % auxiliaries. The concentration of lubricating oils is intended to include the emulsifiers necessary to form a stable emulsion ofthe oil. The auxiliaries biocides, antistatic agents, anti-sling agents, and wetting agents, and their use in fiber finishes well known to those skilled in the art. The invention may be practiced wim a wide variety of conventional lubricating oils. By way of example, suitable oils include: (a) mineral oil derivatives which include paraffinic, alicyclic and aromatic hydrocarbons and combinations mereof; the molecular weights ofthe mineral oils typically range from 175-1000; (b) synthetic oils including: (i) organic esters such as C β -C„ esters of fatty acids, particularly dibasic esters derived from C β -C, 0 diacids esterified with C β -C 10 alcohols and esters of higher polyols such as triglycerides and esters of pentaerythritol; (ii) alkoxylated fatty acids and alcohols, primarily propylene oxide and ethylene oxide adducts of C 10 -C„ organic acids and alcohols; (iii) low molecular weight polyolefins, which are liquid at ambient conditions, such as polyisobutylene and polyalphaolefins; and (iv) silihydrocarbon oils. Reference may be made to the Kirk-Othmer, Encyclopedia of Chemical Technology, 3rd Edition, Volume 14, page 477 tt. seq. "Lubrication and Lubricants" (1981); Ross et al, U.S. Patent No. 4,995,884; and Plonsker, U.S. Patent No. 4,932,976. Conventional soil release agents may be employed in the composition of the present invention. The soil release agents are characterized by a macromolecule having a hydrophilic component such as a carboxyl, hydroxyl, alkali metal sulfonate and/or oxyethylene group, and a lipophilic component with an affmity for the fiber, which functions to add durability or to anchor the soil release agent to the fiber surface. The backbone ofthe macromolecule is generally formed by either vinyl polymerization or condensation reaction. Molecular weights may range from 500 to 100,000, preferably from 1,000 to 25,000, most preferably 1,000 to 10,000. By way of example, smtable soil release agents include: (a) non-ionic soil release agents having oxyethylene hydrophiles, such as the condensation polymers of polyethylene glycol and/or ethylene oxide addition products of acids, amines, phenols and alcohols which may be monofunctional or polyfunctional, together wim binder molecules capable of reacting with the hydroxyl groups of compounds wim a poly(oxyalkylene) chain, such as organic acids and esters, isocyanates, compounds with N-methyl and N-methoxy groups, bisepoxides etc. Particularly useful are the condensation products of dimethyl terphthalate, ethylene glycol and polyethylene glycol (ethoxylated polyester) and ethoxylated polyamides, especially ethoxylated polyesters and polyamides having a molecular weight of at least 500, as well as the soil release agents described in the following patents, U.S. 3,416,952; U.S. 3,660,010; U.S. 3,676,052, U.S. 3,981,807; U.S. 3,625,754; U.S. 4,014,857; U.S. 4,207,071; U.S. 4,290,765; U.S. 4,068,035 and U.S. 4,937,277. (b) anionic soil release agents particularly, vinyl polymers containing carboxylic acid as d e hydrophile as can be obtained by polymerizing acrylic acid, methacrylic acid or maleic acid, usually with a comonomer such as an alkyl acrylate, preferably methyl or ethyl acrylate, to increase the lipophilic character ofthe polymer and to decrease brittleness. Cross¬ linking improves the durability ofthe soil release agent and accordingly, it is desirable to copolymerize wim a cross-linking agent such as N-methyl acrylamide, or to cross-link the polymer wim a small amount of a bisepoxide. Examples of representative anionic soil release agents may be found in the following patents: U.S. 3,377,249; U.S. 3,535,141; U.S. 3,540,835; U.S. 3,563,795; U.S. 3,598,641; U.S. 3,574,620; U.S. 3,632,420; U.S. 3,650,801; U.S. 3,652,212; U.S. 3,690,942; U.S. 3,897,206; U.S. 4,090,844; and U.S. 4,131,550. (c) combinations of anionic soil release agents wim oxyethylene hydrophile condensates, such as are generally referred to as sulfonated ethoxylated polyesters and the soil release agents disclosed in the following patents: U.S.3,649,165; U.S. 4,073,993; and U.S. 4,427,557. (d) nonionic soil release agents with hydroxyl hydrophiles, particularly cellulose derivatives such as cellulose acetate and the soil release agents disclosed in the following patents: U.S. 3,620,826; U.S. 4,164,392; and U.S. 4,168,954. The so i l release agent may be in the form of an emulsion, dispersion or solution. Preferably, the soil release agent has a nonionic hydrophilic component and is in the form of an aqueous dispersion or aqueous solution. All of the United States patents heretofore listed are incorporated by reference herein. The lubricating oil and soil release agent are combined, along with the desired ancillary additives, to form an oil-in-water emulsion using conventional techniques. Preferably, the soil release agent is in the form of an aqueous dispersion, solution or emulsion, as are commercially available. For example, first an emulsion of the lubricant and water is formed by vigorous agitatioh wim a laboratory stirrer, and next the soil release agent may be added while continuing to agitate the composition. It may be desirable to improve the stability ofthe emulsion by incorporating surface active agents (surfactants) or emulsifiers into the composition, as is well known to mose skilled in the art Suitable emulsifiers include nonionic, ionic and zwitterionic surfactants, such as alkoxylated alcohols, alkyl phenols, fatty acids and amides; carboxylate, sulfonates and phosphate esters, quaternary compounds and mose surfactants disclosed in the Kirk- Othmer Encyclopedia of Chemical Technology, 3rd Edition, Surfactants and Detersive Systems, pp. 332-432 (1983). If an emulsifier is necessaiy to stabilize the finish composition, the emulsifier may be employed at a ratio of emulsifier to oil of from about 1:20 to 2:1, preferably 1:10 to 1:1. The lubricant/soil release finish composition may be applied at any stage of yam processing diat a lubricant alone could be applied. Prior to application ofthe finish, me yam may be subjected to vaiious treatments, such as one or more of the following: drawing, twisting, heat setting, entanglement or crimping. In a preferred embodiment the finish is applied at the texturing frame to textured polyester yam made from drawn partially oriented yam (POY). The finish may be applied by conventional techniques used to apply a lubricant emulsion to yam. By way of example, the finish of the present invention may be applied from a kiss roll, metered applicator, sprayer, or by immersion. The add on of finish composition (as is) ranges from I to 30 wt. % owf, preferably from 3 to 15 wt. % owf, most preferably from 3 to 8 wt% owf. Following application of die present finish to die yarn, die yam may be handled and processed as are yams treated wim conventional lubricants. For example, die yam may be wound into a package and men formed into a fabric, preferably a woven knitted fabric, as is well known in die art. The yam or fabric may be scoured, heat set and even dyed. One of die advantages of die present process is diat it is particularly useful when die yam or fabric is not dyed. Since the soil release agent is applied early in the yam processing process, me dyeing step can be eliminated when it is desirable to do so. Surprisingly, die performance and durability of die soil release treatment is not adversely affected by omission ofthe dyeing step, or omer treatment in a heated aqueous badi, which was once tiiought necessary to exhaust the soil release agent into d e fiber, before soil release properties could be achieved. The invention may be further understood by reference to die following examples, but die invention is not to be construed as being unduly limited diereby. EXAMPLE 1 The following example demonstrates me washability and moisture transport performance of a fabric constmcted of yarn, which has been treated widi die lubricant soil release agent emulsion of me present invention. A partially oriented polyester yam, 150/34, was heated, drawn and textured. At die texturing frame, a lubricant soil release agent finish was applied in emulsion form to die yam to achieve 1 wt%, 2 wt% or 3 wt% (owf), on a neat basis. The composition of the finish was 3.2 wt% of an ethoxylated polyester soil release agent identified as lubπl QCX™ available from Rhone Polenc; 20 wt% of an emulsified ester lubricant identified as Synlube™ 6340 available from Milliken Chemical, U.S.A.; and 76.8 wt% water. For each level of finish, the yam was knitted into a sock and die sock was cut in half. One half of die sock was scoured in a 120° F home wash (12 minute "cotton/sturdy" wash cycle in a residential washing machine with detergent present). The scoured and unscoured halves of fabric, Samples A and B, respectively, were then dyed blue (Resolin Blue GFL) in a disperse dye cycle (130° C for 30 minutes) on a Mathis laboratory jet dyeing machine. The fabrics were then tested for soil release using com oil according to AATCC Test Method 130-1977, and moisture transport according to AATCC Test Method 39- 1977. The soil release test is designed to measure die ability of a fabric to release oily stains during home laundering. Briefly, a sample fabric is stained widi com oil and washed under conventional home laundry conditions. The samples are then rated on a scale from 1-5, wid 1 representing me poorest stain removal and 5 representing die best stain removal. The moisture transport or wettability test measures die time it takes for a fabric to absorb a drop of water, while die fabric is held taut and horizontal. The time it takes for the drop to completely absorb into die fabric is measured in seconds, wi a stop watch, and recorded. A high number is indicative of slow absorption, and mus poor wettability. The fabric made from yam treated widi die lubricant soil release agent finish ofthe present invention were compared to fabrics made from yam treated widi a lubricant finish only, which was knitted, cut in half and one half only was scoured, Samples C and D. The results for 1 wt% (owf) finish levels are reported in Table I. TABLE 1 Sample Finish Finish Level Scour? Soil Release Wettability Treatment Rating (1-5) (Seconds) A lubricant/soil 1 wt% (owf) scour 4.5 I release agent B lubricant soil I wt% (owf) no scour 4.8 1 release agent C lubricant 1 wt% (owf) scour 2.8 >30 D lubricant 1 wt% (owf) no scour 3.0 >30 EXAMPLE 2 The procedures of Example 1 were repeated except diat an equal amount of an emulsified hydrocarbon lubricant identified as Lube Stat™ 5101 available from Milliken Chemical, U.S.A., was substituted for die lubricant in me lubricant soil release agent finish. The resτdts of finish applications at 1 wt%, 2 wt% and 3 wt% (owf), on a neat basis, are reported below in Table 2. EXAMPLE ? The procedures of Example 1 were repeated except dat an alkoxylated lubricant identified as Syn Lube™ 6278, available from Milliken Chemical, U.S.A., was substimted for die lubricant in die lubricant soil release agent finish. The results of finish applications at 1 wt%, 2 wt% and 3 wt% (owf), on a neat basis, are reported below in Table 2. TABLE 2 Finish Composition Add On (owf) Soil Release Rating ( 1-5) (Sample) 1 wt% 4.5 Example 1 2 wt% 5.0 (Sample A) 3 wt% 4.8 l wt% 5.0 Example 2 2 wt% 5.0 3 wt% 5.0 l wt% 5.0 Example 3 2 wt% 5.0 3 wt% 5.0 EXAMPLE 4 The following example shows variation of d e relative proportion of lubricant soil release agent in water, and die affect die variation has on friction and soil release properties. The procedures of Example 1 were repeated, except diat the components of die lubricant soil release agent finish of Example 1 was varied as shown in Table 3 below, and designated E, F and G. Also included in Table 3 are me test results for Sample A of Example 1, and die test results for a control yam which had been treated wiui a producer supplied primary lubricant finish at approximately 0.3 wt% owf. Yam-to-metal and yam-to-yam friction was evaluated using a Rodischild frictometer. The finish composition was applied to 150 denier/34 filament, textured polyester yarn, at a conventional texturing frame, at me level specified. The yam was allowed to condition for at least 24 hours at 72° F and 63% humidity. After conditioning, die hydrodynamic yam-to-metal friction was obtained on die frictometer at a speed of 100 meters minute at a contact angel of 180° and pre-tensions of 20 grams, Yam-to-yam friction was evaluated at die above conditions, widi die exception diat die friction pin was bypassed and die yam was given two full twists. TABLE 3 Sample Add On Lubricant Soil Water Yam to Yam to Soil (owf) (wt%) Release (wt%) Yam Metal Release Agent Friction Friction (1 poorest (wt%) - 5 best) I wt% 20 3.2 76.8 33 33.5 4.5 A 2 wt% 20 3.2 76.8 31 26.5 5 3 wt% 20 3.2 76.8 32 26.5 4.8 l wt% 15 3.75 81.25 40 47 5 E 2 wt% 15 3.75 81.25 34 31 5 3 wt% 15 3.75 81.25 33 28.5 5 l wt% 10 4.5 85.5 38 44.5 5 F 2 wt% 10 4.5 85.5 33 33.5 5 3 wt% 10 4.5 85.5 33 29.5 -- 5 l wt% 5 5.3 89.7 36 44.5 5 G 2 wt% 5 5.3 89.7 34 34.5 5 3 wt% 5 5.3 89.7 34 31.5 5 Control 42.5 34.5 1 EXAMPL S The following example demonstrates die efficacy of die lubricant/soil release composition on an undyed textile. The lubricant soil release composition of Sample A and G were apphed at levels of 1, 2 or 4 wt% (owf), on a neat basis, to a polyester yam, 150/34, made from recycled polyethylene terephdialate fiber. The treated yam was then knitted into a sock and test for soil release according to AATCC Test Mediod 130-1977. The results were compared against a control fabric made with yam to which only a primary finish had been applied, i.e. lubricant only at about 1 wt% (owf) on a neat basis. The results are summarized below in Table 4, with a Soil Release Rating of "5" being die best and " 1" being die poorest TABLE 4 Sample Add On (owf) Soil Release. (1-5) Control Primary Finish Only 3.0 A 1% 3.5 A 2% 4.5 A 4% 5.0 G 1% 3.5 G 2% 5.0 G 4% 5.0 There are, of course, many alternative embodiments and modifications ofthe invention which are intended to be included widiin die scope of die following claims.

Claims: v ha r we claim is: 1. In a lubricating finish for a textile yam, an improvement comprising providing the finish as an oil-in-water emulsion, wherein die aqueous phase of die emulsion incorporates a soil release agent 2. The finish of Claim 1 comprising: 1 to 49.7 wt.% of a lubricating oil; 0.3 to 49 wt.% of die soil release agent; 50 to 95 wt.% water; and up to 5 wt.% auxiliaries. 3. The finish of Claim 3 wherein die lubricating oil is selected from the group consisting of emulsified mineral oils, emulsified organic esters, alkoxylated fatty acids and esters, and emulsified low molecular weight polyolefins; and die soil release agent is a macromolecule formed by vinyl polymerization or condensation reaction, having a hydrophilic component selected from the group consisting of carboxyl, hydroxyl, alkali metal sulfonate and oxyethylene functionalities, and l pophilic component widi an affinity for a hydrophobic textile yam. 4. The finish of Claim 1 comprising: 2.5 to 29.5 wt.% of a lubricating oil; 0.5 to 25 wt.% of die soil release agent; 70 to 95 wt% water; and up to 3 wt% auxiliaries. 5. The finish of Claim 4 wherein die lubricating oil is selected from the group consisting of emulsified mineral oils, emulsified organic esters, alkoxylated fatty acids and esters, and emulsified low molecular weight polyolefins; and me soil release agent is selected from the group consistmg of ethoxylated polyesters and etiioxylated polyamides having molecular weights from 500 to 100,000. 6. A method of treating a textile yarn, comprising die steps of applying a finish composition to the yam to achieve an add on of a lubricating oil of from 0.15 to 6 wt.% owf and an add on of a soil release agent of from 0.05 to 3 wt.% owf, wherein the finish composition is applied as an oil-in-water emulsion. 7. The mediod of Claim 6 wherein die yam comprises hydrophopic fibers selected from die group consisting of polyester, polyamide and polyolefin fibers. 8. The method of Claim 7 wherein die lubricating oil is selected from die group consisting of emulsified mineral oils, emulsified orgamc esters, alkoxylated fatty acids and esters, and emulsified low molecular weight polyolefins; and die soil release agent is a macromolecule formed by vinyl polymerization or condensation reaction, having a hydrophilic component selected from the group consisting of carboxyL hydroxyl, alkali metal sulfonate and oxyemylene functionalities, and lipophilic component widi an affinity for the hydrophobic fibers. 9. The method of Claim 6 wherein me add on of die lubricating oil is from 0.375 to 2 wt.% owf and me add on of die soil release agent is from 0.075 to 0.75 wt.% owf. 10. The method of Claim 9 furdier comprising e steps of winding die yam into a package and knitting or weaving die yam into a fabric. 11. The mediod of Claim 10 wherein die lubricating oil is selected from the group consisting of emulsified mineral oils, emulsified organic esters, alkoxylated fatty acids and esters, and emulsified low molecular weight polyolefins; and die sod release agent is an etiioxylated polyester having a molecular weight of from 1,000 to 25,000. 12. The memod of Claim 11 wherein the finish composition is apphed to textured polyester yam and die yam has a yam to yam friction of 33 to 39 grams of output tension and a yam to metal friction of less dian 50 grams of output tension at a contact angle of 180 degrees. 13. The method of Claim 10 wherein the fabric has a soil release according to AATCC Test Method 130-1977 of 3.5 or greater and a moisture transport according to AATCC Test Method 39-1977 of 10 seconds or less. 14. A lubricated textile ya comprising a finish apphed as an oil-in-water emulsion having a continuous aqueous phase which is between 50 and 95 wt.% of die finish and has a soil release agent incorporated therein, and a lubricating oil in the discontinuous phase, wherein die sod release agent is present on die yam at add on of from 0.05 to 3 wt.% owf and die lubricating oU is present on die yam at an add on of from 0.15 to 6 wt% owf. 15. The textile yam of Claim 14 wherein die yam comprises fibers selected from the group consisting of polyester, polyamide and polyolefin fibers. 16. The textile yam of Claim 15 wherein the lubricating oil is selected from die group consisting of emulsified mineral oils, emulsified organic esters, alkoxylated fatty acids and esters, and emulsified low molecular weight polyolefins; and the soil release agent is a macromolecule foimed by vinyl polymerization or condensation reaction, having a hydrophilic component selected fiom me group consistmg of carboxyl, hydroxyl, alkali metal sulfonate and oxyethylene functionalities, and lipophilic component wim an affinity for die fibers of die yam. 17. The textile yam of Claim 16 wherein the yam is a textured polyester yam and die yam has a yam to yam friction of 33 to 39 grams of output tension and a yam to metal friction of less dian 50 grams of output tension at a contact angle of 180 degrees. 18. The textile yam of Claim 15 wherein die lubricating oil is selected from the group consisting of emulsified mineral oils, emulsified organic esters, alkoxylated fatty acids and esters, and emulsified low molecular weight polyolefins; and die soil release agent is an ethoxylated polyester having a molecular weight of from 1,000 to 10,000. 19. The textile yam of Claim 18 wherein die add on of die lubricating od is from 0.375 to 2 wt.% owf and the add on of the soil release agent is from 0.075 to 0.75 wt.% owf. 20. The textile yam of Claim 19 wherein die yam is a textured polyester yam which is knitted or woven to form a fabric and the fabric, in an undyed state, has a soil release according to AATCC Test Method 130-1977 of 3.5 or greater and a moisture transport according to AATCC Test Method 39-1977 of 10 seconds or less.

Inventors: DEMOTT PHILLIP, LEE ANGEL, SCHUETTE ROBERT LOUIS, TAYLOR DEREK, DEMOTT, PHILLIP, LEE, ANGEL, SCHUETTE, ROBERT, LOUIS, TAYLOR, DEREK
Applicants: DEMOTT PHILLIP, LEE ANGEL, MILLIKEN RES CORP, SCHUETTE ROBERT LOUIS, TAYLOR DEREK, DEMOTT, PHILLIP, LEE, ANGEL, MILLIKEN RESEARCH CORPORATION, SCHUETTE, ROBERT, LOUIS, TAYLOR, DEREK
Application year: 1996
Main classification: C10M1
IPC codes: D06M13, D06M15