Stain resistance of nylon carpet

Abstract

Stain-resistant nylon, especially cationic-dyeable carpet nylon, is prepared by dyeing cationic-dyeable nylon fibers with acid or premetallized dye. Lightfastness and depth of shade of an apparent value equal to acid dyeable nylons is obtained with superior stain resistance equal to commercially available solution dyed nylon carpeting.

Description

This invention relates to improving the stain resistance, lightfastness and ozone resistance of nylon, especially nylon carpet.

BACKGROUND OF THE INVENTION

Stain resistant nylon carpets enjoy significant market acceptance. Stain resistance is typically imparted to nylon by treating the fiber as a solid filament or in a carpet form by the application of a chemical finish as described in U.S. Pat. Nos. 4,501,591; 4,592,940; and 4,839,212 to Monsanto.

Nylon carpet fiber is generally classified as to type, depending upon its receptivity to acid dyes and basic or cationic dyes. Cationic dyeable nylons contain within the polymer structure sufficient SO.sub.3 H groups or COOH groups (which groups are receptive to cationic or basic dyes) to render the nylon fiber dyeable with cationic dyes. Acid dyeable nylons are essentially conventional nylons, such as polyhexamethylene adipamide and polycaprolactam. Acid dyeable nylons vary as to type and are characterized as being weakly dyed with acid dyes, average dyed with acid dyes, or deeply dyed with acid dyes.

Cationic dyeable nylons generally exhibit inherent stain resistant properties, especially to acid-type stains, as compared to other nylon types used for carpet. Cationic dyeable nylons are dyeable with selected cationic dyes, but suffer from poorer colorfastness to light, especially in light shades, than do comparable shades dyed on acid dyeable nylon using monosulfonated or premetallized acid dyes. This has resulted in the under-utilization of cationic dyeable nylon as a carpet fiber. The fiber's inherently useful properties which otherwise make it attractive as a carpet fiber previously have not been fully realized.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is further described and illustrated in the attached drawings in which:

FIG. 1 is a graph plotted from the data of Tables I and II of Example 6 comparing the percent dye exhausted from a dyebath versus pH of the dyebath in dyeing filament type 634 cationic dyeable nylon (duPont) twisted into a two ply yarn then heatset to retain twist. Four types of dyebaths were compared over the pH 2.about.10 range; they were level acid dye (straight line), premetallized acid dye (O), level acid dye with 2% sodium sulfate (.quadrature.), and premetallized acid dye with 2% sodium sulfate (.DELTA.);

FIG. 2 is a is a graph plotted from the data of Table III of Example 7 showing the premetallized acid dyeing of 12 samples of type 494 cationic dyeable nylon (Antron, dupont) prior to heatsetting comparing lightness/darkness (Delta L*) over the pH range of 2.about.10; and;

FIG. 3 is a graph plotted from the data of Table IV of Example 7 comparing the same parameters of dyeing 12 samples of the same cationic dyeable nylon prior to heatsetting using an acid dye under similar conditions.

Dyeing conditions and assessment of results are explained in more detail in Examples 6 and 7 that follow.

DESCRIPTION OF THE INVENTION

It has been found that significant differences in color yield are observed when dyeing is accomplished/conducted at various pH levels and that significant differences appear between acid dyes and premetallized acid dyes. In general, I have observed that cationic dyeable nylon is most effectively dyed when operating in an acid pH range for both acid dyes and premetallized acid dyes with better dye exhaustion at pH values less than 7.0 than with pH values above 7.0. Efficient utilization of dye is important to process economics in using dye more effectively to reduce costs, environmentally in reducing or virtually eliminating (when possible) dye in process effluent, and repeatability of the dyeing process--the closer to complete exhaust, the more likely a repeat dyeing will look exactly the same.

My investigations reveal a sharp and significant increase in dye efficiency as the pH decreases from the neutral (pH 7) toward the acid range indicating distinctly improved results at 6.5.about.6.0 with improved results at lower pHs. Premetallized acid dyes provide greater dyeing efficiency, in terms of exhaustion, than do acid dyes and exhibit this characteristic over a broader range of pH values.

This invention provides a procedure for dyeing cationic dyeable nylon with acid and premetallized acid dyes over a wide range of pHs resulting in nylon carpet having improved stain resistance and fastness properties.

The preferred techniques for practicing the invention include exhaust dyeing, pad/steam dyeing, continuous carpet dyeing and the like. Illustrative examples for dyeing procedures thought to be suited to the process of this invention are:

Pad/Steam

A dyebath is prepared as follows:

The following compounds (in grams per liter) were mixed together:

______________________________________guar gum (Celcagum V-60) 3antifoam (Sedgekill AO) 1.5wetting/penetrating agent(Dyebath SS-75) 7premetallized acid dyestuff X%(pH adjusted to 6.0 with monosodium phosphate)______________________________________ and applied to the cationic dyeable nylon at wet pickup of 90 to 140% based on the weight of the yarn. For proper fixation, the yarn is steamed for 6 to 12 minutes and then washed, extracted, treated with a fluorochemical soil repellant and dried. Exhaust Dyeing

An aqueous dyebath is prepared containing the required amount of premetallized acid dyestuff, the pH is adjusted to 6.0 with monosodium phosphate and, optionally, up to 0.5% Irgasol SW is added (this is a weakly cationic agent which complexes with the dye and then slowly releases the dye to the fiber as the temperature rises). The dyebath temperature, initially at 80.degree. F., is increased at a rate of 2.degree. F. per minute to 140.degree. F. and held there for 15 minutes, then raised again at 2.degree. F. per minute to 208.degree.-212.degree. F. Cationic dyeable nylon is then exhaust dyed for 30 to 60 minutes or longer as needed to achieve the desired depth of shade.

Illustrative cationic dyeable nylons include:

__________________________________________________________________________DuPont Monsanto Allied BASF__________________________________________________________________________Filament:"Antron" Type 924 "Ultron" 2360-68-JEJ "Anso" Type 7L422"Antron" Type 494 "Anso" Type 7K53"Antron" Type 754"Antron" Type 854"Antron" Type P695"Antron" Type 564"Antron" Type 574"Antron" Type 634"Antron" Type 744"Antron Lumena"Type H-554ASolution dyed nylonType H-544ANylon Staple:"Antron" P-676A "Ultron"-750-JES "Anso" Type 591 "Zeftron" W118S"Antron" P-683A"Antron" 543A"Antron" S47A"Antron" 971A"Antron" 1055__________________________________________________________________________

An affinity for cationic dyes is usually imparted by the incorporation of a monomer containing sulfonic acid groups. Thus one such modification of a polyamide fiber is obtained by adding a certain amount of sulphoisophthalic acid prior to polymerization.

Premetallized and acid dyes considered suited to the process are:

______________________________________ ColorTrade Name Manufacturer Index Name Number______________________________________AmichromeBlack RB ICI Acid Black 63 --Red RB " Acid Red 226 --AtalanFast Orange YF ATL Acid Orange 69 --Orange GRE " Acid Orange 62 --Yellow GR " Acid Yellow 99 13900Inochrome ICI Acid Black 52 --Black BNIIntrachromeBlack RPL C&K -- --Black WA Ex Conc " Acid Black 52 15711Bordeaux RM " Acid Red 194 --Grey RC " Acid Black 127 --Orange G " Acid Orange 74 --Yellow GR Conc " Acid Yellow 99 13900IntralanBlack BGL 150% " Acid Black 107 --Black M-RL " Acid Black 194 --Bordeaux M-B " Acid Violet 90 --Brilliant Yellow " Acid Yellow 127 --3GLDark Blue M-BR " -- --Red Brown RW " -- --Gray BL 200% " Acid Black 60 --Navy NLF " -- --Orange RDL " Acid Orange 60 18732Yellow 2GL Extra " Acid Yellow 129 --Yellow GL-S " -- --Yellow NW " Acid Yellow 151 13906IrgalanBlack BGL Ciba-Geigy Acid Blk 107 --Black GBL " -- --Black RBL " Acid Black 132 --Bordeaux EL " Acid Red 251 --Bordeaux GRL " Acid Red 213 --200%Brown 2RL " Acid Brown 45 --Gray BL " Acid Black 58 --Gray BRLA " Acid Black 60 --Olive 3BL " Acid Green 70 --Orange 2RL " Acid Orange 60 --Organe RL " Acid Orange 86 --Red B 200% " Acid Red 182 --Red 2GL " Acid Red 211 --Yellow DRL " Acid Yellow 151 13906Yellow 2GL " Acid Yellow 129 --Irganol Ciba-Geigy Acid Yellow 127 --Brilliant Yellow3GLSIsolanBlack RL, Liq Mobay Acid Black 139 --Bordeaux R 220% " Acid Red 182 --Brown S-RL " Acid Brown 413 --Grey KP- BL 200 " -- --Navy Blue S-RL " Acid Blue 335 --Red S-RL " Acid Red 414 --Yellow K-PRL " Acid Yellow 137 --200%Yellow NW 250% " Acid Yellow 151 13906Yellow S-GL " Acid Yellow 232 --LanaperlBlue GN 200 Hoechst Acid Blue 41 --Blue GN " Acid Blue 40 62125Fast Navy Blue " Acid Blue 113 --R 200Turquoise Blue GL " -- --LanasynBlack BGL 200% Sandoz Acid Black 131 --Black BRL 200% " Acid Black 132 --Black S-DL, Liq " Acid Black 194 --Black S-GL, Liq " Acid Black 222 --Black S-RL, Liq " Acid Black 218 --Bordeaux GRL " Acid Red 213 --Bordeaux RL " Acid Red 217 --Brown 2GL " Acid Brown 304 --Carbon BL Acid Black 170 --Dark Brown S-BL " Acid Brown 289 --Dark Brown S-GL " Acid Brown 298 --Grey BL " Acid Black 58 --Grey BLR " Acid Black 60 18165Navy S-BL, Liq " Acid Blue 296 --Navy S-DNL " -- --Olive Green S-4GL " Acid Green 106 --Olive S-2GL " Acid Green 106 --Orange S-RL " Acid Orange 168 --Red 2GLN " Acid Red 404 --Red S-G, Liq " Acid Red 399 --Rubine S-5BL " Acid Violet 125 --Yellow LNW " Acid Yellow 151 13906Yellow 2RL " Acid Orange 80 --Yellow S-2GL, Liq " Acid Yellow 235 --LevalanBrown I-BRL Cold Mobay Acid Brown 330 --SOLDark Brown I-TL " Acid Brown 331 --NeolanBlack WA Ciba-Geigy Acid Black 52 15711Blue 2G Conc " Acid Blue 158 14880Bordeaux RM 133% " Acid Red 194 --Orange G " Acid Orange 74 18745Pink BNA 300% " Acid Red 186 18810Yellow GR " Acid Yellow 99 13900NeutrichromeM Black M-R ICI Acid Black 194 --M Bordeaux M-B " Acid Violet 90 18762M Navy M-BD " -- --M Yellow M-3R " Acid Brown 384 --NeutrichromeS Black S-2B " Acid Black 224 --S Bordeaux S-BD " Acid Violet 121 --S Brown S-2R " Acid Brown 357 --S Grey S-BG " Acid Black 188 --S Navy S-B " Acid Blue 284 --S Navy S-NA " -- --S Orange S-R " Acid Orange 144 --S Red S-G " Acid Red 359 --S Yellow S-GR " Acid Yellow 121 18690S Yellow S-5R " Acid Orange 120 --OrcolanFast Black WAN ORC Acid Black 52 15711ExFast Blue GGN " Acid Blue 158 15050Fast Orange GEN " Acid Orange 74 18745Fast Orange GLE-S " Acid Orange 62 --Fast Red RN " Acid Red 183 --Fast Yellow BELN " Acid Yellow 54 19010Fast Yellow GRN " Acid Yellow 99 13900Neutral Black BGL " Acid Black 107 --Neutral Black BR " Acid Black 194 --Neutral Black EKC " Acid Black 164 --Ex ConcNeutral Black LDS " -- --Neutral Blue GL " Acid Blue 127 61135Neutral Bordeaux " Acid Violet 90 18762BSBNeutral Brilliant " Acid Yellow 127 --Yellow 5GNeutral Brown " -- --BRLNeutral Brown 2GL " Acid Brown 44 --Neutral Brown " Acid Brown 282 --GRSNeutral Brown 2RL " Acid Brown 45 --Neutral Dark Blue " Acid Blue 193 15707BRNeutral Grey B " Acid Black 60 --Neutral Grey " Acid Black 58 --BLGY-NNeutral Orange NR " Acid Orange 60 --Neutral Orange RL " Acid Orange 86 --250%Neutral Red B " Acid Red 182 --Neutral Yellow ORC Acid Yellow 121 --EXLEx ConcNeutral Yellow " Acid Yellow 129 --2GL ExNeutral Yellow " Acid Yellow 114 --GLSNNeutral Yellow WN " Acid Yellow 151 --250%The following level dyeing acid dyes are thought to workparticularly in the light depths but do not build very well asstrength is increased:NylanthreneBlack GLRT C&K -- --Black GLWC " -- --Blue B-AR 67% Liq " -- --Blue B-AR 200% " -- --Blue B-GA " -- --Blue B-NB " -- --Blue GLF " -- --Blue LGGL " -- --Brilliant Blue 3BLF " -- --Brilliant Blue 2RFF " -- --Brilliant Yellow " Acid Yellow 49 --4NGLBrilliant Yellow " -- --B-NGLBrilliant Yellow " Acid Yellow --B-4RK 219:1Brilliant Yellow " -- --CGL p.a.f.Brown RSM " -- --Navy LFWG " -- --Orange B-GN " -- --Orange 3G " Acid Orange 156 --Orange SLF Conc " Acid Orange 116 --Pink BLRF (pat) " -- --Red B-2B " -- --Red B-2BSA " Acid Red 266 --Red B-CLN Conc " -- --Red 2RDF " -- --Red 4RL (pat) " -- --Rubine 5BLF " Acid Red 299 --Scarlet B-YKS " -- --Scarlet GYL Ex " -- --(pat)Scarlet YDL p.a.f. " -- --Yellow FLW " Acid Yellow 159 --Yellow RAR Liq " Acid Yellow 152 --Yellow SL 200% " Acid Yellow 198 --Yellow SL Liq " Acid Yellow 198 --NylomineBlack D-2R ICI Acid Black 172 --Blue A-G Conc " Acid Blue 25 62055GrainsBlue A-2R " Acid Blue 62 62045Blue B-3G " Acid Blue 40 62125Blue C-B " Acid Blue 127:1 --Blue C-2G " Acid Blue 175 --Blue C-3R " Acid blue 140 --Bordeaux C-B " Acid Red 128 24125Bordeaux C-3B Acid Red 119 --Green C-G " Acid Green 27 61580Green C-3G " Acid Green 28 --Navy C-2R " Acid Blue 113 --Red A-B " Acid Red 396 --Red A-2B 100% " Acid Red 266 --Red B-3B " Acid Red 57 --Red C-2B " Acid Red 138 18073Red C-BA " Acid Red 249 18134Red C-G " Acid Red 151 --Violet C-B " Acid Violet 48 --Yellow A-G " Acid Yellow 135 --Yellow A-G " Acid Yellow 135 --33% PstYellow A-2GA " Acid yellow 49 --200%Yellow A-4R 150 " Acid Yellow 199 --NylosanBlue 2AL/C-2AL Sandoz Acid Blue 25 62055Blue E/C-BGL " -- --200%Blue E/C-BRL " Acid Blue 288 --Blue E/C-GL " Acid Blue 72 --Blue F-GBL " Acid Blue 127:1 --Blue F-L " Acid Blue 80 61585Blue F-RL Sandoz Acid Blue 247 --Blue N-BLN " -- --Blue N-5GL 200% " Acid Blue 280 --Blue PRL " Acid Blue 129 --Bordeaux E-2BL " Acid Red 301 --Bordeaux N-BL " Acid Red 119 --Brilliant Blue N-FL " Acid Blue 278 --Brilliant Green " Acid Green 28 --F-6GLBrown N-2R " Acid Orange 51 26550Green F-BL, 200% " Acid Green 40 --Navy N-RBL Conc " Acid Blue 113 26360Orange " Acid Orange 156 --C-GNS/E-GNSPatOrange E-2GL " Mord Orange 6 26520Orange N-RL " Acid Orange 127 --Red E-BM " -- --Red F-5B " Acid Red 143 --Red F-BR " Acid Red 167 --Red F-2R/C-2R " Acid Red 151 26900Red F-RL " Acid Red 263 --Red F-RS, Conc " Acid Red 114 23635Red N-2RBL Sandoz Acid Red 336 --Rubine N-5BL, " Acid Red 299 --200%Scarlet F-3GL " Acid Red 111 23266Violet F-BL " Acid Violet 48 --Yellow N-7GL " Acid Yellow 218 --Yellow N-3RL " Acid Orange 67 --TectilonBlack GD Ciba-Geigy -- --Blue 4GN " Acid Blue 343 --Blue GRL " Acid Blue 25 62055Blue 5GS " -- --Blue 4R " Acid Blue 277 --Floxine KL 220% Acid Red 257 --Orange 3G " Acid Orange 156 --Orange 3R " -- --Orange 4R " -- --Red 2B - Acid Red 361 --Red GR " Acid Red 73 27290Yellow 2G " Acid Yellow 169 --Yellow 4R " Acid Yellow 219 --TelonBlue ANL Mobay Acid Blue 25 62055Blue ANL Liq 33 " Acid Blue 25 --Blue BL 125 " Acid Blue 78 62105Blue BRL 200 " Acid Blue 324 --Blue BRL Disp 67 " Acid Blue 324 --Blue BRL Liq 67 " Acid Blue 324 --Blue CD-FG " Acid Blue 145 32905Blue 2GL 200 " Acid Blue 40 62125Blue 2GL Disp 50 " Acid Blue 40 62125Blue 4GL " -- --Blue RRL 182 " Acid Blue 62 62045Fast Black LD " Acid Black 172 --Fast Black LG " -- --Liq 40Fast Black NW " -- --Fast Blue A-FN " Acid Blue 264 --Fast Blue A-3GL " Acid Blue 290 --Fast Blue A-RW " Acid Blue 205 --Fast Blue ESN " Acid Blue 221 --Fast Blue 5G " Acid Blue 232 --Fast Blue GL 200 " Acid Blue 102 50320Fast Blue GGN " Acid Blue 127:1 --Fast Blue RLW " Acid Blue 204 --Fast Blue BW " Acid Green 84 --Fast Navy Blue " Acid Blue 113 26360R 182Fast Navy Blue RF " Acid Blue 113 26360Fast Orange A-RTL " Acid Orange 116 --200Fast Red A-FG " Acid Red 360 --Fast Red BRL 200 " Acid Red 260 --Fast Red 3BW " Acid Red 274 --Fast Red ER " Acid Red 158 20530Fast Red GN Mobay Acid Red 111 23266Fast Rubine A5BL " -- --167Fast Rubine " Acid Red 299 --A-5BLWFast Violet A-BB " Acid Violet 103 --Fast Yellow A-3GL " Acid Yellow 216 --Fast Yellow A-3RL " -- --Fast Yellow 4GL " Acid Yellow 79 --175Red 2BL 200 " Acid Red 266 --Red 2BL Liq 33 " Acid Red 266 --Red 2BL Disp 67 " Acid Red 266 --Red BR-CL Disp 83 " -- --Red BR-CL 250 " -- --Red CD-R " Acid Red 395 --Red FL 200 " Acid Red 337 --Red FL Liq 33 " Acid Red 337 --Red FL Disp 67 " Acid Red 337 --Yellow FGL 200 " Acid Yellow 49 --Yellow FGL Liq 66 " Acid Yellow 49 --Yellow K-RNL 200 " Acid Yellow 230 --Yellow Brown 3GL " Acid Brown 248 --______________________________________

The tests employed in the examples that follow are identified by their AATCC or other monograph designations and are briefly described as follows:

Test 1. A-2 Proposed AATCC Stain Test

A solution of eight milligrams FD&C Red Dye No. 40 per liter of distilled water is prepared with pH of the solution adjusted to 5.5 with citric acid. The temperature of this solution is maintained at 75.degree. F..+-.5.degree. F.

The carpet sample to be tested is placed on a flat surface, and an approximately two inch diameter cylinder (open on both ends) is placed onto the surface of the carpet. Twenty ml. of the above test solution is poured into this cylinder and allowed to absorb into the carpet, after which the cylinder is removed. The carpet is allowed to stand with the stain on it undisturbed for 24 hours. After 24 hours, the carpet is thoroughly flush rinsed under cold or cool tap water, then extracted and either dried in an oven or air dried.

The degree of staining is judged by comparing the amount of discoloration produced in the spotted area as compared to the surrounding area. The Modified Allied Stain Resistance Scale, a 10 point transparency scale, is used to provide a numerical rating. For the purpose of these studies, more interest was given to the relative staining differences between carpet samples.

Test 2. B-1-DuPont Blue Dye 1 "Stainmaster" Test

A solution is prepared the same as in the above test except eight milligrams of FD&C Blue Dye 1 is used; the test is carried out in the identical manner as the AATCC stain test just described.

Test 3. A-40-DuPont Red Dye 40 "Stainmaster" Test

A solution of 45 grams of cherry flavored "Kool-Aid" (sweetened) in 500 ml of distilled water is prepared. The solution is maintained at 75.degree. F..+-.5.degree. F. Spotting, washing, etc., is conducted the same as that described above.

In the following examples cationic dyeable filament yarn (duPont type 494) which was not heatset was dyed across a range of different pH values (2.0.about.10.0) by adjusting the pH to the desired level with phosphoric acid, monosodium phosphate or tetrasodium phosphate.

The invention is further explained with reference to the following illustrative examples. All parts and percentages are by weight unless otherwise indicated.

EXAMPLE 1

A sample carpet was made using type 854 cationic dyeable Antron dyed in two shades, air entangled into a 4-ply yarn, then tufted into a level loop carpet swatch. The following dyebaths were used:

______________________________________ Beige Gray______________________________________Irgalan Yellow 3RL .072% .0247%200%Irgalan Bordeaux EL .0211% .0045%200%Irgalan Black GBL .05% .0448%200%______________________________________ Percentages (%) are based upon weight of dye to weight of fiber Each dyebath was adjusted to pH 6 with 0 2% monosodium phosphate (MSP).

For performance comparisons, two previously dyed yarns of type 856/857 Antron (acid dyeable) of the same shade were each tufted into carpet swatches. As a control a third pair of carpet swatches was prepared from DuPont's solution dyed Antron Lumena, two ends each of light grey and smoke beige.

The three sets of samples were subjected to each of Tests 1, 2 and 3 according to the test procedure identified above. The two acid dyeable Antron samples performed poorly for stain resistance, whereas the cationic-dyeable Antron 854 dyed with premetallized acid dyes according to the present invention and Antron Lumena performed very well for stain resistance in all three tests with no residual stain after washing with cold clear water and extracting.

EXAMPLE 2

Cationic dyeable Antron 854 knitted sock was dyed with the following premetallized acid dyes at concentrations of 0.05, 0.1, 0.25 and 1.0%:

______________________________________Irgalan Bordeaux EL 200%Irgalan Yellow 3RL-KWL 250%Irgalan Red Brown RL 200%Irgalan Blue 3GL 200%Irgalan Black RBL 200%Irgalan Brilliant Blue 7GS 200%______________________________________ at pH 6.0 adjusted with MSP. No other additives were used in the aqueous dyebath.

To determine the ability to build the depth of shade, a similar dyeing was made on type 855 light acid dyeable Antron. The type 855 yarn was only appreciably darker at the 1.0% level, indicating the ability to dye light to medium shades on type 854 Antron cationic dyeable nylon with premetallized acid dyes.

EXAMPLE 3

Colorfastness to light and ozone resistance were tested on the twelve representative shades of premetallized acid dyes on cationic dyeable Antron type 854 nylon.

The dye constituents used to prepare the shades were as follows:

__________________________________________________________________________ Lt Rose Dusty Bur- Med Green Lt Gold Beige Green Blue Beige Rose Rust gundy Black Gray Gray Blue__________________________________________________________________________Irgalan Yellow .16% .12% .17% .012% .148% .0115% .02% .074% .022%3RL 200%(Acid Orange 162)Irgalan Red Brown .029% .029% .288% 1.0% .018%RL 200%(Acid Brown 226)Irgalan Bordeaux .08% 1.0% .007%EL 200%(Acid Red 251)Irgalan Blue .016% .02% .288% .064% .16% .076%3GL 200%(Acid Blue 171)Irganol Brilliant .25%Blue 7GS 200%(Acid Blue 239)Irgalan Black 1.0% .20%RBL 200%(Acid Black 132)__________________________________________________________________________ % dyestuff based upon the weight of the fiber 2.0% Monosodium Phosphate pH 6.0 ______________________________________ Colorfastness to Light* AATCC-OzoneShade 120 hrs 200 hrs 5 cycle______________________________________light gold 4/5 3/4 3/4beige 4/5 4 3/4green 4/5 3 3blue 4/5 4 3rose beige 4/5 4/5 3dusty rose 5 4 3/4rust 5 5 4burgundy 5 4/5 3/4black 4/5 4/5 3/4medium gray 5 4/5 3green gray 4/5 3/4 3light blue 4/5 3/4 2/3______________________________________ *AATCC Test Method 16E1971 The level of colorfastness to light achieved performs very well under the most severe exposure conditions such as those found in direct sunlight or behind glass. In contrast, the cationic dyes began to perform poorly after only 40 hours. A grade of 3 or better after 5 cycles of ozone is accepted by the industry in tropical climates in un-airconditioned installations.

EXAMPLE 4

Traffic performance was evaluated using a commercial carpet construction in a two-tone gray color. Three fibers were selected:

______________________________________Name Type______________________________________Antron T-854 cationic dyeableAntron Lumena solution dyedAntron T-857 acid dyeable______________________________________ The cationic dyeable nylon was dyed with the following premetallized dyes: ______________________________________Red GreyIrgalan Yellow 3RL-KWL 250% .054%Irgalan Black RBL 200% .204%Green GreyIrgalan Yellow 3RL-KWL 250% .083%Irgalan Bordeaux EL 200% .022%Irganol Brilliant Blue 7GS 200% .08%______________________________________ Both dyeings were exhaust dyed with 0.25% Irgasol SW and 2.0% MSP to adjust the pH to 6.0. The other two carpets were used as comparisons as conventionally dyed contract carpets. All three carpets were subjected to spotting with staining agents including coffee, cherry Kool-Aid, organic-bound iodine and laundry bleach. Each agent was applied, allowed to remain on the carpet overnight, then cleaned with a water flush.

The carpet of this invention performed in an equal manner to the solution dyed carpet in all areas except resistance to household bleach where the solution dyed carpet was found to be resistant to bleach discoloration whereas the carpet of this invention was not resistant. Conventionally dyed Antron type 856/857 stained heavily.

EXAMPLE 5

Cationic dyeable yarn (Antron type 854) knit into a tube was continuously dyed in a laboratory Ilma pad/steam unit with 100% wet pickup with the indicated premetallized dyes depending upon the shade desired, then steamed for approximately 8 minutes to provide the desired base shade. The base shade-dyed tube was then overprinted using a silk screen process:

Pad baths for the background shade were:

______________________________________Gray: Irgalan Bordeaux EL .015% Irgalan Yellow 3RL .015% Irgalan Blue 3RL .1487%Light Gold: Irgalan Yellow 3RL .05%______________________________________ Each pad bath also included Celcagum V-60 (0.3%) and Dyebath SS-75 (0.7%) and was adjusted to pH 6 with MSP.

Print pastes in 4 shades were prepared from a base of thickener (Lyngum CP-3) 2.35%, penetrant (Tergitol) 1%, an antifoaming agent (Antifoam CK-2) 0.15% and adjusted to pH 6.0 with MSP. Dyes used for the 4 shades were:

dark gold: Irgalan Yellow 3RL 1% bright blue: Irgalan Brilliant Blue 7GS 0.25% burgundy: Irgalan Bordeaux EL 200% 1% green: Irganol Brilliant Blue 7GS 0.25% Irgalan Yellow 3RL 0.25% The printed samples were fixed with steam, washed and dried. The print design was satisfactorily fixed to the nylon tube with good crockfastness. This dyed and space printed product offers a styling versatility advantage over solution dyed nylon, in which pigment is extruded with the polymer, by allowing multiple colors on one yarn while maintaining the antistaining advantage inherent in cationically dyeable nylon yarns.

Additionally a skein of "Antron Lumena" P-807A solution pigmented yarn (colored pigment is incorporated into the polymer prior to extrusion into filament form) which also exhibits cationic dyeable properties, was printed with the same dark gold, bright blue and burgundy formulation above. This was followed by fifteen minutes atmospheric steaming at 210.degree. F., washing and drying. The resulting overprint with the premetallized acid dye was judged to have acceptable crock fastness and performance as a product styling tool.

EXAMPLE 6

The following two examples used filament type 634 cationic dyeable dupont nylon, which is twisted into a two ply yarn (4.75z.times.4.75s) and Superb heat-set to retain twist. This yarn was then tufted into a 48 ounce/sq.yd. plush cut pile Saxony carpet.

The carpet was divided into nine 20 gram swatches and dyed for one hour, in dyebaths adjusted for pH (pH 2 to pH 10) with phosphoric acid or tetrasodium phosphate (TSPP), utilizing both a level dyeing acid dye formula and a premetallized acid dye formula for a medium beige shade. Level Acid Dye Formula:

______________________________________Level Acid Dye Formula:0.152% "Tectilon" Yellow 3 RK 200% Acid Yellow0.05% "Tectilon" Red 2B Acid Red 3610.0284% "Telon" Blue BRL 200% Acid Blue 324Premetallized Acid Dye Formula:0.00361% "Erionyl" Yellow MR 250% Acid Yellow 1510.00106% "Intralan" Bordeaux 3 RS Conc Acid Red 1820.0019% "Irgalan" Black RBL 200% Acid Black 132______________________________________

The carpet was dyed from an exhaust bath at 40 to 1 water to goods ratio where the only variable was the pH of the bath. After the dye cycles were complete, the carpet was removed from the bath and rinsed with water. All baths were then adjusted to pH 2.0 with phosphoric acid and a 10 g swatch of deep acid dyeable nylon sock (type 857 Antron) was added to the bath. This procedure scavenged the remaining dyes and permitted estimation of the percent exhaustion of dye by the carpet values.

The carpet swatches were then laid out in a display ranging from pH 2 up to pH 10. The deep acid dyeable sock which exhausted any dyestuff remaining in the respective bath was arranged above the carpet. A visual judgement was made estimating the degree of exhaust obtained at each pH value. Results are found in Table I, and the results of dyeing in the presence of 2% Glauber's salt are shown in Table II. These data are represented graphically in FIG. 1.

TABLE I______________________________________Level Acid Dye Premetallized DyepH Exhaust % pH Exhaust %______________________________________2 80% 2 98%3 40% 3 95%4 30% 4 90%5 30% 5 90%6 30% 6 90%7 25% 7 80%8 20% 8 80%9 20% 9 75%10 40% 10 90%______________________________________ TABLE II______________________________________Level Acid Dye + Premetallized Dye +2% Sodium Sulfate 2% Sodium SulfatepH Exhaust % pH Exhaust %______________________________________2 90% 2 100%3 60% 3 98%4 60% 4 98%5 50% 5 98%6 40% 6 95%7 30% 7 90%8 30% 8 90%9 20% 9 90%10 75% 10 90%______________________________________

From these data it will be observed that, in general, premetallized acid dyes exhausted much better at all pH values than level dyeing acid dyes on cationic dyeable nylon. The highest degree of exhaust was obtained at acid pH values of less than 7.0 (pH 2.0-7.0) with pH 2.0 showing the highest degree of exhaust. When 2% (on weight of fiber) sodium sulfate (Glauber Salt) was added to the dyebath, better exhaustion was obtained with both dye classes.

It will be apparent from the results presented above that the preferred class of dyes is the premetallized acid dyes with a pH range on the acid side; that is, the pH should be less than 7.0. Sodium sulfate can be used to promote even greater degrees of exhaustion (95% plus) when combined with premetallized acid dyes at pH's of less than 7.0. As a practical matter, pH values of around 2.0 while operable are to be avoided with premetallized acid dyes because of a tendency to demetallize some dyes and the poorer solubility of the dyes in general. These factors are apt to detract from the quality and reproducibility of dyeing.

EXAMPLE 7

The following experiment was conducted to compare the dyeing of cationic dyeable nylon dyed with either an acid dye or a premetallized acid dye over the pH range of 2-10.

Non-heatset cationic dyeable nylon (DuPont Antron) was dyed with two dyes: "Nylanthren" Blue GLF, an acid dye, and "Irgalan" Black RBL (200%), a premetallized acid dye. Both dyeings employed 0.5% of dye (oil the weight of fabric), and were conducted at the following pH values: 2, 4, 6, 6.2, 6.4, 6.6, 6.8, 7.0, 7.3, 7.6, 8 and 10. Phosphoric acid was added to the dyebath to achieve pH 2 and 4; monosodium phosphate for 6.-6.8; distilled water at neutral pH 7; and tetrasodium pyrophosphate at pH 7.3-10. Twelve swatches of 20 grams each of 494 knitted filament nylon sock were dyed from an exhaust bath at a 40 to 1 water to goods ratio in which the only variable was the pH of the bath. The results are shown graphically in Table III.

The light reflections of the dyed knitted socks were then read on the Hunter Lab "Color Quest" 4-inch field spectrophotometer with the pH 7.0 dyeing at neutral pH taken as control. The numerical values recorded were referenced back to the value at neutral pH as darker or lighter. The number used is the Delta L* (lightness/darkness value) from the CIELCH Color Difference equation.

TABLE III______________________________________Premetallized Acid Dye______________________________________ pH 10.0-3.46 light pH 8.0-2.5 light pH 7.6-3.13 light pH 7.3-2.37 light pH 7.0-Control pH 6.8-0.14 dark pH 6.6-0.55 dark pH 6.4-0.78 dark pH 6.2-2.85 dark pH 6.0-2.30 dark pH 4.0-3.32 dark pH 2.0-5.95 dark______________________________________ TABLE IV______________________________________Acid Dye______________________________________ 4.60 light 3.02 light 1.04 light 0.06 light Control 1.63 dark 1.89 dark 4.83 dark 4.36 dark 5.03 dark 6.70 dark 9.92 dark______________________________________

The values are shown in the attached Tables III and IV, respectively, which demonstrate the much better dye exhaust at acid pH values less than 7.0 than at alkaline values above pH 7.0. The amount of dye left in the bath also reflects this difference between an acid pH and an alkaline pH, with the acid bath range 4.0-6.6 causing much less residual color than pH 7.0-8.0.

In the foregoing description, the materials identified for convenience by trade name or trademark are more specifically described in the literature and materials available to the trade as follows:

______________________________________Dyestuffs Color Index Name______________________________________"Irgalan" Yellow 3RL 200% Acid Orange 162"Irgalan" Yellow 3RL 200% Acid Orange 162(cold water soluble version)"Irgalan" Red Brown RL 200% Acid Brown 226"Irgalan" Bordeaux EL 200% Acid Red 251"Irgalan" Blue 3GL 200% Acid Blue 171"Irgalan" Black RBL 200% Acid Black 132"Irgalan" Black BGL 200% Acid Black 107"Irganol" Brilliant Blue 7GS 200% Acid Blue 239"Tectilon" Yellow 3RK Acid Yellow"Tectilon" Red 2B Acid Red 361"Telon" blue BRL 200% Acid Blue 324"Erionyl" Yellow MR 250% Acid Yellow 151"Intralan" Bordeaux 3RS Conc Acid Red 182"Nylanthrene" Blue Acid Blue"Irgalan" Black RBL 200% Acid Black 132______________________________________

Chemicals

"Irgasol" SW (Ciba Geigy Corp)--Alkyl Amino Polyglycol Ether. A nonionic aliphatic, nitrogenous compound which complexes with the anionic dye forming addition compounds which break down as temperature rises allowing controlled exhaustion of the dyestuff. "Progacyl" V-60 VDMIL (Rhone Poulenc) (formerly Celcagum V-60 Lydal Chemical)--Nonionic Guar Gum--a derivatized, low residue, acid hydrating, nondusty guar gum designed specifically for the carpet and textile industries. "Progacyl" CP-3 (Rhone-Poulenc) (formerly CP3, Lyngum, Lyndal Chemical)--Anionic Guar Gum--An anionic acid hydrating, derivatized guar gum thickener. "Sedgemul" SS-75 (Sedgefield Specialties) (formerly Dyebath SS-75, BI Chem)--An aqueous mixture of sulfated ether and alcohols--A concentrated anionic wetting agent exhibiting exceptionally rapid wetting properties at temperatures usually employed in textile processing. "Sedgekil" CK-2 (Sedgefield Specialties) (formerly Antifoam CK-2, BI Chem)--An aqueous mixture of organosilicone, sulfactants and acrylic polymer. "Tergitol" Nonionic 15-S-3 (Union Carbide Corp)--A linear alcohol polyethylene glycol ether.

Claims

1. A process of dyeing cationic-dyeable nylon fibers comprising dyeing said fibers in a dyebath with a premetallized acid dye at a pH of from about 2.0 to about 6.5 and fixing the dye to the fibers.

2. A process of preparing a stain-resistant, lightfast nylon carpet comprisint dyeing cationic-dyeable nylon fibers in a dyebath with a premetallized acid dye at a pH of from about 2.0 to about 6.5 to dye the nylon fibers and heating the dye-laden fibers to fix the dye into the fibers.

3. The process of claim 1 or 2, in which the nylon fibers contain SO.sub.3 H or COOH or both SO.sub.3 H and COOH groups receptive to cationic or basic dyes in an amount sufficient to render the cationic fiber dyeable with a cationic or basic dye.

4. The process of claims 1 or 2, in which the nylon fibers are overprinted to give multiple color effects on the same strand of yarn.

5. The process of claim 1 or 2, in which, subsequent to dye fixation, a fluorocarbon repellant is applied to the fibers.

6. The process of claim 1 or 2, which sodium sulfate is also present in the dyebath.

7. Nylon carpet having improved stain resistance composed of cationic-dyeable fibers dyed at a pH of from about 2.0 to about 6.5 with a premetalllized acid dye and having a colorfastness to light rating of at least Class 4-5 after 120 hours of exposure according to AATCC Test Method 16E-1971.

8. A nylon carpet composed of cationic-dyeable nylon and dyed at a pH of from about 2.0 to about 6.5 with a premetalllized acid dye, the carpet being resistant to acid type stains and having a colorfastness to light rating of at least Class 4-5 after 120 hours of exposure according to AATCC Test Method 16E-1971.

9. Cationic dyeable nylon fibers, suitable for use in nylon carpets, dyed with a premetallized acid dye at a pH of about 2.0 to about 6.5, said fibers being resistant to acid type stains and having a colorfastness to light rating of at least Class 4-5 after 120 hours of exposure according to AATCC Test Method 16E-1971.

10. Stain-resistant nylon fibers, suitable for use in producing improved stain resistant carpets, consisting essentially of cationic-dyeable nylon fibers dyed with a premetallized acid dye at a pH of about 2.0 to about 6.5, said fibers having a colorfastness to light rating of at least Class 4-5 after 120 hours of exposure according to AATCC Test Method 16E-1971.

11. The product of claim 10 where the fibers are staple fibers.

12. The product of claim 10 wherein the fibers are in continuous filament form.

13. The product of claim 11 or 12 where the fibers are in yarn form.

14. The product of claim 11 or 12 where the fibers are blended with other carpet fibers in the form of staple fibers.

15. The product of claim 11 or 12 where the fibers are blended with other carpet fibers in the form of continuous filaments.

16. The product of claim 11 or 12 where the fibers are in yarn form and are present in carpet containing other fibers or filaments in the same yarn.

17. The product of claim 11 or 12 where the fibers are in yarn form and are present in carpet containing yarns composed of one or more other fibers present in staple fiber or continuous filament form.

18. The dyed product of claim 10 in the form of a strand of yarn having a fluorocarbon soil repellent applied thereto.

19. The product of claim 10 in the form of a strand of yarn in which the cationic dyeable fibers are first dyed with a premetallized acid dye and are then overprinted with acid dyes or premetallized acid dyes to give multiple color effects on the same strand of yarn.

20. Nylon carpet having improved stain resistance composed of heatset cationic-dyeable fibers dyed at a pH of from about 2.0 to less than about 6.5 with a premetallized acid dye having a colorfastness to light rating of at least Class 4-5 after 120 hours of exposure according to AATCC Test Method 16E-1971.

21. A process of preparing stain-resistant, lightfast nylon fibers comprising dyeing cationic-dyeable fibers with a premetallized acid dye at a pH of about 4.0 to less than about 6.5 and fixing the dye to the fibers.

22. The process of claim 21, in which the nylon fibers contain SO.sub.3 H groups or COOH groups or both SO.sub.3 H and COOH groups receptive to cationic or basic dyes in an amount sufficient to render the cationic fiber dyeable with a cationic or basic dye.

23. The process of claim 22 in which the nylon fibers contain COOH groups.

24. A process of dyeing heatset cationic-dyeable nylon fibers comprising dyeing said fibers with a premetallized acid dye at a pH of from about 2.0 to less than about 6.5 and fixing the dye to the fibers.

25. A process of preparing a stain-resistant, lightfast nylon carpet comprising dyeing heatset cationic-dyeable nylon fibers with a premetallized acid dye at a pH of from about 2.0 to less than about 6.5 to dye the nylon fibers and heating the dye-laden fibers to fix the dye into the fibers.

26. The process of claim 24 or 25, in which the nylon fibers contain SO.sub.3 H or COOH or both SO.sub.3 H and COOH groups receptive to cationic or basic dyes in an amount sufficient to render the cationic fiber dyeable with a cationic or basic dye.

27. The process of claim 24 or 25, in which the nylon fibers are dyed at a pH of from about 4.0 to about 6.0.

28. The process of claim 24 or 25, in which, subsequent to dye fixation, a fluorocarbon repellant is applied to the fibers.

29. A nyloon carpet composed of cationic-dyeable nylon and dyed at a pH of from about 2.0 to about 6.5 with an acid dye, the carpet being resistant to acid type stains and having a colorfastness to light rating of at least Class 4-5 after 120 hours of exposure according to AATCC Test Method 16E-1971.

30. A nylon carpet composed of heatset cationic-dyeable nylon and dyed at a pH of from about 2.0 to about 6.5 with a premetallized acid dye, the carpet being resistant to acid type stains and exhibiting a colorfastness to light rating of at least Class 4-5 after 120 hours of exposure according to AATCC Test Method 16E-1971.

31. A process of dyeing 100% cationic dyeable nylon fibers comprising dyeing said fibers with a dyebath containing at least one acid dye and devoid of cationic dyes at a pH of from about 2.0 to less than about 6.5 and fixing the dye to the cationic dyeable fibers.

32. A process of preparing a stain-resistant, lightfast nylon carpet comprising dyeing cationic-dyeable nylon fibers in a dyebath with an acid dye at a pH of from about 2.0 to less than about 6.5 to impart the requisite depth of shade to the nylon fibers and heating the dye-laden fibers to fix the dye into the fibers.

33. The process of claim 31 or 32, in which the nylon fibers contain SO.sub.3 H or COOH or both SO.sub.3 H and COOH groups receptive to cationic or basic dyes in an amount sufficient to render the cationic fiber dyeable with a cationic or basic dye.

34. The process of claim 31 or 32, in which the nylon fibers are dyed at a pH of from about 4.0 to about 6.5.

35. The process of claim 31 or 32, in which, subsequent to dye fixation, a fluorocarbon repellant is applied to the fibers.

36. The process of claim 31 or 32, in which sodium sulfate is also present in the dyebath.

37. Nylon carpet having improved stain resistance composed of cationic-dyeable fibers dyed at a pH of from about 2.0 to about 6.5 with an acid dye, said carpet having substantially the same stain resistance and fastness to light as acid dyeable nylon dyed to the corresponding shade.

38. The process of claims 31 or 32, in which the nylon fibers are overprinted to give multiple color effects on the same strand of yarn.

39. Cationic dyeable nylon fibers, suitable for use in nylon carpets, dyed with an acid dye at a pH of about 2.0 to about 6.5, said fibers being resistant to acid type stains and having a colorfastness to light rating of at least Class 4-5 after 120 hours of exposure according to AATCC Test Method 16E-1971.

40. Stain-resistant nylon fibers, suitable for use in producing improved stain resistant carpets, consisting essentially of cationic-dyeable nylon fibers dyed with an acid dye at a pH of about 2.0 to about 6.5, said fibers having a colorfastness to light rating of at least Class 4-5 after 120 hours of exposure according to AATCC Test Method 16E-1971.

41. The product of claim 40 where the fibers are staple fibers.

42. The product of claim 40 wherein the fibers are in continuous filament form.

43. The product of claim 41 or 42 where the fibers are in yarn form.

44. The product of claim 41 or 42 where the fibers are blended with other carpet fibers in the form of staple fibers.

45. The product of claim 41 or 42 where the fibers are blended with other carpet fibers in the form of continuous filaments.

46. The product of claim 41 or 42 where the fibers are in yarn form and are present in carpet containing other fibers or filaments in the same yarn.

47. The product of claim 41 or 42 where the fibers are in yarn form and are present in carpet containing yarns composed of one or more other fibers present in staple fiber or continuous filament form.

48. The product of claim 40 in the form of a strand of yarn in which the cationic dyeable fibers are first dyed with an acid dye and are then overprinted with acid dyes or premetallized acid dyes to give multiple color effects on the same strand of yarn.

49. The dyed product of claim 40 in the form of a strand of yarn having a fluorocarbon soil repellent applied thereto.

50. A process of preparing stain-resistant, lightfast nylon fibers comprising dyeing cationic-dyeable fibers with an acid dye at a pH of about 2.0 to less than about 4.0 and fixing the dye to the fibers.

51. The process of claim 50, in which the nylon fibers contain SO.sub.3 H groups or COOH groups or both SO.sub.3 H and COOH groups receptive to cationic or basic dyes in an amount sufficient to render the cationic fiber dyeable with a cationic or basic dye.

52. The process of claim 51 in which the nylon fibers contain COOH groups.

53. A process of dyeing heatset cationic-dyeable nylon fibers comprising dyeing said fibers with an acid dye at a pH of from about 2.0 to less than about 6.5 and fixing the dye to the fibers.

54. A process of preparing a stain-resistant, lightfast nylon carpet comprising dyeing heatset cationic-dyeable nylon fibers with an acid dye at a pH of from about 2.0 to less than about 6.5 to dye the nylon fibers and heating the dye-laden fibers to fix the dye to the fibers.

55. The process of claim 53 or 54, in which the nylon fibers contain SO.sub.3 H or COOH or both SO.sub.3 H and COOH groups receptive to cationic or basic dyes in an amount sufficient to render the cationic fiber dyeable with a cationic or basic dye.

56. The process of claim 53 or 54, in which the nylon fibers are dyed at a pH of from about 4.0 to about 6.0.

57. The process of claim 53 or 54, in which, subsequent to dye fixation, a fluorocarbon repellant is applied to the fibers.