This invention relates to textile materials and, more particularly, to the application of finishing agents to textile materials.

5 Conventionally, the treating of textile materials with finishing agents, e.g., coloring agents or dyes, resins, softeners, flame retardant agents, soil release agents and the like involves a procedure wherein the finishing agent is either dissolved or dispersed in a suitable li- o quid medium carrier such as an aqueous or organic li¬ quid, and then applied to the textile, such as by pas¬ sing the textile through a bath or vat containing the solution or dispersion. Thereafter, the carrier is re¬ moved from the fabric, usually by evaporation with or 5 _ without heat. Since only a small amount of the fin¬ ishing agent is needed to achieve the desired effect, a relatively large amount of carrier (water) is used to assure uniform distribution of the finishing agent. This results in relatively large amounts of liquid o medium whichmust be removed from the fabric. Conse¬ quently, a substantial amount of the cost incurred in.such processes resides in the liquid medium removal s ep.

5 For many .textiles it is desired to apply more than one

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finishing agent thereto. For example, it may be de¬ sirable to first dye the textile and then apply a durable press agent or to apply both durable press and soil release agents to the textile. Since rela- 5 tively few of such combinations of finishing agents can be applied together from the same medium, such multiple agents are typically applied to the textile in a serial manner. Thus, for example, a coloring agent is first applied to the textile; the textile is o then dried; and the colored textile then treated with a further fabric finishing agent in a conventionalman¬ ner and then re-dried.

In the foregoing process, the disadvantages earlier 5 described as being associated with the conventional utilization of large quantities of liquid medium in the application of finishing agents are necessarily multiplied. In an effort to avoid the difficulties involved with large amounts of liquid and the high o cost of liquid removal processes, it has been attem¬ pted to conduct the serial application of finishing agents to a textile without intermediate drying of the textile after each application. However, this manner of operation itself leads to serious problems. Thus, 5 when the wet textile to which a first finishing agent solution or dispersion has been applied is brought in¬ to contact with a second liquid finishing agent com¬ position, e.g., when the wet textile is passed through a bath thereof, the liquid associated with the textile o from the first application serves to dilute or other¬ wise alter the composition of the second finishing agent solution or dispersion. It is thereby nearly impossible to accurately control the application of specified quantities of the second finishing agent to 5 the textile, even with the utilization of complicated measuring devices and bath replenishment techniques.

SUMMARY OF THE INVENTION

It is accordingly an object of the present invention to provide a process for treating a textile with more than one finishing agent.

A further object of the present invention is to provide a serial process for treating a textile with a least one finishing agent which does not require intermediate fixation of the textile prior to application of a foam composition thereover. o

A still further object of the present invention is to provide a process of the type mentioned which does not present difficulties in the control of the amounts of finishing agent applied to the textile. 5

These and other objects are achieved by the provision of a process wherein a textile is first treated with a finishing agent-containing composition and, prior to any significant drying or fixation (i.e., complete re- o moval of all liquid therefrom) , is thereafter treated with a second covering composition which is applied in the form of a foam. The textile is then treated to collapse the foamed composition and effect uniform penetration of the finishing agent into the fabric, if 5 desired.

The treatment of textiles in accordance with the pre¬ sent invention has the advantage of eliminating costly liquid removal procedures between application of fin- o ishing agents. Moreover, it has been found that appli¬ cation of the second finishing agent in the subse¬ quently applied foamed composition avoids the earlier- referred to dilution effect arising.from conventional

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application of the second finishing agent in a liquid solution or suspension since significantly less liquid per se is required when such compositions are applied as. foams, and since the foam can be applied without 5 the need for passing the textile through a bath or vat containing the liquid finishing agent composition.

In accordance with the present invention, the applica¬ tion of the first finishing agent-containing composi- o tion to the textile can be accomplished in accordance with conventional techniques, e.g., by continuously passing the textile through a bath or vat containing the liquid composition. However, according to a pre¬ ferred embodiment of this invention, the first finishin 5 agent composition may be applied in the form of a foam. In this method of operation, this first foam applied to the textile is collapsed, prior to application of the second foamed composition to the textile. Such collapsing of the first applied foam may occur upon o application such as when using rotary screen printers and the like.

Finishing agent-containing compositions for utilization in the present invention are known in the art and typi- 5 cally comprise a finishing agent and an aqueous or or¬ ganic liquid carrier medium along with other known, optional ingredients.

For the case where the finishing agent-containing com- o position is applied as a foam, the preparation and formulation of such foamed compositions is described in the commonly-assigned application of Gregorian., and Namboodri, Serial No. 584,389, now U.S. Patent No. , incorporated herein by reference. These 5 foamed compositions are prepared by foaming a mixture

comprised of finishing agent, liquid medium and a foam¬ ing agent (foam stabilizer) to a blow ratio of from about 2:1 to about 2o:1 to result in a foamed composi¬ tion having a foam density in the range of from about 5 o,5 gm/cc to about o.o5 gm/cc.

The various finishing agents which may be utilized in the treatment of textiles according to the present in¬ vention include coloring agents, dyes, pigments, dura-

-jo ble press agents, soil release agents, weighting agents, flame retardants, water repellents, softeners, and the like. Foamable, liquid compositions containing such ^• finishing agents, and methods of ^" preparing foams there¬ from, are extensively described in detail in the above-

15 mentioned application Serial No. 584,389.

In specific embodiments of the present invention, the application of the first finishing agent-containing composition may comprise printing the textile with a

2o pre-selected pattern in accordance with known procedu¬ res, e.g., by use of an intaglio printing cylinder or a rotary screen printer. The first composition may be a conventional liquid printing composition, a foamed printing composition or a powdered composition. After

25 application, a foamed composition, with another fin¬ ishing agent, is applied to the textile prior to fixa¬ tion of the first applied finishing agent to the prin¬ ted textile.

3o The process of the present invention will typically be utilized for the serial application of two or more differing types of finishing agents to a textile, e.g., a colorant and a water-repellent or a colorant and a durable press agent, although numerous other combina-

35 tions exist.

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As utilized herein, textile material is intended to include, without limitation, fabrics made from threads, yarns, woven or knitted goods, resin bonded mats of fibres, and the like.

5

According to this invention, the second, serially applied fabric finishing agent is applied to the texti¬ le in the form of a foam while the textile still con¬ tains a first finishing agent-containing composition o (either foam, liquid or powder). Thus, as utilized herein, application of the second composition without prior fixation of the textile is intended to describe and embrace processes wherein the textile has not been fully dried after application of the first composition. 5 Hence, it is possible according to this invention that varying degrees of liquid removal, short of complete or near-complete drying, from the textile can be per¬ formed before application of the second, foamed compo¬ sition, although the economic advantages of the present o invention necessarily decrease in proportion to the de¬ gree of such an intermediate liquid removal step. More¬ over, a certain degree of liquid removal from the textile may occur simply as a result of normal proces¬ sing prior to application of the second, foamed compo- 5 . sition. For example, some liquid may be removed by - virtue of passage of the textile through conventional squeeze rolls prior to passing to the second serial application step. In the case of foam printing, the generally preferred manner of collapsing the foam is o accomplished by the printing screen or print roller at the instant the foam is applied to the fabric.

In- general, the textile to which the second finishing agent composition is applied will have about 1o to 65% 5 liquid, by weight, associated therewith.

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BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is as schematic representation of an embodiment depicting the process of the present invention wherein 5 the first liquid and finishing agent-containing compo¬ sition is applied as a solution or dispersion.

Fig. 2 is a schematic representation of. an embodiment of the present invention wherein the first finishing _Q agent-containing composition is applied in the form of a foam.

DESCRIPTION OF THE PREFERRED EMBODIMENT

5 The present invention is more fully described with re¬ ference to the description of the drawings and the Examples which follow.

With reference to Fig. 1 , a roll of fabric 1o, travel- o ling in the direction indicated by the arrow, is passed by suitable conveying means to a bath 12 containing a pre-prepared liquid, e.g. , aqueous or organic liquid, solution or dispersion containing an appropriate finish¬ ing agent, e.g., a dye material ^' to color the fabric. 5 . The -dyed fabric is then passed through squeeze or com- - pression rollers 14 and 16 which serve to remove some of the liquid contained in the fabric by virtue of its passage through the solution or dispersion. Without any further liq ^' uid removal, i.e., before complete drying, o the dyed fabric is coated with a foamed finishing agent composition. Thus, a foamable liquid composition com- ^■ prised of liquid, foaming agent and finishing agent, e. g. ^' a durable press agent, is formed into a foam in foa er 18. Foamer 18 may be any type foaming device 5 conventionally utilized in the art, e.g., Oakes, God¬ win card', Kitchenaid, etc.

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The foamed composition is transferred trough line 22 b pump 2o to knife 24. At this point the foamed composi¬ tion is coated onto the dyed fabric to produce a coate fabric 26. The coated fabric 26 then goes trough nip 5 rollers 28 and 3o to compress and collapse the foam an achieve penetration of finishing agent into the fabri Such foam collapse may also be achieved by the applica tion of vacuum, or a combination of vacuum and padding Thereafter, the impregnated fabric is conveyed through o a fixation means 32 which may be any of those conven¬ tionally known in the art. The fixed fabric is then wound on to take-up roll 34.

An alternative embodiment of the process of the presen 5 invention is shown in Fig. 2. A roll of fabric 4o, travelling in the direction of the arrow by suitable conveying means, is coated with a first foamed fabric finishing agent composition. Such a foamed composition is prepared by foaming a suitable composition, e.g., a ₀ dye-containing foamable composition, in foamer 42. The foamed composition is pumped by pump 44 through line 4 to a rotary printing screen 48 at which a predeter¬ mined pattern is applied to the fabric. As mentioned previously, with such a printing screen, the foam is 5 caused to collapse upon application. If a procedure is employed in which the foam is not collapsed upon appli cation, the so-coated fabric 5o is then passed over va cuum or padding device 56 or a combination of the two which serves to collapse the foam but which does not o effect liquid removal from the fabric.

. The so treated fabric 66 is then coated with a second foamed finishing agent composition, formed by foaming a suitable composition, e.g., a durable press-containi 5 foamable composition, in foamer 58. The second foamed

composition is transferred by pump 60 through line 62 to knife 64 where it is coated on the fabric. The so- coated fabric 68 then passes through nip rollers 7o . and 72 to collapse the foam and deeply penetrate the 5 finishing agent into the fabric. The fabric is then conveyed to a fixation means 74 and wound on take-up roll 76.

In the foregoing embodiments, the foamed finishing Q agent composition may also be applied by spraying or blowing it through a nozzle onto the fabric.

The following Examples illustrate various specific features of the process of the present invention. 5

EXAMPLE I

A foamable pigment composition containing 7o.86% water, 2.o7% ammonium stearate, o,78% lauryl alcohol, 4.29% o Acrysol ASE-60 (an acrylic po-lymer emulsion having 28% solids (Rohm & Haas Co.)), 2% Valmel-45 (a methylolated melamine) , 1o% Valbond-6o63 (an acrylic copolymer emul¬ sion) and 1o% Questral Blue 3G (phthalocyanine pigment) was foamed to a 3:1 blow ratio and printed through a 5 5o mesh rotary screen on 1oo% cotton print cloth and 5o/5o polyester/cotton blend sheeting samples. The printing foam was collapsed by the action of the screen upon application of the foam to the fabric.

o A foamable durable press resin composition was prepared containing 52.1o% water, o.62% Methocel J-75MS (an etherified hydroxyethyl cellulose), 1.37% Unamide N-72-3 (a coconut alkanolamide from Lonza Chem. Co.), 36.16% Valrez-248 (a modified glyoxal resin) and 9.8% Valcat 5 No. 7 (a magnesium chloride catalyst) . This composition

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was foamed to a blow ratio of 9:1 and knife coated to a thickness of 6 mils on the wet printed samples previously prepared as described above. The fabric samples were then vacuumed, dried and cured at 35o°F.

The definition of the prints was excellent and the fa¬ brics possessed durable press properties tested after repeated laundering.

As a control, a sample of the previously described foam printed 1oo% cotton was passed through a conventional finishing bath of Valrez-248 and Valcat No. 7 and nippe through a ^" vertical pad. The fabric was dried and cured as before.

The print exhibited severe flushing and loss of defini¬ tion so as to make the fabric commercially unacceptable. There was also some transfer of color to the pad bath.

EXAMPLE II

The foamable durable press resin composition described in Example I was foamed to a blow ratio of 8:1 and knif coated to a thickness of 6 mils onto 1oo% cotton and - 5o/5o polyester/cotton blend fabrics. The fabrics were - vacuumed and, while wet, were printed utilizing the foamed pigment composition and conditions described in Example I.

Good print definitions and durable press properties wer obtained.

EXAMPLE III

A foamable composition containing 2% Resolin Blue FBL

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(disperse) , 1% Procion Blue HA (reactive) , 1% sodium bicarbonate and 96% of a foamable composition contain¬ ing 97.75% water, o.75% QP-52ooo (hydroxethyl cellulo¬ se-thickener from Union Carbide) and 1.5% Unamide 5 N-72-3 was prepared and foamed to a blow ratio of 10:1.

A second durable press resin composition containing 5o.75% water, o.75% QP-52ooo, 35% Valrez-248, 3% Val- sof PE-19 (a polyethylene emulsion), 1% Unamide N-72-3 o and 9.5% Valcat No. 7 was also foamed to a blow ratio of 1o:1.

On a 65/35 polyester/cotton blend fabric, the dye foam was coated to a thickness of 2o mils and the coated 5 fabric pulled over a vacuum (wet pick-up 45%) . On the dye-applied wet fabric, the durable press foam composi¬ tion was knife-coated to a thickness of 25 mils. The fabric was then vacuumed (total wet pick-up 62%) , and dried and cured at 33o F for 3 minutes. o

The fabric contained good durable press properties and was uniformly dyed.

A sample of the wet foam dyed fabric was also passed 5 . through a conventional finishing bath consisting of - Valrez-248, Valsof PE-19 and Valcat No. 7 in the same ratio as the foam finishing composition but at an 8% solids concentration. There was significant bleeding of color into the pad- bath causing the fabric to be o off-shade.

- EXAMPLE ^"' IV

A sample of 65/35 polyester/cotton blend was dyed, 5 using the beck dyeing procedure, with 1% Sirius Supra

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Blue BRL (direct dye) and 2% Resolin Blue FBL (disperse) based on the weight of the fabric. After the dyeing cycle, the fabric was rinsed, padded and vacuumed.

The durable press resin composition of Example III was foamed to a blow ratio of 10:1 and coated to a thicknes of 25 mils onto the wet beck-dyed fabric. The fabric wa then padded at 35 p.s.i.g., dried at 22o°F and cured at

33o°F for 3 minutes. o

The fabric possessed durable press properties and was uniformly dyed.

As a control, a sample of the wet dyed fabric was passe 5 through a conventional finishing bath of the compositio described in Example III. Again ^' there was bleeding of the color from the fabric into the pad bath.

EXAMPLE V o

A foamable disperse dye composition containing 2% Re¬ solin Brill. Yellow 7 GL in 98% of a composition con¬ taining o.75% QP-52ooo, 1.5% Unamide N-72-3 and 97.75% water (adjusted to a pH of 5.5 with acetic acid) was 5 prepared and foamed to a blow ratio of 8:1. This foamed composition was then knife coated to a thickness of 35 mils on a polyester double knit fabric. The fabric was then passed over a vacuum slot.

o second foamable composition containing 2% Resolin Red FB (Disperse Red-6o) in 98% of a composition containing .o,75% QP-52ooo, 1.5% Unamide N-72-3, and 97.75% water (adjusted to pH 5.5) is foamed to a blow ratio of 3:1 and over printed through a 5o mesh rotary screen prin- 5 ter on the wet foam-dye applied polyester knit. The

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knit fabric is then dried and thermosoled at 35o°F for color fixation to produce special over printing effects.

EXAMPLE VI 5

A foamable composition containing 4 parts Rapidogen Red KB, 1 part caustic (5o% soln.) and 95 parts of an alka¬ line foamable composition containing 3.5% 3o9-7o acrylic, 9o.5% water, o.5% ammonia and 5.5% 3o9-59 ammonium o stearate (2o% soln.) was foamed to a blow ratio of 8:1 and knife coated to a thickness of 25 mils on a cotton sheeting sample. The coated sample was then padded at 3o p.s.i.g. (wet pick-up 4o%) . A second sample was foam printed through a 5o mesh rotary screen printer with 5 the same foam.

An acid color developing foam was prepared by dissolving 2 parts acetic acid and 2 parts formic acid in 96 parts of a foamable composition containing 1.5 parts Unamide o N-72-3, o.75 parts QP-52ooo and 97.75 parts water, and foaming to a 1o:1 blow ratio. This foamed composition was coated to a thickness of 25 mils onto each of the above-referred to wet samples. The samples were then vacuumed from the back to collapse the foam and then 5 steamed at 21o°F to remove acid vapor and water. The color was developed and demonstrated good fixation. The printed fabric had excellent definition.

When the printed wet samples were developed by conven- o tional padding through a formic/acetic acid mixture, there was color bleeding and the resulting prints had flushing.

5

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EXAMPLE VII

A foamable prewetting composition containing o.5 parts Valdet4o16 and 94.5 parts water was prepared. The co - 5 position was foamed to a 1o:1 blow ratio and 25 mils of foam was coated on a cot-ton velour upholstery ma¬ terial and padded. On the prewetted material direct dye foam was applied as follows:

o A dye composition containing 1 part direct dye-Sirius Supra Blue 2RL and 99 parts of a mix containing 3.5% Valthick-7o, o.5% aqua ammonia, 9o.5% water and 5.5% Am. stearate (2o%) was foamed to 6:1 blow ratio. Then 5o mils of the foam was coated wet-on-wet on the foam 5 prewetted sample and the so treated sample was vacuumed and padded. The sample was then steamed for 7 minutes at 21o°F. and dried at 22o°F.

Uniform dyeings were obtained on the cotton fabric o having good color fastness.

EXAMPLE VIII

A 1o% solution of procion Red MX 5B reactive dye in wa- 5 _, ter was prepared. The dye solution was applied to a _ cotton carpet pile in a random pattern.

An alkaline composition containing 2 parts sodium hy¬ droxide (5o% -soln.) and 98 parts of a mix containing o 3.5% Valthic-7o (an acrylid acid polymer emulsion), o.5% ammonia, 9o.5% water and 5.5% Am. stearate (2o%) ■ was prepared. This composition was foamed to a 6:1 blow ratio and 5o mils of foam was knife coated on the aforementioned carpet pile having reactive dye applied. 5 The carpet was vacuumed from the back side and padded.

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Then for reactive dye fixation, the sample was wet stored for 4 hrs. and dried at 22o°F. The randomly applied color had good penetration inside pile.

5 EXAMPLE IX

A foamable composition consisting of 3.5 parts of Val- thick-7o (an acrylic acid emulsion polymer) , o.5 parts of aqua ammonia 5.5 parts of a 2o% solution of ammonium o stearate and 9o.5 parts of water was prepared.

To 95 parts of this foamable composition was added 3 parts Naphthol AS (C.I. Azoic Coupling component 2) and 2 parts of 5o% sodium hydroxide. This mixture was 5 mechanically foamed to an .8 to 1 blow ratio and knife coated onto cotton print cloth to a thickness of 1o mils. The fabric was then padded at 3o psi.

A second foamable composition consisting of 1.5 parts o of Valdet CC(a fatty acid die ^' thanolamide manufactured by Valchem) o.75 parts of Cellosize QP 52ooo (a hydroxy¬ ethyl cellulose manufactured by Union Carbide) and 97.75 parts of water was prepared.

5 To 9o parts of this second foamable composition was added 8 parts of Fast Scarlet 2G salt (C.I. Azoic Diazo Component 3) and 2 parts of acetic acid. The composition was mechanically foamed to an 8 to 1 blow ratio and a 1o mil coating was applied to the wet fabric samples o previously coated with the first composition. The sample was padded at 3o psi. and exposed to air for 3 minutes.

The fabric was then dried. The dried fabric was soaped to remove the uncoupled components. Good color develop- 5 ment was achieved.

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EXAMPLE X

A first foamable composition consisting of 3.5 parts of Acrysol ASE-60 (an acrylic acid emulsion polymer anu- 5 factured by Rohm and Haas) , o.5 parts of aqua ammonia, 5.8 parts of a 2o% solution of ammonium stearate and 9o.2 parts of water was prepared.

To 1oo parts of the foamable composition was added 6 o parts of Sodyesul Liquid Blue 4BGCF (C.I. Leuco Sulfur Blue 13) and 6 parts of Sodified B (a solution of so¬ dium sulfide manufactured by Southern Dyestuff Company) and 3 parts of soda ash.

5 The composition was mechanically foamed to a 6 to 1 blow ratio. Fifty mils of the foamed composition was then knife coated onto a cotton corduroy fabric. The coated fabric was passed over a vacuum slot and then padded at 3o psi. o

A second fabric sample was coated with 25 mils of the foamed composition and padded only.

Both samples were steamed at 21o°F for 5 minutes. 5

A foamable oxidizing composition consisting of 1 part of Valdet CC, 1 part of acetic acid, 1 part of 35% hy¬ drogen peroxide solution and 97 parts of water was prepared. o

This composition was foamed to a 1o to 1 blow ratio and ^■ 2oomils ^' of the foam was knife coated onto the previ¬ ously wet steamed samples. The thus coated fabric sam¬ ples were passed over a vacuum slot to draw the foam 5 into the fabric. The dye was oxidized.

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The samples were then dried. The sulfur dyed cotton corduroys possessed level dyeing and good color fast¬ ness properties.

5 EXAMPLE XI

A foamable vat pigment composition consisting of 96 parts of the first foamable composition described in Example X and 4 parts of Vat Yellow 4 paste (manufac- o tured by Ciba Geigy) was prepared.

The composition was foamed to an 8 to 1 blow ratio and then knife coated to a thickness of 25 mils onto cotton sheeting. The coated fabrics was then padded and dried. 5

A second foamable reducing composition was prepared from 5 parts of 5o% sodium hydroxide solution, 3 parts of sodium hydrosulfite, 2 parts of Valdet CC and 9o parts of water. This composition was then mechanically foamed o to an 8 to 1 blow ratio and a 1oo mil coating applied to the previous vat pigment coated fabric. The fabric was then passed over a vacuum slot and steamed at 21o°F for 5 minutes for reduction of vat pigment.

5 . .The wet steamed fabric was then oxidized to develop and _ fix the color by applying the foamed oxidizing composi¬ tion previously described in Example X. The fabric was then dried. A level dyeing with good fastness proper¬ ties was obtained. o

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