This invention relates to a home fabric dye product. In particular, it relates to a solid dye product, which is capable of changing the colour of a fabric or topping up faded colours and is also suitable for use in a domestic washing machine.

Solid dye products for use in domestic washing machines and containing a dye, salt and alkali are known. In one known product, which is available under the trade name "Dylon Renovator", the dye, salt and alkali, as well as an anti-dumping or free flow agent, are contained in a single water- permeable sachet of the tea-bag type. The anti-dumping agent is required to avoid clumping of the dye which will lead to slower dissolution of the dye material and uneven dyeing results. In use, a Renovator sachet containing 50 g of dye/alkali/salt is placed in the drum of a washing machine with up to 600 g of fabric. Additional salt (usually about 250 g of sodium chloride) must be added by the user to obtain optimum dyeing results. One of the problems with this product is that the anti- clumping or free flow agent, being a fine powder, can cause the dye powder to come through the sachet causing staining on the packaging and on the user's hands. Furthermore, this product is only suitable for topping up faded colours and is not suitable for changing the colour of a fabric.

In another known product, all of the dye, salt and alkali are contained in a water-impermeable container means, such as a water-impermeable sachet, thereby overcoming the clumping issue. However, as the sachet must be cut by the user to empty its contents into the washing machine, it is difficult for the user to avoid contact with the dye resulting in staining of the user's skin.

It is an object of the invention to avoid or minimize the disadvantages of the prior art.

According to the invention there is provided a solid dye product, which is suitable for changing the colour of a fabric and for use in a domestic washing machine, said dye product comprising: a) a water-permeable sachet formed from a non-woven, water-permeable material and

containing a water-soluble dye composition comprising from about 40 to about 70% by weight of one or more reactive dyes and from about 30 to about 60% by weight of one or more salts or one or more alkalis or a mixture thereof, the percentages being percentages by weight of the total dye composition in the water-permeable sachet; and

b) a water-impermeable container means containing a water-soluble dye fix composition comprising one or more alkalis, alone or in combination with one or more salts;

wherein the weight ratio of the dye composition to the dye fix composition is from about 1 :5 to about 1 :20.

As used herein, the term "reactive dye" is intended to mean that a reactive substituent group in the dye molecule can form a covalent chemical bond with molecules in the fabric to be dyed. Reactive dyes are the most suitable dyes for home use as they work at a low temperature, give colour fast results and do not stain the washing machine.

Suitable reactive dyes include those from the triazine, pyrimidine and vinyl derivative classes, having the following formulae:

Dye

wherein A ¹ is CI and A ² is aryl or CI, preferably CI;

CI

E

wherein A is CI and E is H or CI; and

Dye-X-CH ₂ -CH ₂ -0-S0 ₃ H

wherein X is -S0 ₂ - , -NHCO- or -S0 ₂ NH-.

As used herein, the term "aryl" means a monocyclic or polycyclic-aromatic ring or ring radical comprising carbon and hydrogen atoms and which may be substituted or unsubstituted. Examples of suitable aryl groups include, but are not limited to, phenyl, tolyl, anthracenyl, fluorenyl, indenyl, azulenyl, and naphthyl, as well as benzo-fused carbocyclic moieties such as 5,6,7,8- tetrahydronaphthyl.

Preferred reactive dyes for use in the invention include one or more of the following:

^■ CI Reactive Black 5 =tetrasodium 4-amino-5-hydroxy-3,6-bis[[4-[[2- (sulphonatooxy)ethyl]sulphonyl]phenyl]azo]naphthalene-2,7-di sulphonate

^■ Everzol Orange GR (does not have a CI number) = disodium 6-(4,6-dichloro-1 ,3,5-triazin-

2- ylamino)-1-hydroxy-2-(4-(2-(sulfonatooxy)ethylsulfonyl)pheny lazo)naphthalene-3- sulfonate

^■ CI Reactive Red 239 = pentasodium 2-[[8-[[4-chloro-6-[[4-(2-sulfonato

ethylsulfonyl)]phenyl]amino]-1 ,3,5-triazin-2-yl]amino-1- hydroxy-3,6-disulfonato-2- naphthalenyl]azo]naphthalene-1 ,5-disulfonate 2-[[8-[[4-chloro-6-[[4-[[2- ethenyl]sulfonyl]phenyl]amino]-1 ,3,5-triazin-2-yl]amino]-1-hydroxy-3,6-disulfonato-2- naphthalenyl]azo]naphthalene-1 ,5-disulfonate

• CI Reactive Yellow 125 = disodium 7-[[2-(acetylamino)-4-[(5-chloro-2,6-difluoro-4- pyrimidinyl)amino]phenyl]azo]naphthalene-1 ,3-disulphonate

^■ CI Reactive Yellow 27 = trisodium 4-[[4-[[(2,3-dichloro-6-quinoxalinyl)carbonyl]amino]-2- sulphonatophenyl]azo]-4,5-dihydro-5-oxo-1-(4-sulphonatopheny l)-1 H-pyrazole-3- carboxylate

^■ CI Reactive Orange 64 = 2-[[6-[(5-chloro-2,6-difluoro-4-pyrimidinyl)amino]-1-hydroxy -3- sulpho-2-naphthyl]azo]naphthalene-1 ,5-disulphonic acid, sodium salt

^■ CI Reactive Red 123 = disodium 7-[(5-chloro-2,6-difluoropyrimidin-4-yl)amino]-4-hydroxy-

3- [(4-methoxy-2-sulphonatophenyl)azo]naphthalene-2-sulphonate

■ CI Reactive Red 159 = 5-(benzoylamino)-3-[[5-[[(5-chloro-2,6-difluoro-4- pyrimidinyl)amino]methyl]-1-sulpho-2-naphthyl]azo]-4-hydroxy naphthalene-2,7-disulphonic acid, lithium sodium salt

^■ CI Reactive Red 147 = tetrasodium 2-[[8-[[3-[(5-chloro-2,6-difluoro-4- pyrimidinyl)amino]benzoyl]amino]-1-hydroxy-3,6-disulphonato- 2- naphthyl]azo]naphthalene-1 ,5-disulphonate

^■ CI Reactive Blue 224

^■ CI Reactive Blue 1 16 = Copper, [[[[3-[(5-chloro-2,6-difluoro-4- pyrimidinyl)amino]phenyl]amino]sulfonyl]-29H,31 H-phthalocyaninato(2-)- N29,N30,N31 ,N32]-, aminosulfonyl sulfo derivatives, sodium salts

■ CI Reactive Blue 21 = Copper, [29H,31 H-phthalocyaninato(2-)-N29,N30,N31 ,N32]-, sulfo [[4-[[2-(sulfooxy)ethyl]sulfonyl]phenyl]amino]sulfonyl derivatives

^■ CI Reactive Blue 225 = lithium sodium hydrogen 4-amino-6-(5-(5-chloro-2,6- difluoropyrimidin-4-ylamino)-2-sulfonatophenylazo)-5-hydroxy -3-(4-(2- (sulfonatooxy)ethylsulfonyl)phenylazo)naphthalene-2,7-disulf onate ^■ CI Reactive Blue 204 = hexasodium 6, 13-dichloro-3,10-bis((4-(2,5-disulfonatoanilino)-6- fluoro-1 ,3,5-triazin-2-ylamino)prop-3-ylamino)-5, 12-dioxa-7, 14-diazapentacene-4, 1 1- disulphonate The reactive dye used herein preferably comprises at least 50%, or at least 60%, or at least 70%, or at least 75%, or at least 80%, or at least 85%, or at least 90%, or at least 95%, by weight of the dye itself, of a black, navy or deep blue reactive dye or a combination thereof. A suitable black reactive dye is CI Reactive Black 5, and a suitable navy dye is CI Reactive Blue 225. It should be noted that commercial preparations of reactive dyes generally contain salt, usually sodium chloride or sodium sulphate, as a diluent. However, the percentages by weight quoted herein for the reactive dye do not include the salt of the commercial preparations, which is included in the percentages by weight quoted for the salt in the dye composition. The salts suitable for use in the dye composition or in the dye fix composition herein include alkali metal salts of inorganic acids, preferably sodium or potassium chloride and sodium or potassium sulphate and combinations thereof. Sodium salts are preferred, especially sodium chloride.

The alkalis suitable for use in the dye composition or in the dye fix composition include sodium or potassium carbonate, sodium or potassium hydroxide, sodium or potassium metasilicate, sodium or potassium silicate, sodium or potassium bicarbonate, trisodium phosphate, ammonium hydroxide and organic alkalis such as triethanolamine, and combinations thereof. The sodium salts are preferred, especially sodium carbonate and sodium metasilicate. The alkali used is such that the final pH in the dye bath in the washing machine will be from about 10.5 to about 12.5, preferably about 1 1 .5.

The dye composition herein preferably comprises no anti-clumping or free flow agent or substantially no anti-clumping or free flow agent. The dye composition may include from 0.1 to 1 % by weight of minor additives such as perfumes and the like.

The dye composition herein may be in particulate and/or granular and/or powder form. The dye composition herein preferably comprises the reactive dye in an amount of from about 45 to 65%, or about 50 to 60%, or about 55 to 65%, or about 60 to 70%, by weight of the total dye composition in the water-permeable sachet.

The dye composition herein preferably comprises from about 35 to 55%, or about 40 to 50%, or about 35 to 45%, or about 30 to 40%, by weight of the total dye composition in the water- permeable sachet, of a mixture of salt and alkali, wherein, preferably, the weight ratio of salt to alkali in the dye composition is from about 2.5:1 to 7: 1 , more preferably about 3.5: 1 to 5:1 or about 4: 1 to 5:1.

The dye fix composition herein preferably comprises a mixture of one or more alkalis and one or more salts, wherein, preferably, the weight ratio of alkali to salt is from about 3.8: 1 to 2: 1 , more preferably about 1 : 1 to 1.5:1 or about 1 : 1 to 1.25:1 .

The weight ratio of the dye composition to the dye fix composition is preferably from about 1 :5 to 1 : 10, more preferably about 1 :6 to 1 :10, especially about 1 :6 or about 1 :8.

The water-permeable sachet containing the dye composition is formed from a non-woven, water- permeable material and is sealed at its periphery. The non-woven material may be formed from a thermoplastic material such as polyester, polypropylene or polyethylene or any combination thereof, optionally in combination with cellulose. The weight of the material in the water-permeable sachet is preferably about 50 g/m ² , the porosity is preferably about 340 L/m ² /s, and the thickness is preferably about 159 μηη. The sachet dimensions are conveniently about 140 mm ^χ 85 mm. The water-permeable sachet is conveniently a tea-bag type sachet.

The dye fix composition is contained in any suitable water-impermeable container means, such as, e.g., a sachet, carton or plastic tub. A container means in the form of a water-impermeable sachet is particularly preferred. The water-impermeable sachet may be formed from any suitable water- impermeable material. The water-impermeable sachet may be cut open by the user and then placed in the drum of the washing machine with its contents or, alternatively, the contents only of the water-impermeable sachet may be placed in the drum of the washing machine.

The dye product of the invention comprising the water-permeable sachet with the dye composition, together with the dye fix composition that is preferably contained in a water-impermeable sachet, is typically presented in a single package, such as for example, a box or carton, for the convenience of the user.

The invention also provides a method of dyeing a fabric using the dye product of the invention, the method comprising: a) placing the water-permeable sachet containing the dye composition, the dye fix composition, and the fabric to be dyed in the drum of a washing machine; and b) allowing the dyeing to take place at a temperature of from about 30°C to about 60°C.

The water-permeable sachet preferably contains from about 40 to 50 g of dye composition; the dye fix composition is preferably present in an amount of about 300 g to 400 g; and the fabric weight is preferably from about 200 g to about 1.2 kg. The temperature in step b) is preferably about 40°C. The dye fix composition may be contained in a water-impermeable sachet, which has been cut open by a user before placing in the drum of the washing machine.

The fabric to be dyed may be, for example, one or more items of clothing or a home furnishing fabric and is preferably moistened before dyeing.

The following Examples illustrate the invention.

Example 1

A dye product according to the invention was prepared containing the following components

Everzol Orange GR is available from Everlight Chemical Industrial Corp.

CI Reactive Red 239 is available from Everlight Chemical Industrial Corp. under the trade name Everzol Brilliant Red 3BS he.

CI Reactive Black 5 is available from Everlight Chemical Industrial Corp. under the trade name Everzol Black GSP. The amount of salt present in the commercial dye preparations used is as follows:

Everzol Black GSP = 40% salt in commercial dye = contributes 30.40% salt to the final formula. Everzol Brilliant Red 3BS he = 50% salt = contributes 0.5% salt to the final formula. Everzol Orange GR = 10% salt = contributes 0.18% salt to the final formula.

Accordingly, a total of 31.08% of the salt comes from the commercial dyes and an additional 1 1.45% is added to give 42.53% total salt in the dye composition.

40-50 g of the dye composition are filled into a water-permeable sachet (140 mm ^χ 85 mm) of the tea-bag type, grade IMA C51 , available from Glatfelter, and heat-sealed. 300-400 g of the dye fix composition are filled into a water-impermeable sachet having dimensions of approximately 15 cm (length) x 10 cm (width), and the sachet is heat-sealed.

Comparison of the product prepared in Example 1 above with a known product:

• Inventive product prepared in Example 1 above: 50g dye / 300g dye fix composition

i. 400g cotton

ii. Hotpoint washing machine = Hotpoint Aquarius WML 520

iii. Tea-bag of dye composition and contents of water-impermeable sachet containing dye fix composition added to drum of machine

iv. Damp fabric added to machine

v. Cotton 40°C cycle run

vi. Washing powder added and another 40°C cycle run to clean excess dye off fabric and machine

vii. Fabric dried

Known product: Ideal from AC Marca - dye for cotton, linen, silk, viscose

75ml trough of liquid dye, 100g trough of fix

ii I.. 400g cotton

ii. Hotpoint washing machine (same as above)

v. Corners cut off the dye and fix troughs and placed into machine. 500g table salt added

v. Damp fabric added to machine

vvii.. Cotton 40°C cycle run

vii. Washing powder added and another 40°C cycle run to clean excess dye off fabric and machine

viii. Fabric dried

• Result: both the fabric dyed with the inventive product and Ideal were level. The inventive product was 70% stronger than the Ideal black as shown by

spectrophotometric analysis, using Spectroflash 600 Data Color, dataMaster V2.3. Both products were used at their full strength, which for the Ideal product was as recommended in the manufacturer's instructions. Using the Ideal product as standard (set at 100%), the colour strength relation % of the product of Example 1 , at 610 nm, was 170.09. The colour difference between the two products was calculated using CMC 1.0, 2.0: 1.0. The results are illustrated in Fig. 1 , which is a graph of % reflectance vs wavelength in nm.

Example 2

A dye product according to the invention was prepared containing the following components:

CI Reactive Blue 225 is available from Dystar under the trade name Levafix Navy EBNA.

The amount of salt present in Levafix Navy EBNA = 18% salt in commercial dye and contributes

6.48% salt to the final formula. The product prepared in Example 2 above was compared with the "Ideal black" product according to the procedure in Example 1 , except that 400 g of dye fix were used (50g of dye composition) and the wavelength of measurement was 600 nm. Using the Ideal product as standard (set at 100%), the colour strength relation % of the product of Example 2, at 600 nm, was 196.96. The colour difference between the two products was calculated as in Example 1 using CMC 1 .0, 2.0:1 .0. Thus, the inventive product was 96% stronger than the Ideal black. The results are illustrated in Fig. 2.

The dye compositions prepared in Examples 1 and 2 above have the following properties:

• They are sufficiently free flowing to allow them to be filled into a small sachet opening during production

• They are not so free flowing that they will pass through the sachet walls as a powder during transport causing staining of the sachet and outer container and transferring to the hands of the user

• Once in the washing machine, they will dissolve very quickly so that good dyeing results will be obtained.

The invention is not limited to the embodiments described herein, which may be modified or varied without departing from the scope of the invention.