AND FLAME RESISTANCE TO FABRIC

TECHNICAL FIELD

The present disclosure relates to a composition for treating a fabric to impart stain and flame resistance/repellence.

Particularly, the present disclosure relates to a composition comprising compound A and compound B to impart stain repellence to the fabric, without adversely affecting the flammability of the fabric. Compound A is a dispersion of fluoropolymers containing extender and compound B is a dispersion of an oxime-blocked isocyanate. The present disclosure also relates to a method of imparting stain repellence and flame resistance to fabric using said composition.

BACKGROUND OF THE PRESENT DISCLOSURE

Fabrics are used in automobiles for applications such as seats, door trims, door panels, headliners, trunk liners, vinyl tops, etc. and any other such application in automobiles. All such fabrics in automobiles are susceptible to stain for example by dust, water, food, eatables, oils from the human body, etc. All stains have deteriorated appearances, emit odor through microorganism growth and impair the durability of the product.

Fabric stains may be prevented by making the fabric resistant to staining. As any fabric to be changed after installation is very difficult and cumbersome, it is recommended to use stain resistant fabrics in automobiles. Thus, vehicle manufacturers have set up their own stain standards for car fabrics to perform stain resistance and stain removal efficiency tests.

Further, while focusing on the aspect of stain resistance to the fabrics, one should not compromise on the safety aspect of flammability of the fabrics post stain resistant treatment, as fabrics which are treated to add stain resistance increase the flammable behavior of the fabric.

Hence, there is a need in the art to arrive at a fabric having stain resistance which would not adversely affect the flammability of the fabrics. Therefore, the present disclosure was made to ensure no deterioration in fabric behavior when subjected to flame while imparting stain resistance, stain repellence and stain release.

SUMMARY OF PRESENT DISCLOSURE

The present disclosure relates to a composition comprising Compound A and Compound B; optionally along with additives; wherein compound A is a dispersion of fluoropolymers containing extender, and compound B is a dispersion of an oxime-blocked isocyanate; a process for preparing composition comprising Compound A and Compound B of the present disclosure, wherein the process comprises step of combining the compound A and the compound B optionally along with additives to obtain the composition; a method of treating fabric with a composition of the present disclosure, wherein the method comprises steps of (a) padding the fabric with the composition to obtain a padded fabric, (b) drying the padded fabric, and (c) curing the padded fabric of step (b); a fabric treated by the composition of the present disclosure; a method of imparting stain repellence to fabric, said method comprising act of treating the fabric with a composition of the present disclosure; a method of imparting flame repellence to fabric, said method comprising act of treating the fabric with a composition of the present disclosure; a method of imparting stain repellence and reducing flammability of a fabric, said method comprising act of treating the fabric with a composition of the present disclosure; a fabric treated by the composition of the present disclosure; and the use of a fabric treated by the composition of the present disclosure for stain repellence and flame resistance.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

In order that the disclosure may be readily understood and put into practical effect, reference will now be made to exemplary embodiments as illustrated with reference to the accompanying figures. However, the figures are purely for the purpose of exemplifying and are non-limiting in nature. The figures together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages, in accordance with the present disclosure where:

Figure 1 provides a schematic representation of the process of treating fabric wherein the drying and curing is carried out separately. Figure 2 provides schematic representation of the rapid curing process of treated fabric wherein drying and curing is carried out simultaneously.

DETAILED DESCRIPTION OF DISCLOSURE

The present disclosure relates to a composition comprising Compound A and Compound B; optionally along with additives; wherein compound A is a dispersion of fluoropolymers containing extender, and compound B is a dispersion of an oxime-blocked isocyanate.

In an embodiment of the present disclosure, the compound A and the compound B is at a ratio of 1 : 1.

In an embodiment of the present disclosure, the composition comprises 15g/L to 30g/L, preferably 20g/L of compound A and 15g/L to 30g/L, preferably 20g/L of compound B.

In an embodiment of the present disclosure, the additives are selected from a group comprising water, pH adjuster, wetting agents and combinations thereof.

In an embodiment of the present disclosure, the pH adjuster and wetting agents are selected from any industrially known agents as known to any person skilled in the art. The present disclosure also relates to a process for preparing composition comprising Compound A and Compound B of the present disclosure, wherein the process comprises step of combining the compound A and the compound B optionally along with additive to obtain the composition, wherein compound A is a dispersion of fluoropolymers containing extender, and compound B is a dispersion of an oxime-blocked isocyanate. In an embodiment of the present disclosure, the compound A and the compound B is at a ratio of 1 : 1.

In an embodiment of the present disclosure, the composition comprises 15g/L to 30g/L, preferably 20g/L of compound A and 15g/L to 30g/L, preferably 20g/L of compound B.

The present disclosure also relates to a method of treating fabric with a composition of the present disclosure, wherein the method comprises steps of (a) padding the fabric with the composition to obtain a padded fabric, (b) drying the padded fabric, and (c) curing the padded fabric of step (b). In an embodiment of the present disclosure, the composition comprise Compound A and Compound B optionally along with additives; wherein compound A is a dispersion of fluoropolymers containing extender and compound B is a dispersion of an oxime-blocked isocyanate. In an embodiment of the present disclosure, the step (a) comprises immersing the fabric into a container containing the composition followed by squeezing the fabric with rollers.

In an embodiment of the present disclosure, the drying in step (b) is carried out at a temperature of 100°C to 140°C for time duration of 8 minutes to 12 minutes.

In an embodiment of the present disclosure, the curing in step (c) is carried out at a temperature of 140°C to 200°C for time duration of 10 seconds to 5 minutes.

In an embodiment of the present disclosure, the step of drying and curing is optionally combined and carried out at a temperature of 150°C to 200°C for time duration of 10 seconds to 2 minutes.

The present disclosure also relates to a method of imparting stain repellence to fabric, said method comprising act of treating the fabric with a composition of the present disclosure.

The present disclosure also relates to a method of imparting flame resistance to fabric, said method comprising act of treating the fabric with a composition of the present disclosure.

The present disclosure also relates to a method of imparting stain repellence and reducing flammability of a fabric, said method comprising act of treating the fabric with a composition of the present disclosure.

The present disclosure also relates to a fabric treated by the composition of the present disclosure.

In an embodiment of the present disclosure, the fabric is selected from a group comprising woven, non-woven, knitted, netting fabrics and technical fabrics. The present disclosure also relates to the use of a fabric treated by the composition of the present disclosure for stain repellence and flame resistance. In an embodiment, the compound A of the present disclosure is a dispersion of flouropolymer containing an extender. One such commercially available fluropolymers containing extender is OLEOPHOBOL®.

In another embodiment, compound A is an aqueous dispersion containing perfluoropolymers and one such example is OLEOPHOBOL®.

In an embodiment, the compound B of the present disclosure is an oxime blocked isocyanate. One such commercially available oxime blocked isocyanate is PHOBOL®.

In an embodiment, the terms "resistance" and "repellence" have been used interchangeably and have the same meaning within the ambit of the disclosure. In an embodiment, the compound A when used alone for stain repellence of the fabric will have higher flammability of the fabric.

In another embodiment of the present disclosure, an extender is a material used to dilute or extend or change the properties of compounds.

In an automotive vehicle, fabric plays an important role. It provides aesthetic appearance as well as protects substrate beneath.

Conventionally, fabrics have tendency to soil and stain during handling or use. Fabric once stained has negative effect on the look and feel of the vehicle. Hence, stain resistance of fabric is very critical to imparting lasting aesthetics to the vehicle.

However, stain repellent fabric tends to have very low flame resistance property. Hence, the present disclosure provides a composition for treating fabrics to impart stain resistance/repellence without adversely affecting flammability of the fabric.

In an embodiment of the present disclosure, the stains caused on the fabric are essentially oil and water based stains.

In an embodiment, the present disclosure makes use of the composition comprising flouropolymers containing an extender and oxime-blocked isocyanate to impart stain resistance to the fabric, without adversely affecting flammability of the fabric. The present disclosure also relates to a process of preparation of composition for treating fabric to impart stain resistance as well as imparting flame resistance to ensure that the treated fabric has stain resistant property with improved flame behavior or reduced flammability which is well within the prescribed norms. The treated fabric is an improved fabric which provides stain resistance and reduced flammability.

While the disclosure is susceptible to various modifications and alternative forms, specific aspect thereof has been shown by way of examples and drawings and will be described in detail below. It should be understood; however, that it is not intended to limit the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the present disclosure as defined by the appended claims.

The present disclosure is further described with reference to the following examples, which are only illustrative in nature and should not be construed to limit the scope of the present disclosure in any manner.

EXAMPLES:

Example 1: Physical and Chemical Properties of the chemicals in the composition

The composition of the present disclosure is prepared from the compounds mentioned below.

1. Compound A: is an aqueous dispersion of perfluoropolymers; for example: commercially available fluoropolymers containing extender used in the example is

OLEOPHOBOL®.

2. Compound B: is a dispersion of an oxime-blocked isocyanate. For example: commercially available oxime-blocked isocyanate used in the examples is PHOBOL® RSH ^® . The chemicals are obtained from Huntsman Chemicals. The properties of the chemicals are as follows:

1. Compound A: dispersion of fluoropolymers containing extender; For example: Oleophobol ^® Co Chemical constitution: Dispersion of fluoropolymers containing extender

Ionic character: Non-ionic/cationic

pH (500 g/l): 3.0-5.0

Specific gravity at 20 °C: 1.07-1.09g/cm ³

Physical form: White - beige dispersion

2. Compound B: is a dispersion of an oxime-blocked isocyanate; For example: Phobol®RSH

Chemical constitution of the aqueous formulation of the modified resin

Ionic character: Non-ionic / cationic

pH of the compound: 4.0 - 5.5

Specific gravity at 20°C: 0.99 - 1.00 g/cm3

Physical form: White to slightly beige liquid

Storage stability: PHOBOL® RSH is stable for 1 year when properly stored in closed containers at 20°C.

The compound is sensitive to cold below 0°C and sensitive to heat above 40 °C.

Example 2: Compositions and Methods of Preparing the same

The compound A and compound B of the composition are taken at different concentrations for the treatment of the fabric. The specific concentrations of the compounds which are used for stain resistance property to fabrics are as follows. I. Composition I:

i. Compound A = 40 g/1

II. Composition II:

i. Compound A = 20 g/1

ii. Compound B= 20 g/1 III. Composition III:

i. Compound A = 30 g/1

ii. Compound B= 20 g/1

Preparation of the Compositions: The said compositions are prepared by combining the two components of the composition in the amounts as mentioned above.

For example, to prepare 1 litre of a composition II, 20g of Compound A and 20g of Compound Bare mixed and made up to 1 litre with water. This can be scaled up to any volume as required.

Example 3: Method of Treating the Fabric with the composition to impart stain and flame resistant

The sample fabric is treated with the compositions of the present disclosure to obtain the treated fabric which has both stain and flame resistant properties. The process for obtaining the treated fabric is provided in detail in this example and is carried out as below:

The process involves the following three steps in order to obtain a stain and flame resistant fabric:

Padding: Initially, the fabric (untreated) is immersed in a water bath containing the composition containing Compound A and Compound B (either composition I/II/III). In a more specific manner, the fabric is first padded in a 'padder' with composition containing compound A and compound B at a concentration of 20g/L each. The 'padder' consists of a trough and a pair of squeeze rollers. During the padding process, the fabric passes under a submerged roll in the trough filled with the composition and then through the squeeze rollers. In this manner, the fabric is continuously being immersed in the trough and pulled out of the trough which is the treated fabric.

The fabric passes through the chemical bath with defined pick up depending on the roller speed. The fabric treated with the composition is then squeezed by the squeeze rollers in order to remove excess of the composition.

The fabric emerging from the squeeze rollers is then subjected to drying and curing as described below.

Drying and Curing: Drying is the process of evaporation of the embedded liquid/composition from the fabric. The treated fabric is now dried in an oven at a temperature of about 110°C to 130°C. As a dryer cylinder, stenter (stenter machine is used to control the shrinkage, width, GSM of the fabric also finish chemicals is used by the stenter) etc. can be used. During drying at a higher temperature, fixation of the composition in the fibre of the fabric increases and at the same time water is removed by evaporation. After drying, the fabric can be washed in a washing machine to remove the unreacted composition.

Curing is a process of subjecting a sample to a temperature cycle in order for two chemical components to reinforce with each other. Herein, the dried, treated fabric is cured under a temperature cycle which helps in even reinforcement of the chemical composition containing Compound A and Compound B with which it is treated.

In the event that the fabric is capable of withstanding higher temperature or is capable of reaching cure temperatures, the drying and curing process can occur simultaneously. However, the two processes can be carried out independently also, wherein drying occurs separately and curing separately.

The aforementioned treated fabric is further subjected to various tests for stain and flame resistance as discussed in the below examples.

Example 4: Stain Performance of the fabric/sample

In order to assess the stain performance of the fabric, the test is done with the following commercially available chemicals/staining substances which are test solvents used for studying the stain behaviour of the fabric:

1. Petrol (P),

2. Diesel (D),

3. General purpose thinner (GPT),

4. Engine oil (EO),

5. Brake fluid (BF),

6. Automotive transmission fluid (ATF),

7. Soap water, and

8. Tea.

Standards used in checking for stain resistance properties and flammable properties:

Stain resistance for fabrics is checked as per the standard parameters for checking the stain resistance and flame resistance of a fabric. The chemicals used for staining the fabrics were Petrol (P), Diesel (D), General purpose thinner (GPT), Engine oil (E.O), Brake fluid (BF) and Automotive Transfer fluid (ATF). The process employed for conducting stain resistance test is as follows:

1) The sample i.e. the fabric is taken and the area where the test is to be performed is selected.

2) The chemicals/test solvents for staining of the fabric (i.e. Petrol, Diesel, General purpose thinner, Engine oil, Brake fluid and Automotive Transfer fluid) one by one with the help of a dropper (two drops) are applied on the fabric/sample from a distance of 5 cm.

3) After applying chemicals on sample, the behavior of chemicals is observed and the fabric is treated with the chemicals and incubated for about 1 min. Also, absorption of a chemical on to the sample/fabric is observed during this incubation time.

4) If the chemicals remain in the form of spherical drop up to at least 1 min of the incubation time, then the chemical is easily blotted out with the help of cotton cloth.

5) After blotting out the unabsorbed chemicals from sample/fabric, observation for any stain mark on the fabric is done.

The results for the above test carried out for checking stain resistance of a sample/fabric is provided in table 1 below:

Table 1 The result in Table 1 shows comparison of stain performances of the various compositions as per the standard. Herein, it is observed that the composition II having compound A and compound B at 20g/l each is better when compared to compositions I and III for imparting stain repellence to the fabric. The treatment for stain resistance is done on woven fabric. This treatment can be done on knitted fabrics as well as non-woven fabrics. Thus, the said treatment can also be carried out on all other fabrics which are used in automotive industries such as woven, non-woven, knitted fabrics etc. The treatment can also be carried out for any fabric which is prone to staining. The aforementioned test is carried out to unfinished/untreated fabric without any stain repellent treatment and also to fabrics treated with different formulations of the chemicals for imparting stain resistance.

Few drops of these chemicals are placed on the fabric with dropper and the time taken to absorb these chemicals is noted down. In case of volatile chemicals i.e. Petrol, Diesel and General purpose thinner (GPT), the presence of stain mark after evaporation is captured. Example 5: Flammability test of the fabric/sample

Flammability test as per FMVSS 302 mentions compliance to only burning rate. i.e. burning rate should be less than 102 mm/min. However, the standard does not mention anything about flammable drops during burning.

The treated fabric by the composition arrived in the present disclosure is checked for stain resistance, the flammability aspects for burn rate and also for flammable drops. Flammable drop adversely affect the fabric and is potentially dangerous. Therefore, in addition to the burn rate, the present disclosure also analyses the aspects of flammable drops present after the treatment of the fabric. The composition of the present disclosure goes beyond the requirement of the standard of FMVSS 302, as the composition does not exhibit any flammable drops which are a common problem with stain resistance treatment of fabric. The present disclosure also records the aspect of dripping of flammable drops during burning.

Table 2 below provides comparison of flammability behaviour as per FMVSS 302 for the above two compositions with an untreated fabric. Comp.

COMPOSITION Specification Observations Remark

No.

No treatment/ No Flammable drops

- 72.57 mm/min

unfinished with slow burning.

102 mm/min Flammable drops &

1 Compound A - 40g/L 57. 69mm/min

MAX fast burning observed

Compound A - 20g/L (FMVSS No Flammable drops

2 32.15 mm/min

Compound B - 20g/L :302) with slow burning.

Compound A - 30g/L Flammable drops &

3 - Compound B - 20g/L fast burning observed

Table 2

INFERENCE:

Composition I which is Compound A = 40 g/L shows 57.69 mm/min burning rate and flammable drops were observed during burning.

Composition II which is Compound A = 20 g/L and Compound B = 20 g/1 shows reduction in flammabihty rate to 32.15 mm/min with no flammable drops. These results are achieved without drop in stain resistance performance.

Composition III which is Compound A = 30 g/L and Compound B = 20 g/1 shows flammable drops.

From the table 2 and above results, it is evident that Compound A as composition I when used alone has high flammability results (57.69 mm/min), whereas when compound A and compound B are used together in composition II has reduced flammability. While compound A and compound B in composition III also show flammable drops. Therefore, it can be derived that the flammability of the fabric is reduced when compound A and compound B are used together in specific ratios as disclosed in composition II.

CONCLUSION

As can be seen from results, Compound A with 40g/l (Composition I) shows absorption of chemicals and shows 57.69 mm/min of burning rate and flammable drops with fast burning are observed. This is treated as control and the results of composition I and II are compared with the results of the control composition I. Composition II with Compound A = 20 g/1 and Compound B =20g/l shows improved stain behaviour as the chemical drops do not get absorbed after 24 hours as well as flammability rate is reduced to 32.15 mm/min and no flammable drops are observed.

Composition III with Compound A = 30 g/1 and Compound B =20g/l does not show as much improved stain behaviour as the composition II and the flammability rate is also higher in the case of composition III when compared to composition II.

Overall, it is evident from the examples of the present disclosure that composition II having Compound A at a concentration of 20 g/1 and Compound B at a concentration of 20g/l provides better stain repellence and flame resistance than compositions I and III of the present disclosure. Therefore, it is observed that the concentration of compound A and compound B at 20g/l each serves to be the best concentration for treating a fabric to impart stain repellence without affecting the flame resistance behaviour of the fabric. Also, the results establish the fact that flammability of the fabric is reduced when compound B is used along with compound A of the present disclosure.