Aqueous dispersion of dye, stain-blocker, and fluorochemical and its use in the manufacture of carpet

Abstract

Disclosed is composition comprising an aqueous dispersion containing a dye, a stain blocker component, and an anti-soil component. The composition provides uniform dyeing, and superior stain blocking and anti-soil characteristics to fibers, carpets, and fabrics by adjusting the conductivity and pH of the dispersion. Alternatively, the composition can comprise an aqueous dispersion containing a dye, a stain blocker component, and a retarder for slowing down the rate of dye reaction. Also disclosed is a method of applying the compositions and dispersions to fibers, carpets, and fabrics.

1 . A composition comprising an aqueous dispersion of a dye, an anti-soil component, and a stain blocker, wherein said aqueous dispersion has a conductivity between about 2000 to about 9000 micromhos and a pH between about 1.5 to about 5. 
     
     
         2 . The composition of  claim 1 , wherein said anti-soil component comprises a fluorochemical. 
     
     
         3 . The composition of  claim 2 , wherein said fluorochemical has less than or equal to six fluorinated carbons. 
     
     
         4 . The composition of  claim 1 , further comprising a metal salt. 
     
     
         5 . The composition of  claim 1 , further comprising a retarder. 
     
     
         6 . The composition of  claim 4 , wherein said metal salt is selected from the group consisting of: sodium sulfate, magnesium sulfate, potassium sulfate, calcium sulfate, manganese sulfate, iron sulfate, copper sulfate, zinc sulfate, aluminum sulfate, sodium nitrate, magnesium nitrate, potassium nitrate, calcium nitrate, manganese nitrate, iron nitrate, copper nitrate, zinc nitrate, aluminum nitrate, sodium chloride, potassium chloride, calcium chloride, magnesium chloride, manganese chloride, copper chloride, iron chloride, sodium phosphate, potassium phosphate, calcium phosphate, manganese phosphate, iron phosphate, copper phosphate, zinc phosphate, aluminum phosphate, sodium bicarbonate, sodium carbonate, calcium bicarbonate, calcium carbonate, potassium bicarbonate, and potassium carbonate. 
     
     
         7 . The composition of  claim 6 , wherein said metal salt is magnesium sulfate. 
     
     
         8 . The composition of  claim 4 , wherein said metal salt is present between about 1 gram of metal/Liter to about 16 gram of metal/Liter of said aqueous solution. 
     
     
         9 . The composition of  claim 1 , wherein said conductivity is between about 4000 to about 7000 micromhos. 
     
     
         10 . The composition of  claim 1 , wherein said pH is between about 1.5 to about 4. 
     
     
         11 . The composition of  claim 8 , wherein said metal salt is present between about 1 gram of metal/L to about 6 gram of metal/L of said aqueous solution. 
     
     
         12 . The composition of  claim 9 , further comprising a retarder. 
     
     
         13 . The composition of  claim 1 , further comprising an additive that performs a function selected from the group consisting of: aid in dye penetration, aid in anti-soil penetration, aid in stain blocker penetration, protect the carpet from long term exposure to the elements, and keep the dye, stain blocker, and anti-soil components in suspension. 
     
     
         14 . The composition of  claim 13 , wherein said additive is selected from the group consisting of: dye auxiliaries, sequestrants, pH control agents, surfactants, fluoro-surfactants, nano materials, odor control agents, antimicrobial agents, fragrance agents, bleach resist agents, softeners, and UV stabilizers. 
     
     
         15 . A method of applying a composition to a fiber comprising: (a) providing an aqueous dispersion comprising a dye, an anti-soil component, and a stain blocker, wherein said aqueous dispersion has a conductivity between about 2000 to about 9000 micromhos and a pH between about 1.5 to about 5; (b) contacting said fiber with said aqueous dispersion at temperature between about 20° C. to about 40° C.; (c) steaming said fiber for at least 60 seconds; (d) rinsing said fiber with water; and (e) drying said fiber. 
     
     
         16 . The method of  claim 15 , wherein said anti-soil component comprises a fluorochemical. 
     
     
         17 . The method of  claim 15 , wherein said aqueous dispersion further comprises a metal salt. 
     
     
         18 . The method of  claim 15 , wherein said aqueous dispersion further comprises a retarder. 
     
     
         19 . The method of  claim 17 , wherein said metal salt is selected from the group consisting of: sodium sulfate, magnesium sulfate, potassium sulfate, calcium sulfate, manganese sulfate, iron sulfate, copper sulfate, zinc sulfate, aluminum sulfate, sodium nitrate, magnesium nitrate, potassium nitrate, calcium nitrate, manganese nitrate, iron nitrate, copper nitrate, zinc nitrate, aluminum nitrate, sodium chloride, potassium chloride, calcium chloride, magnesium chloride, manganese chloride, copper chloride, iron chloride, sodium phosphate, potassium phosphate, calcium phosphate, manganese phosphate, iron phosphate, copper phosphate, zinc phosphate, aluminum phosphate, sodium bicarbonate, sodium carbonate, calcium bicarbonate, calcium carbonate, potassium bicarbonate, and potassium carbonate. 
     
     
         20 . The method of  claim 19 , wherein said metal salt is magnesium sulfate. 
     
     
         21 . The method of  claim 17 , wherein said metal salt is present between about 2 gram/Liter to about 16 gram/Liter of said aqueous solution. 
     
     
         22 . The method  claim 21 , wherein said metal salt is present between about 2 gram/Liter to about 6 gram/Liter of said aqueous solution. 
     
     
         23 . The method of  claim 15 , wherein said aqueous dispersion has a conductivity between about 4000 to about 7000 micromhos. 
     
     
         24 . The method of  claim 15 , wherein said aqueous dispersion has a pH between about 1.5 to about 4. 
     
     
         25 . The method of  claim 15 , wherein said aqueous dispersion further comprises an additive selected from the group consisting of: dye auxiliaries, surfactants, fluoro-surfactants, nano materials, odor control agents, antimicrobial agents, fragrance agents, bleach resist agents, softeners, and UV stabilizers. 
     
     
         26 . The method of  claim 15 , wherein said aqueous dispersion temperature is between about 24° C. to about 28° C. 
     
     
         27 . The method of  claim 15 , wherein said steaming said fiber is between about 2 minutes to about 3 minutes. 
     
     
         28 . The method of  claim 15 , further comprising pre-steaming said fiber prior to contacting said fiber with said aqueous solution. 
     
     
         29 . The method of  claim 15 , wherein said steaming is performed at a temperature of about 100° C. 
     
     
         30 . The method of  claim 15 , wherein said drying is performed at a temperature between about 130° C. to about 135° C. 
     
     
         31 . The method of  claim 15 , wherein said at least one fiber is a polyamide fiber. 
     
     
         32 . The method of  claim 31 , wherein said polyamide fiber is selected from the group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof. 
     
     
         33 . The method of  claim 15 , wherein said fiber is formed into a carpet or fabric either before or after contacting said fiber with said aqueous dispersion. 
     
     
         34 . The method of  claim 15 , further comprising steam heat setting said fiber at a temperature of about 100° C. prior to contacting said fiber with said aqueous dispersion. 
     
     
         35 . The method of  claim 15 , further comprising dry heat setting said fiber at a temperature between about 130° C.-135° C. prior to contacting said fiber with said aqueous dispersion. 
     
     
         36 . The method of  claim 15 , wherein said contacting is done by a process selected from the group consisting of: bathing, exhaustion, foaming, spraying, and nip-rolling, skein dyeing, beck dyeing, space dyeing 
     
     
         37 . The method of  claim 15 , further comprising removing water from the fiber prior to drying said fiber. 
     
     
         38 . A method of applying a composition to a fiber comprising: (a) providing an aqueous dispersion comprising a dye and a stain blocker, wherein said aqueous dispersion has a conductivity between about 2000 to about 9000 micromhos and a pH between about 1.5 to about 5; (b) contacting said fiber with said aqueous dispersion at temperature between about 20° C. to about 40° C.; (c) steaming said fiber for at least 60 seconds; (d) rinsing said fiber with water; and (f) drying said fiber. 
     
     
         39 . The method of  claim 38 , wherein said method further comprises applying an anti-soil component after contacting said fiber with said aqueous dispersion solution. 
     
     
         40 . The method of  claim 38 , wherein said anti-soil component comprises a fluorochemical. 
     
     
         41 . The method of  claim 40 , wherein said anti-soil is applied by a method selected from the group consisting of: spraying or foaming. 
     
     
         42 . The method of  claim 38 , further comprising removing water from the fiber prior to drying said fiber. 
     
     
         43 . The method of  claim 38 , further comprising steam heat setting said fiber at a temperature of about 100° C. prior to contacting said fiber with said aqueous dispersion. 
     
     
         44 . The method of  claim 38 , further comprising dry heat setting said fiber at a temperature between about 130° C. to about 135° C. prior to contacting said fiber with said aqueous dispersion. 
     
     
         45 . The method of  claim 38 , wherein said at least one fiber is a polyamide fiber. 
     
     
         46 . The method of  claim 45 , wherein said polyamide fiber is selected from the group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof. 
     
     
         47 . The method of  claim 38 , wherein said fiber is formed into a carpet or fabric either before or after contacting said fiber with said aqueous dispersion. 
     
     
         48 . A composition comprising an aqueous dispersion of a dye, a stain blocker, and a retarder, where the retarder reduces the rate of dyeing. 
     
     
         49 . The composition of  claim 48 , further comprising an anti-soil component. 
     
     
         50 . The composition of  claim 48 , where the retarder adjusts the conductivity of the aqueous dispersion from about 2000 to about 9000 micromhos. 
     
     
         51 . A carpet fiber comprising a dye, an anti-soil component, and a stain block, wherein said stain block penetrates farther into said fiber than said stain block applied separately from a dyeing step.