FABRIC-SCOURING COMPOSITION AND METHOD OF USE

Abstract

A surfactant concentrate includes, based on the total weight of the concentrate, 5 to 40 weight percent of a surfactant of the formula R.sup.1(OCHCH.sub.2)OH wherein n has an average value from 3 to 15 and R.sup.1 is a combination of C.sub.12-14 alkyl having an average value of C.sub.13 or higher; 10 to 70 weight percent of a surfactant of the formula R.sup.2(OCHCH.sub.2).sub.mOH wherein m has an average value from 5 to 15 and R.sup.2 is a C.sub.13-18 alkyl or a combination of C.sub.13-18 alkyl; 1 to 20 weight percent of a cosolvent; and the remainder water. A scouring bath and method of scouring textile using the concentrate are also disclosed.

Claims

1. A surfactant concentrate comprising, based on the total weight of the concentrate, 5 to 40 weight percent of a surfactant of the formula R.sup.1(OCHCH.sub.2).sub.nOH wherein n has an average value from 3 to 15 and R.sup.1 is a combination of C.sub.12-14 alkyl having an average value of C.sub.13 or higher; 10 to 70 weight percent of a surfactant of the formula R.sup.2(OCHCH.sub.2).sub.mOH wherein m has an average value from 5 to 15 and R.sup.2 is a C.sub.13-18 alkyl or a combination of C.sub.13-18 alkyl; 1 to 20 weight percent of a cosolvent; and the remainder water.

2. The surfactant concentrate of claim 1, wherein the composition does not include an alkylphenol ethoxylate or an anionic surfactant.

3. The surfactant concentrate of claim 1, wherein n is from 3 to 10.

4. The surfactant concentrate of claim 1, wherein n is from 7 to 10.

5. The surfactant concentrate of claim 1, wherein n is from 8 to

10.

6. The surfactant concentrate of claim 1, wherein m is from 5 to 12.

7. The surfactant concentrate of claim 6, wherein m is from 7 to 10.

8. The surfactant concentrate of claim 1, wherein the compatibilizer is a glycol ether.

9. A surfactant concentrate comprising, based on the total weight of the concentrate, 5 to 30 weight percent of a surfactant of the formula R.sup.1(OCHCH.sub.2).sub.nOH wherein n has an average value of 9 and R.sup.1 is a combination of C.sub.12-14 alkyl having an average value of C.sub.13 or higher; 10 to 60 weight percent of a surfactant of the formula R.sup.2(OCHCH.sub.2).sub.mOH wherein m has an average value from 5 to 12 and R.sup.2 is a C.sub.13-18 alkyl or a combination of C.sub.13-18 alkyl; 5 to 15 weight percent of a cosolvent; and the remainder water.

10. A scouring bath composition for a textile, comprising 1 to 20 weight percent of the surfactant concentrate of claim 1; and 0.1 to 10 weight percent of an oxidant; an amount of base effective to provide a basic pH; and the reminder water.

11. A method of scouring a textile, comprising contacting the textile with the scouring bath composition of claim 10 for a time and at a temperature effective to scour the textile.

12. The method of claim 11, wherein a cotton fabric scoured in the scouring bath composition containing the surfactants has a result in the absorbency test AATCC no. 79-2007 of 6.0 seconds or less.

13. The method of claim 11, wherein a cotton fabric scoured in the scouring bath composition containing the surfactants has a result in the absorbency test AATCC no. 79-2007 of 1.0 seconds or less.

14. The method of claim 11, wherein a cotton fabric scoured in the scouring bath composition containing the surfactants, has a result in the wicking test AATCC no. 197-2011 of 320.0 seconds or less.

15. The method of claim 14, wherein a cotton fabric scoured in the scouring bath composition containing the surfactants has a result in the wicking test AATCC no. 197-2011 of 200.0 seconds or less.

16. The scouring bath composition of claim 10, wherein the oxidant is a peroxide or a hypochloride.

17. The method of claim 12, wherein the scouring bath composition comprises 0.05% to 0.4% of the surfactants.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0009] The FIGURE is an exemplary embodiment illustrating a method of using the cotton-scouring composition.

DETAILED DESCRIPTION

[0010] Described herein is an alkaline scouring bath with an eco-friendly scouring agent that effectively cleans natural cellulose fibers, while rapidly wetting the fibers. In particular, the composition is an alcohol-based, non-ionic surfactant formulation, which is particularly useful in cotton textile processing.

[0011] The composition comprises a polyethoxylate surfactant combination selected to have certain properties, in particular a C.sub.10-18 fatty alcohol polyethoxylate with straight chain, methyl branching, or ethyl branching, and selected to have a hydrophilic-lipophilic balance (HLB) of 9.5 to 13.5.

[0012] Thus, the scouring agent in the scouring composition is a surfactant concentrate comprising, based on the total weight of the concentrate, 5 to 40 weight percent, specifically 10 to 35 weight percent, or 15 to 30 weight percent, or 10 to 30 weight percent, of a surfactant of formula (1)

R.sup.1(OCHCH.sub.2).sub.nOH (1)

wherein n has an average value from 3 to 15 and R.sup.1 is a C.sub.12-14 alkyl having an average value of C.sub.13 or higher. R.sup.1 is straight chain, methyl branching, or ethyl branching, or a combination thereof. In an embodiment, n is 3 to 10, or 7 to 10, or 8 to 10.

[0013] The surfactant concentrate further comprise 10 to 70 weight percent, or 10 to 60 weight percent, or 20 to 60 weight percent, or 20 to 50 weight percent, or 30 to 70 weight percent, or 30 to 60 weight percent, of a surfactant of formula (2)

R.sup.2(OCHCH.sub.2).sub.mOH (2)

wherein m has an average value from 5 to 15 and R.sup.2 is a C.sub.13-18 alkyl or a combination of C.sub.13-18 alkyl. R.sup.2 is straight chain, methyl branching, or ethyl branching, or a combination thereof. In an embodiment, m is 5 to 12, or 7 to 10.

[0014] The surfactant concentrate further comprises 1 to 20 weight percent, or 5 to 10 weight percent, or 5 to 20 weight percent, or 10 to 20 weight percent of a cosolvent; and the remainder water. The cosolvent is selected to be effective to aid dissolution of the surfactant concentrate in the scouring bath. Suitable cosolvents can accordingly depend on considerations such as the particular surfactants, their final concentration in the scouring bath, the pH of the scouring bath, and any other components of the scouring bath. Possible surfactants include a glycol ether, an aliphatic or cycloaliphatic ether, e.g., tetrahydrofuran, an alcohol, e.g., methanol or ethanol, and the like.

[0015] Other surfactants known in the art can be present in addition. In a preferred embodiment, the surfactant concentrate does not include an alkylphenol ethoxylate or an anionic surfactant. In other embodiments no other surfactant is present.

[0016] In a preferred embodiment, the surfactant concentrate comprises, consists essentially of, or consists of, based on the total weight of the concentrate, 5 to 30 weight percent of a surfactant of the formula R.sup.1(OCHCH.sub.2).sub.nOH wherein n has an average value of 9 and R.sup.1 is a combination of C.sub.12-14 alkyl having an average value of C.sub.13 or higher; 10 to 60 weight percent of a surfactant of the formula R.sup.2(OCHCH.sub.2).sub.mOH wherein m has an average value from 5 to 12 and R.sup.2 is a C.sub.13-18 alkyl or a combination of C.sub.13-18 alkyl; 5 to 15 weight percent of a cosolvent, preferably an alkyl glycol; and the remainder water.

[0017] The surfactant concentrate can be used in a scouring bath composition for a textile, in amounts generally known in the art. For example, the surfactants can be present in an amount of 0.001 to 5 weight percent, based on the total weight of the textile, or 0.01 to 3 weight percent, or 0.05 to 1 weight percent, or 0.05 to 0.5 weight percent, each based on the total weight of the textile (owt). Other surfactants known in the art can be present in addition in the scouring bath composition, but in a preferred embodiment, the scouring bath composition does not include an alkylphenol ethoxylate or an anionic surfactant. In other embodiments no other surfactant is present in the scouring bath composition.

[0018] The scouring bath composition can further comprise other components known in the art for such compositions, for example an oxidant, an oxidant stabilizer, a pH-adjusting agent, and the like, in amounts generally used.

[0019] The oxidant can be a peroxide, for example hydrogen peroxide, or a hypochlorite.

[0020] The pH-adjusting agent is added to activate the oxidant, such that a pH of about 7.0 to about 10.0, and preferably from about 7.5 to about 9.0, is achieved. The agent can be a caustic such as sodium hydroxide or potassium hydroxide; an alkali salts of organic acid, such as trisodium citrate, a transition metal salt or and complex, such as a copper salt or complex. It is also possible to use an organic activator, such as a urea, dicyandiamide or tetraacetylethylene diamine, or acetyl caprolactam; and certain pigments, e.g., pigmented Sulfur Black 1 with a particle size less than 150 m; fully pre-oxidized sulfur dyes, such as Diresul Black 4G-EV, or titanium dioxide.

[0021] In a preferred embodiment, the scouring bath composition comprises 1 to 20 weight percent, or 5 to 15 weight percent, or 1 to 15 weight percent, or 10 to 20 weight percent of the surfactant concentrate; 0.1 to 10 weight percent of an oxidant, preferably a peroxide or a hypochlorite; an amount of base effective to provide a basic pH; and the reminder water.

[0022] Further disclosed herein is a method of scouring a textile, comprising contacting the textile with the scouring bath for a time and at a temperature effective to scour the textile. Steps and conditions are known in the art. An exemplary process is shown in the FIGURE, and described, for example, in US2006/0112495; and U.S. Pat. No. 4,080,164.

[0023] The textile can contain cellulosic fibers, or a combination of cellulosic fibers and synthetic fibers. It is also possible for each fiber to be a blend of a cellulosic and a synthetic material. Synthetic fibers include, for example, polyester and nylon.

[0024] In some embodiments, a textile, e.g., a cotton fabric scoured in the bath containing the surfactant concentrate, particularly 0.05% to 0.4% of the surfactants, based on the weight of the textile, has a result in the absorbency test AATCC no. 79-2007 of 6.0 seconds or less.

[0025] In some embodiments, a textile, e.g., a cotton fabric scoured in the bath containing the surfactant concentrate, particularly particularly 0.05% to 0.4% of the surfactants, has a result in the absorbency test AATCC no. 79-2007 of 1.0 seconds or less.

[0026] In some embodiments, a textile, e.g., a cotton fabric scoured in the bath containing the surfactant concentrate, particularly particularly 0.05% to 0.4% of the surfactants, has a result in the wicking test AATCC no. 197-2011 of 320.0 seconds or less.

[0027] In some embodiments, a textile, e.g., a cotton fabric scoured in the bath containing the surfactant concentrate, particularly particularly 0.05% to 0.4% of the surfactants, has a result in the wicking test AATCC no. 197-2011 of 200.0 seconds or less.

[0028] This disclosure is further illustrated by the following examples, which are non-limiting.

EXAMPLES

[0029] The materials used are shown in Table 1.

TABLE-US-00001 TABLE 1 Designation Description (Trade designation) Source C12-14 alcohol/3EO Naturally derived C12-14 fatty SABIC alcohol ethoxylated with 3 mole of ethylene oxide (SABICOL L-3) (linear, primary, unsaturated alcohol-based ethoxylate) C12-14 alcohol/7EO Naturally derived C12-14 fatty SABIC alcohol ethoxylated with 7 mol of ethylene oxide (SABICOL L-7) (linear, primary, unsaturated alcohol-based ethoxylate) C12-14 alcohol/9EO Naturally derived C12-14 fatty SABIC alcohol ethoxylated with 9 mol of ethylene oxide (SABICOL L-9) (linear, primary, unsaturated alcohol-based ethoxylate)) C13 alcohol/10EO C13 alcohol ethoxylated with 10 mol of ethylene oxide (branched, unsaturated alcohol-based ethoxylate) C13 alcohol/7EO C13 alcohol ethoxylated with 7 mol of ethylene oxide (branched, unsaturated alcohol-based ethoxylate) DGMBE Diethylene glycol monobutyl ether (cosolvent) (unsaturated)

Preparation of Surfactant Concentrates

[0030] Examples 1 to 5 were formulated as shown in Table 2, wherein amounts are in weight percent, based on the total weight of the composition. The compositions were produced by mixing the appropriate components, including heating where needed in order to achieve a homogenous solution.

TABLE-US-00002 TABLE 2 Example No. Component 1 2 3 4 5 C12-14 alcohol/3EO 5 5 C12-14 alcohol/7EO 20 25 C12-14 alcohol/9EO 10 10 25 C13 alcohol/10 EO 50 45 25 15 C13 alcohol/7 EO 25 DGMBE 10 10 8 10 10 Water 30 30 42 35 45 Sodium Chloride 5 5 Total 100 100 100 100 100

Fabric Scouring

[0031] Fabric scouring was carried out as generally shown in the FIGURE. A section of 100% cotton grey knitted fabric of medium GSM (grams per square meter) after desizing was obtained from a textile process house. Prior to testing, each sample of fabric (100 g) was treated with an alkaline scouring process as shown in FIG. 1. This process is widely accepted in the industry.

[0032] In the process, the scouring tank was filled with 1 L of a scouring liquor at 50 C.

[0033] In the Examples, the scouring liquor included water, 2 to 10 grams (g) of flaked sodium hydroxide, 1 to 5 g of aqueous 50% hydrogen peroxide, and 2 to 10 g of the surfactant concentrate in an amount effective to provide a concentration of the surfactant (based on the weight of the fabric) shown in Table 5 below.

[0034] In a first comparative process, the scouring liquor (Comparative-1) contained no sodium hydroxide, hydrogen peroxide, or surfactant concentrate.

[0035] In a second comparative process, the scouring liquor (Comparative-2) contained sodium hydroxide and hydrogen peroxide, but no surfactant concentrate.

[0036] The test fabric was added to the scouring liquor, which was heated to 70 C. for 60 minutes. Then the fabric was removed from the scouring liquor and washed with hot water at 60 C. for 15 minutes, followed by a second hot water wash at 60 C. for 15 minutes. Finally the test fabric was washed with a dilution solution of water and (2 to 4 wt % acetic acid) at room temperature (20 to 25 C.).

[0037] The samples were tested in the same bath, or removed from the bath and tested directly without drying.

Absorbency Test (AATCC 79-2007)

[0038] Test method AATCC 79-2007 was used to measure the water absorbency of textiles by measuring the time taken by a drop of water placed on the fabric surface to be completely absorbed into the fabric. First, the fabric sample was placed in an embroidery hoop with all creases smoothed out. Then a burette was used to dispense a drop of water onto the surface of the fabric from a distance of 9.5 mm above the fabric, and the time was recorded until the water drop was completely absorbed. Results are shown in Table 3, where the lower the numerical value, the more efficient the water absorbency.

TABLE-US-00003 TABLE 3 Sample Absorbency time (seconds) Comparative-1 Water drop did not absorb on fabric [Fabric without chemical or surfactant] Comparative-2 Water drop did not absorb on fabric [Fabric with chemical without for more than 300 sec. surfactant] Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Fabric at 0.05% surfactant 2.4 4.3 7.4 5.0 9.0 Fabric at 0.1% surfactant 0.5 1.0 4.6 1.5 6.0 Fabric at 0.2% surfactant 0.3 0.7 2.6 0.9 3.7 Fabric at 0.4% surfactant 0.1 0.3 0.5 0.4 1.0

[0039] The results show that without the surfactant concentrate the absorbency time was greater than 300 seconds. Treatment with any of the surfactant concentrates of Examples 1 to 5 resulted in significant improvement of absorbency time. Example 1 (C12-14 alcohol/9EO+C13 alcohol/10 EO) provided the best results at each surfactant concentration. Examples 3 and 5, with a C12-14 alcohol/7EO but no C12-14 alcohol/9EO are not as effective. Further, the improvement for each composition is concentration-dependent, for example for composition 1 as the surfactant level varies from 0.05% to 0.4%, the absorbency time drops from 2.4 seconds to 0.1 second.

Wicking Test (AATCC no. 197-2011)

[0040] Test method AATCC no. 197-2011 was used to evaluate the ability of vertically aligned fabric specimens to transport dye liquor along or through them. First, a 2% reactive dye solution (Reactive Red M5B) was prepared and poured into a petri dish. A piece of test fabric, with a mark 5 cm from one edge was suspended vertically above the petri dish such that one edge of the fabric was touching the surface of the dye solution, and such that the mark on the fabric was now 5 cm above the dye solution. The time was recorded when the dye solution had travelled up the fabric to reach the 5 cm mark. Results are shown in Table 4, where the lower the numerical value, the more efficient the wicking.

TABLE-US-00004 TABLE 4 Sample Wicking time (seconds) Comparative-1 Water drop did not absorb on fabric Comparative-2 Water drop did not absorb on fabric even after 600 sec. Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Fabric at 0.05% surfactant 272 298 326 315 387 Fabric at 0.1% surfactant 195 210 240 228 274 Fabric at 0.2% surfactant 136 172 191 186 219 Fabric at 0.4% surfactant 85 98 108 102 140

[0041] The results show that without surfactant concentrate the water did not even absorb on the fabric, thus there is no wicking time to be listed. Treatment with any of the surfactant concentrates of Examples 1 to 5 resulted in significant improvement of absorbency time, with generally similar times, although Example 1 provided the best results. Further, the improvement for each composition behaved in a concentration-dependent manner, for example in Example 1, as the surfactant level varies from 0.05% to 0.4%, the wicking time drops from 272 seconds to 85 seconds.

Comparative Study

[0042] A pre-treated sample of cotton fabric was treated for one hour at 70 C. with an amount of 0.2% Example 1, and a separate sample of cotton fabric was treated for one hour at 70 C. with a commercial scouring surfactant (an alkylphenol ethoxylate-free mixture of non-ionic surfactants) at the same concentrations. The fabric samples were then tested in both the absorbency test and wicking test as described above.

[0043] In the absorbency test, both the sample treated with Example 1 and the sample treated with the commercial product gave identical absorbency times of 0.3 to 0.4 seconds.

[0044] In the wicking test, the sample treated with composition-1 had a wicking time of 13110 seconds and the sample treated with the commercial product had a similar wicking time of 1166 seconds.

[0045] Thus, Example 1 has a comparable performance to a commercially-available formulation in these two tests.

[0046] The following embodiments illustrate but do not limit the invention.

[0047] Embodiment 1. A surfactant concentrate comprising, based on the total weight of the concentrate, 5 to 40 weight percent of a surfactant of the formula R.sup.1(OCHCH.sub.2).sub.nOH wherein n has an average value from 3 to 15 and R.sup.1 is a combination of C.sub.12-14 alkyl having an average value of C.sub.13 or higher; 10 to 70 weight percent of a surfactant of the formula R.sup.2(OCHCH.sub.2).sub.mOH wherein m has an average value from 5 to 15 and R.sup.2 is a C.sub.13-18 alkyl or a combination of C.sub.13-18 alkyl; 1 to 20 weight percent of a cosolvent; and the remainder water.

[0048] Embodiment 2. The surfactant concentrate of embodiment 1, wherein the composition does not include an alkylphenol ethoxylate or an anionic surfactant.

[0049] Embodiment 3. The surfactant concentrate of embodiment 1 or 2, wherein n is from 3 to 10.

[0050] Embodiment 4. The surfactant concentrate of embodiment 1 or 2, wherein n is from 7 to 10.

[0051] Embodiment 5. The surfactant concentrate of embodiment 1 or 2, wherein n is from 8 to 10.

[0052] Embodiment 6. The surfactant concentrate of any one or more of embodiments 1 to 5, wherein m is from 5 to 12.

[0053] Embodiment 7. The surfactant concentrate of embodiment 6, wherein m is from 7 to 10.

[0054] Embodiment 8. The surfactant concentrate of any one or more of embodiments 1 to 7, wherein the compatibilizer is a glycol ether.

[0055] Embodiment 9. A surfactant concentrate comprising, based on the total weight of the concentrate, 5 to 30 weight percent of a surfactant of the formula R.sup.1(OCHCH.sub.2).sub.nOH wherein n has an average value of 9 and R.sup.1 is a combination of C.sub.12-14 alkyl having an average value of C.sub.13 or higher; 10 to 60 weight percent of a surfactant of the formula R.sup.2(OCHCH.sub.2).sub.mOH wherein m has an average value from 5 to 12 and R.sup.2 is a C.sub.13-18 alkyl or a combination of C.sub.13-18 alkyl; 5 to 15 weight percent of a cosolvent; and the remainder water.

[0056] Embodiment 10. A scouring bath composition for a textile, comprising: 1 to 20 weight percent of the surfactant concentrate of any one or more of embodiments 1 to 9; and0.1 to 10 weight percent of an oxidant, preferably a peroxide or a hypochloride; an amount of base effective to provide a basic pH; and the reminder water.

[0057] Embodiment 11. A method of scouring a textile, comprising: contacting the textile with the scouring bath composition of embodiment 10 for a time and at a temperature effective to scour the textile.

[0058] Embodiment 12. The method of embodiment 11, wherein a cotton fabric scoured in the scouring bath composition containing the surfactants, preferably 0.05% to 0.4% of the surfactants, has a result in the absorbency test AATCC no. 79-2007 of 6.0 seconds or less.

[0059] Embodiment 13. The method of embodiment 11 or 12, wherein a cotton fabric scoured in the scouring bath composition containing the surfactants, preferably 0.05% to 0.4% of the surfactants, has a result in the absorbency test AATCC no. 79-2007 of 1.0 seconds or less.

[0060] Embodiment 14. The method of any one or more of embodiments 11 to 13, wherein a cotton fabric scoured in the scouring bath composition containing the surfactants, preferably 0.05% to 0.4% of the surfactants, has a result in the wicking test AATCC no. 197-2011 of 320.0 seconds or less.

[0061] Embodiment 15. The method of embodiment 14, wherein a cotton fabric scoured in the scouring bath composition containing the surfactants, preferably 0.05% to 0.4% of the surfactants, has a result in the wicking test AATCC no. 197-2011 of 200.0 seconds or less.

[0062] The compositions, methods, and articles can alternatively comprise, consist of, or consist essentially of, any appropriate components or steps herein disclosed. The compositions, methods, and articles can additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any steps, components, materials, ingredients, adjuvants, or species that are otherwise not necessary to the achievement of the function or objectives of the compositions, methods, and articles.

[0063] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of up to 25 wt. %, or, more specifically, 5 wt. % to 20 wt. %, is inclusive of the endpoints and all intermediate values of the ranges of 5 wt. % to 25 wt. %, etc.). Combinations is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms first, second, and the like, do not denote any order, quantity, or importance, but rather are used to denote one element from another. The terms a and an and the do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Or means and/or unless clearly stated otherwise. Reference throughout the specification to some embodiments, an embodiment, and so forth, means that a particular element described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.

[0064] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0065] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.