Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
  • D06M13/10—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
  • D06M13/12—Aldehydes; Ketones
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
  • D02G3/04—Blended or other yarns or threads containing components made from different materials
  • D02G3/045—Blended or other yarns or threads containing components made from different materials all components being made from artificial or synthetic material
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/39—Aldehyde resins; Ketone resins; Polyacetals
  • D06M15/423—Amino-aldehyde resins

Definitions

• This invention relates to a cellulosic textile material and more particularly to an improved yarn comprising both cotton and regenerated cellulose.
• yarns of cotton and regenerated cellulose have had disadvantages because of certain fundamental differences in the properties of these two types of fibers.
• a further object of this invention is to provide a yarn of the class described which when processed into fabric can be subjected to mercerization and pre-shrinking treatments normally given to cotton fabric.
• untreated cotton fiber is intended to mean cotton fibers which have not been treated with a cross-linking agent. However, it includes cotton fibers which have been subjected to non-reactive sizes, lubricants, rnercerization, preshrinking treatments, or other similar treatments or reagents conventional in the processing of cotton fibers.
• regenerated cellulose is used in the present application, in the sense ordinarily used in the textile art, and includes regenerated cellulose made by any of the conventional techniques, i.e. by the viscose, cuprammonium or nitrate processes. However, it is preferred to use regenerated cellulose which has been made by the viscose process.
• Cross-linked regenerated cellulose fibers are fibers in which adjacent cellulose chains are linked together at one or more points along their length. Numerous reagents are known which will etfect this cross-linking. Any of these may be used in the present invention.
• regenerated cellulose fiber used in the invention may be cross-linked, for example, by heat hardenable resinous materials, including the so-called reactant type resinous materials, formaldehyde, and various polyaldehydes and hydroxyaldehydes.
• Suitable heat hardenable resinous materials include the aminoplasts, which may be defined as heat hardenable resinous compositions which are the condensation products of compounds having at least two amino hydrogens, with rnethylol forming compounds.
• Typical aminoplasts are urea-formaldehyde, melamine-formaldehyde, dicyandiamide-formaldehyde, guanidine-formaldehyde and combinations of these.
• the term is also used to include the rnethylol amino-epihalohydrin compounds described in United States Patent No. 2,960,464 to George C. Daul.
• modified urea resins i.e. rnethylol compounds such as methylated rnethylol urea, partially polymerized methylated rnethylol urea, methylated and unmethylated rnethylol ethylene ureas such as dimethylol ethylene urea, and methylated and unmethylated rnethylol 1,2-propylene ureas as Well as dimethylol triazines, triazones and the like.
• reactant type resins which are heat hardenable, but which for the most part remain water soluble under the conditions required for cross-linking.
• resins which are suitable for use in the present invention are those formed by the reaction of formaldehyde and acrolein as described in United States Patent No. 2,696,477; resins formed by the reaction of acetone and formaldehyde as described in United States Patents Nos. 2,504,835 and 2,711,971; and polyepoxy resins, e.g. polyfunctional compounds having at least two epoxy groups linked through a hydrocarbon, polyhydric phenol or polyhydric alcohol group, such as the resins formed from saturated polyglycidyl ethers of polyhydric alcohols as described in United States Patent No. 2,752,269.
• Particularly useful compounds of the last named class are the condensation products of epichlorohydrin with ethylene glycols.
• Cross-linking agents commonly used in the industry also include formaldehyde, dialdehydes such as glutaraldehyde and adipaldehyde; mixed aldehydes such as acrolein; glycidyl aldehydes; polyacetals (including diacetals of polyhydroxy compounds as described for example in United States Patent No. 2,786,081) divinyl sulfone; dihalohydrins, for example, dichlorohydrin; and diand tri-azirdinyl phosphine oxides and sulfides such as are described in United States Patent No. 2,859,134.
• cross-linking material used in the textile industry, and other cross-linking agents used in the textile industry may be employed as desired.
• Resinous materials are preferably applied while they are in a state such that they will form aqueous solutions or stable dispersions containing at least 5% by weight resinous material and such that the molecular size of the material is sufiiciently small to enable the resin molecules to penetrate into the interior of the fiber.
• resinous material it is preferred to apply the resinous material while it is in a substantially precondensed, monomeric or low polymer state, with a molecular weight on the order of -1000, preferably less than about 600.
• the extent of polymerization which is permissible will depend on the type of resin being employed and as will be brought out more fully below, on the condition of the fiber at the time it is treated.
• the regenerated cellulose fiber is preferably treated while still in the never-dried gel state after spinning. In this way the fiber absorbs the crosslinking agent far more readily, permitting a more thorough penetration of the material into the fiber.
• the technique described by G. C. Daul et al. in their Patent No. 2,902,391 and its continuation-in-part application Serial No. 819,465, filed June 10, 1959, now Patent No. 3,038,777 may advantageously be used.
• the fiber while still in the gel state after spinning and before it has ever been dried suificiently to convert it from the gel state, is treated with liquid containing the cross-linking agent and squeezed or otherwise processed until its liquid content (based on the weight of oven-dried impregnated fiber) is less than the water imbibition of the fiber in the gel state.
• the technique described is especially valuable in insuring that all the agent will be carried into the interior of the fibers.
• the temperature of the liquid containing the crosslinking agent used to treat the fiber is not a critical factor and will vary with the particular agent being applied. Normally it will be between about 15 C. and about 50 0., preferably between about 20 C. and about 40 C.
• the concentration of cross-linking agent in the aqueous impregnating liquid will again vary with the particular agent and with the type of fiber treated. Usually it will be between about 0.5 and about 15% by weight of the liquid.
• the bath may contain various ingredients other than the cross-linking agent or its components.
• it may contain a catalyst to aid in curing the cross-linking agent.
• a catalyst to aid in curing the cross-linking agent.
• the type of catalyst will depend on the particular agent being used.
• the cross-linking agent is formaldehyde
• a metallic salt which is a Lewis acid in the solid state is preferably used as the catalyst in accordance with the teaching of copending application Serial No. 81,956 of G. C. Daul et al., filed January 11, 1961, now Patent No. 3,113,826.
• the amount of catalyst or curing agent used is between about 0.003 and about 0.09 mols per 100 g. of cellulose, normally equivalent to concentrations of from about 0.03 to about 0.9 mols/liter.
• the formaldehyde concentration is such as to furnish from 0.1 to 3% formaldehyde bound to the cellulose. This may be economically furnished by concentrations of 0.5 to 6%, though higher concentrations may be used.
• the solution may contain from say to 15 of the resinous material, together with say 2 to 20% on the weight of the resin of a catalyst.
• the liquid may also contain wetting agents to aid in penetration of the fiber by the cross-linking agent, as well as from 0.2 to 4% on the weight of the liquid, of a finishing agent to add lubricity, cohesion, water repellancy, scroop or other desired properties to the fiber.
• wetting agents to aid in penetration of the fiber by the cross-linking agent, as well as from 0.2 to 4% on the weight of the liquid, of a finishing agent to add lubricity, cohesion, water repellancy, scroop or other desired properties to the fiber.
• Materials well known to the art such as polyglycol stearate, lauryl ketene dimer, silicone emulsions, stearamido methyl pyridinium chloride, octadecyl pyridinium sulfate and others may be used alone or in combination for this purpose.
• the regenerated cellulose fiber may be treated as staple fiber or as tow in the manner disclosed, for example, in the copending application of Rowell et al. Serial No. 636,420, filed February 11, 1957, now forfeited, and its continuation-in-part Serial No. 143,093, file-d October 5, 1961, now Patent No. 3,173,752 and then cut up into staple.
• fibers of cotton and cross-linked regenerated cellulose preferably in proportions ranging from 30-70 to 70-30 are blended before spinning on conventional machinery.
• the invention is valuable for blends containing down to about 10% treated regenerated cellulose.
• cotton fibers are loosened up from the bale and prepared for feeding into the pickers.
• the picker room generally contains a number of pickers in which the cotton is opened up so that sand, neps, leaves, and dust may be eliminated, and to form the lint into an increasingly even and filmy lap.
• the treated regenerated cellulose fibers are added while the cotton fibers are being processed in the picker although they may be added at any time before the final stage or finishing picker so that a uniformly-blended lap is provided before entry into the carder.
• the cotton fibers are further cleaned and all of the fibers in the blend are laid substantially parallel.
• the thin band of blended fiber containing cotton and resin-treated regenerated cellulose is then reduced to a narrow sliver by being passed through an eye or other methods conventional in the art.
• the carding process may be repeated to provide fine yarns known as doubly-carded yarn.
• the fibers may be combed when a very fine grade of yarn is desired.
• the yarn is subjected to a drawing process which is usually repeated about three times. In this stage of the process several slivers are united and drawn together thereby removing weak points and providing even, smooth slivers. The slivers are also doubled many times during the drawing and generally receive some twist in order to prevent breakage. Slubbing may be done by a bobbin and fly-frames in which the first twist is put onto the yarn.
• the yarn proceeds through a series of machines in which the attenuated slivers or soft yarns are united so that as the processing proceeds at finer and more twisted yarn is provided.
• the final frame makes the roving which is the last step before spinning.
• the spinning of the blended fibers of this invention may be done by any of the known methods and machines such as the upright frame, by the flyer or ring system, or by the mule.
• the actual processing involved depends upon the size and quality of the yarn desired.
• blended yarn may be given various finishing treatments such as bleaching, mercerizing, dyeing, and sizing, in accordance with procedures well-known in the cotton industry, without any adverse effect on the regenerated cellulose fibers.
• blended yarn made in accordance with the invention is superior to blends of cotton and untreated rayon in its acceptance of many finishes, e.g. in its ability to take further cross-linking treatments.
• a yarn of untreated cotton and rayon is treated with a cross-linking agent, the rayon will pick up so much more agent than the cotton that it tends to become overtreated with loss of physical properties.
• cross-linked rayon is blended with cotton and the resulting yarn is further treated with cross-linking agent the pick up is more nearly the same and an evenly treated final product can be obtained.
• Vacuum is then applied and 22 ml. of water and 3 ml. unreacted epichlorohydrin are removed.
• the product is allowed to cool to room temperature (25 C.) and 20 ml. of 25% sodium hydroxide solution are added and mixed well.
• Staple viscose fibers having a length of from 1 /2 to 1% inches are treated with the resinous material, prepared as above, by the procedure described in Patent No. 2,902,391 and mixed in various proportions with precarded American Upland cotton, middling grade, having an average length of 1 inches. These blends are spun into 20/1 yarns using a range of twist multipliers. For comparison, yarns composed of similar blends of untreated viscose rayon fibers having the same staple length are also spun. Tests are conducted for these samples and also for yarns consisting of 100% rayon, 100% treated rayon and 100% cotton.
• Table YARN BREAK FACTORS densate (1 mol urea: 1.6 mol formaldehyde), 0.75% magnesium chloride hexahydrate (catalyst) and 0.15% of a lauryl ketene dimer and 0.15 polyglycol stearate (finishing agents).
• the impregnated fiber blanket is then squeezed sufiiciently to reduce the liquid content to 90% of the weight of the cellulose.
• the blanket is then opened, dried and cured as before.
• the treated fiber has a water imbibition value of 44% and is combined with staple cotton fibers and spun into yarns comprising 6 treated rayon and %cotton, /2 treated rayon and /2 cotton, and treated rayon and /a cotton.
• Example 3 The procedure of Example 2 is repeated wherein the treating bath contains 15% of an acetone-formaldehyde precondensate (1 mol acetone:4 mol formaldehyde), 4% sodium carbonate (catalyst), and 0.15 lauryl ketene dimer, 0.15 polyglycol stearate (finishing agents). A yarn having improved properties over simple rayon-cotton blends is obtained.
• Example 4 The procedure of Example 2 is repeated wherein the treating bath contains 12% of a polyepoxy-polyglycol precondensate (Eponite 100), 1.5% zinc fluoroborate (catalyst), 0.6% polyvinyl alcohol (emulsifier) and 0.15% epoxidized soyabean oil (finishing agent).
• the fiber blanket is squeezed to retain 85% of the weight of the liquid on the cellulose, or 60 percentage points below the gel water imbibition of the fiber (145%). Similarly good results are obtained.
• 100% UR TR 1 Break factor is the breaking force in ounces for a given yarn multiplied by the cotton count of that yarn.
• Skcin breaking load is measured on a 120 yarn skein of 1.5 yards circumference.
• the improved strength characteristics of the treated rayon cotton blend are also apparent in wet strength tests, and this is believed clue to the lower water absorption of the treated rayon fiber.
• 50-50 blends of cotton and untreated rayon at optimum twist multipliers showed a break factor of 198 (dry) and 170 (wet) whereas 50-50 blends of cotton and treated rayon at optimum twist multiplier showed a break factor of 230 (dry) and 225 (wet).
• Advantages are also found in yarn evenness of the treated rayon-cotton blends in comparison to the untreated rayon-cotton blend.
• Example 2 The procedure of Example 1 is followed except that the treated rayon used is prepared by treating a blanket of textile grade rayon staple fiber still in the gel state with a liquid bath containing 5% by weight of an acroleinformaldehyde precondensate (1 mol acrolein:4 mols formaldehyde), 5% of a urea formaldehyde precon- Skeiu break factor is break- EXAMPLE 5 Regenerated cellulose staple fiber still in the gel state after spinning is impregnated with an aqueous solution containing 1.0% HCHO and 2.0% MgCl .6I-I O, squeezed to pickup, dried at C. and cured at C. for 12 minutes. The fiber has a water imbibition of 55%.
• the treated staple having an average length of 1 /2" is then blended with its own weight of precarded Ameri can Upland cotton, middling grade, having an average length of 1% inches.
• the yarns are then immersed in 18% caustic soda at 18 C. for 2 minutes (normal cotton mercerizing conditions). After drying they are tested for dry tenacity and it is found that their tenacity is about 108% of the untreated blend.
• An identical blend of the same rayon, not cross-linked, with the same cotton retains only 94% of its tenacity after the caustic treatment.
• the present invention provides a new type of yarn having both cotton and regenerated cellulose components which overcomes the difiiculties previously experienced in blending these two materials.
• the regenerated cellulose component is given many properties approaching those of cotton, while retaining the desirable characteristics inherent to it.
• Fabrics made from the yarn are remarkably regular in texture. They can be mercerized in the same manner as all cotton fabrics and they dye evenly with the dyestuifs usually used for cotton.
• the total quantity of cross-linking agent employed in the yarn taken as a whole is kept to a minimum, which is advantageous from a cost standpoint and also avoids the decrease in tear strength of fabrics made therefrom, which often accompanies a high degree of cross-linking.
• a yarn consisting essentially of from 30-70% by weight untreated cotton fibers, and from 70-30% by weight cross-linked regenerated cellulose fibers.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

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Cited By (1)

Citations (11)

• 0
  • BE BE623122D patent/BE623122A/xx unknown
• 1961
  • 1961-10-02 US US141953A patent/US3218792A/en not_active Expired - Lifetime
• 1962
  • 1962-10-01 GB GB37045/62A patent/GB943945A/en not_active Expired

Patent Citations (11)

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