Note: Descriptions are shown in the official language in which they were submitted.
iO~;~OS~
Field o~ Invention
This invention relates to an improved process for rendering
textiles materials flame retardant. More particularly, it
relates to a more rapid and hence more practical process for polymer-
izing poly (hydroxymethyl) phosphonium cation on and in cellulose-
containing materials with ammonia to render them durably flame retard-
ant. It relates also to an apparatus for rapidly and efficiently poly-
merizing the monomer on and in the cellulose containing materials.
Back~round of the Invention
In U.S. Patent No. 3,607,356, it has been proposed to impregnate
cellulose-containing materials with an aqueous solution containing an
equilibrium mixture of tris (hydroxymethyl) phosphine ("THP") and tet-
rakis (hydroxymethyl) phosphonium hydroxide ("THPOH") said solution
having a pH of about 7 to about 8. In this process, the impregnated
material containing from lO to about 40 percent by weight of the monomer
is dried to about lO to about 20 percent moisture and then treated with
gaseous ammonia in an enclosed cabinet to polymerize the resin monomers.
The gaseous ammonia treatment step requires from one or two to 6 minutes
exposure time depending upon the character, i.e., the weight, fibrous
nature, etc. of the treated material. In many textile processes, the
materials are processed in equipment operating at high speed in a con-
tinuous manner. Accordingly, operations involving processing times of
several minutes duration require either static operation or units of a `
size wherein such relatively long residence times can be obtained. It
is, therefore, desired to process such materials in equipment wherein
shorter residence times consistent with high speed continuous operations
can be obtained in a practical manner. Moreover, the treatment accord-
ing ~o the process of U.S. Patent No. 3,607,356, when used with avail-
able ammonia treatment cabinets, has been found to produce finishes on
! 3o cellulosic materials which often tended to dust and the durability of
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the finished materials often failed to meet the stringent government
standards (Department of Commerce Standard FF-3-71) which require that
the treated materials withstand at least fifty home washing and drying ~-
cycles. The enclosed chamber for carrying out the ammonia treatment
commonly used in this field comprises a series of perforated pipes
housed in a box like enclosure having a large opening in the top. The
partially dried impregnated material is passed over the perforated pipes
through which ammonia gas is forced. The excess ammonia gas is vented
through the opening in the top of the enclosure, and discharged into the
lo atmosphere. This venting of considerable quantities of ammonia givesrise to a severe pollution problem. It can thus be seen that the pro-
cess disclosed in U.S. Patent No. 3,607,356 not only results in a
highly inefficient utilization of ammonia but also is hardly practical
for the lighter, open weave, materials and leaves much to be desired
; 15 when processing heavier and/or close knit materials.
It is known also, as disclosed in U.S. Patent No. 2,983,623, to
cure further polymerizable methylol-phosphorus polymeric material con-
taining at least one free methylol group attached to a phosphorus atom
t incorporated in a cellulosic material, by exposing said material in the
dry state to the action of gaseous ammonia followed by subjecting it to
an aqueous ammonia treatment. In this process, the further polymeriz-
able resins disclosed are solutions of reaction products of tetrakis-
(hydroxymethyl) phosphonium chloride and urea which solutions are rela-
tively strongly acid and are applied in the presence of buffers which
3 25 adjust the pH of the solutions to a pH within the range of about 3.5 to
, 4. The impregnated material is thoroughly dried, exposed to ammonia gas
for about 5 to 10 or more minutes, and then immersed in aqueous ammonia
for about 10 or more minutes to complete the cure of the resin on and in
3. the material. Such a process also requires relatively long time cycles
of treatment especially in the aqueous ammonia
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hence is hardly applicable with modern high speed processing techniques.
The problem of the long time cycles and efficiency of the polymeriza-
tion has been substantially overcome by the apparatus and process disclosed
in U. S. Patent 3,933,122, issued January 20, 1976. In this application
an apparatus and process for imparting flame retardance to cellulose
containing materials is disclosed whereby materials which have been im-
pregnated with a solution having a pH of from about 7 to about 9 and a
tetrakis (hydroxymethyl) phosphonium hydroxide content of from about 0 to
about 8 percent and the monomer is polymerized in and on the cellulose
material by exposure in an enclosed chamber to an atmosphere containing
from about 50 to about 90 percent by volume of gaseous ammonia for about
5 to about 30 seconds. By this process and with this apparatus the mono-
mer is rapidly and effectively polymerized on and in the cellulose con-
taining material, thereby imparting durable flame retardance to the -
materials in a rapid and efficient manner. Under certain mill conditions
it was found that substantial amounts of formaldehyde was formed during
the gaseous ammonia exposure step and when the cured fabric was batched
in rolls or on trucks immediately upon exit from the ammonia chamber,
it was noted that the odor of formaldehyde rapidly developed in the batched
processed materials and also that a considerable exotherm was prevalent in
the material. In such materials, i.e., when the odor of formaldehyde
and/or exotherm was noted, the durability of the flame retardant character
was reduced. It is believed that the formaldehyde produced by decomposition
of the polymerized or partially polymerized monomer when confined in the
material, reacted with the polymer or partially polymerized polymer to
~ form a moisture sensitive reaction product which may deleteriously affect
i the durable character of the flame retardant treatment.
The process of the present invention represents an improvement over
the process of the U. S. Patent 3,933,122 whereby the
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deleterious effect of the action of formaldehyde is obviated and thus a
rapid and effective means of imparting durable flame retardance to
cellulose containing materials is provided. Further said improved
process is more generally applicable with the currently used high speed
textile processing equipment and conditions.
Objects of the Invention
It is, therefore, a principal object of the present invention to
provide an improved process for treating textile materials
to render them durably flame retardant.
lo Another object is to provide a more rapid process for imparting
flame retardant characteristics to textile materials where-
by said materials are impregnated with a solution containing poly (hy-
droxymethyl) phosphonium cation, dried to remove substantially all of
the retained moisture and rapidly and efficiently cured by gaseous am-
monia.
A particular object is to provide a process which does not require,
in the curing step, prolonged exposure of the impregnated material to
either large excesses of gaseous ammonia or aqueous ammonia or both.
- A further object is to provide a process which allows operation at
low pH, thereby substantial1y reducing the amount of formaldehyde pro-
duced during the process.
An additional object is to provide a process whereby the deleter-
ious effect of polymer degradation products on the treated material is
substantially prevented.
These and other objects will be apparent to those skilled in the
art by the following description of the present invention.
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Summary of the Invention
It has now been found that textile materials can be
rapidly and economically rendered durably flame retardant by a process
which comprises:
a. Impregnating a textile material with a solution . .
of poly (hydroxymethyl) phosphonium cation having a pH of from
about 2 to about 9, and containing from about lO to about 40
percent by weight of poly (hydroxymethyl) phosphonium cation;
b. Drying the impregnated material, preferably under relatively
mild conditions, to a moisture content of from about 0 to
about 8 percent by weight;
c. Aerating the dried material by directing a current of air
through the dried material;
d. Exposing the aerated material in an enclosed chamber for a
period of at least about 5 seconds but less than about 60
seconds to an atmosphere containing at least about 50 percent
by volume of gaseous ammonia to cure the phosphorus containing
resi~ in and on the material;
e. Contacting the material with water in said enclosed chamber to
render the material durably flame retardant; and
f. Further exposing the water contacted material for a period
of from less than l to about lO seconds to an atmosphere con-
taining at least about 50 percent by volume of gaseous am-
monia.
The curing steps (d), (e), and preferably (f) of the new process -~
'~ are carried out in an enclosed cabinet which comprises:
a housing;
gas inlet means disposed in the upper portion of said housing;
gas outlet means disposed in the lower portion of said housing;
material inlet means and material outlet means disposed in the
lower portion of said housing above said gas outlet means;
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partition means disposed in said housing between said gas inlet
means and said gas outlet means so as to form a gas treatment chamber in
the upper portion of said housing, said partion means including means
for permitting the introduction into or removal from said gas treatment
chamber of textile material to be treated in said chamber while minim-
izing the passage of gas into and from said gas treatment chamber;
water inlet means with connecting application means disposed in the
upper portion of said housing;
water outlet means disposed in the lower portion of said housing
below said gas outlet means; and
means disposed in said gas treatment chamber for supporting textile
material to be treated. Cabinets of similar design are disclosed in
U. S. Patent 3,933,122 issued January 20, 1976.
The ammonia treated material obtained in accordance with the present
invention may be washed and dried numerous times without substantial loss
of fire retardancy. In addition, there is an increase in the flame re-
tardant efficiency of the process, together with a decrease of formalde-
hyde odor from the processing equipment.
Detailed Description of the Invention
In accordance with a preferred mode of carrying out the improved
process of this invention, an aqueous solution containing from about 10
to about 40 percent by weight of poly(hydroxymethyl) phosphonium cation
and having a pH of from about 2 to about 9 is prepared and used to impreg-
nate a textile material, the impregnated material is dried to about 0 to
about 8 percent moisture, the dried material is aerated substantially
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immediately after leaving the drier by directing a current of air through
the material, preferably suction, said material is then exposed for at
least about 5 to less than about 60 seconds and preferably for about 10
to about 30 seconds to an atmosphere containing at least about 50 percent
by volume of ammonia, preferably from
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about 70 to about 95 percent of gaseous ammonia, and the material is con-
tacted substantially immediately after ammonia treatment with water, in
an amount sufficient to provide a wet pick-up of from about 10 to about
40 percent by weight of water. The material is thereafter again contacted
with the gaseous ammonia atmosphere for a short period of time, from about
less than 1 to about 10 seconds, and preferably from about less than 1 to
about 6 seconds, to further enhance cure. The thus treated material, con-
taining an insoluble polymer of the phosphonium compound in and on the
material; is scoured, washed, and dried.
The treatment of the dried impregnated material with ammonia, i.e.,
the curing step, is carried out in an enclosed chamber wherein the impreg-
; nated material is exposed to a gaseous atmosphere containing a high concen-
tration, i.e., above about 50 percent by volume, of ammonia. The material
is preferably passed into and out of the chamber, in a continuous manner ~-
and at a relatively high speed, so that the material is exposed to the
ammonia atmosphere for at least 5 seconds and preferably from about 15
to about 30 seconds.
The improved process of this invention differs from the process dis-
closèd in U. S. Patent 3,933,122 in two respects. In the instant process
the impregnated material after being dried is aerated by directing a current
of air through the dried material, and also the material, after passing
through ammonia curing, is exposed to or contacted by water, while still
in the cabinet, and thereafter exposed to ammonia gas again. By conducting
the process in this manner, the problems caused by the presence of formalde- - -- -
hyde in the dried uncured impregnated material in the curing step and also
after the curing of the monomer on and in the cellulosic material can be
substantially obviated. It has been found that the pH of the process may
be reduced during curing, resulting in the formation of very little formalde-
hyde and significantly decreasing the formaldehyde odor, which can be
sensed in the plant environment outside the ammoniating chamber.
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108'~054
In unexpected addition, a higher efficiency of flame retardancy is
achieved when the material is a blend of varying cellulosic materials.
By the latter, it is meant that a higher add-on of resin occurs re-
sulting in an increase of flame retarding effect together with increased
durability, each without adverse effect to the hand of the material.
The materials which can be treated to impart flame re-
tardant properties thereto in accordance with this invention include
; cotton, rayon, paper, jute, ramie, wood, and mixtures thereof, as well
as blends of cellulosics such as cotton or rayon with synthetic fibers,
such as polyesters, nylons, acrylics, acetate and mixtures thereof ~ -
or with proteinaceous fibers such as wool, silk, mohsir, alpaca,
mixtures thereof and the like. The process of this invention is
particularly effective when applied to the treatment of cellulosic and
cellulosic-blend materials such as cotton and rayon with synthetic materials.
The solution used to impregnate the textile material comprises
poly(hydroxymethyl) phosphonium cation or poly(hydroxymethyl) phosphine
and poly(hydroxymethyl) phosphonium cation as an equilibrium mixture.
Such solutions are well known in the art. One method of preparation
is by reacting a solution of tetrakis (hydroxymethyl) phosphonium
salt with up to an equivalent quantity of an organic or inorganic base.
Typically, sny of the tetrakis (hydroxymethyl) phosphonium salts can
be utilized to make the solutions of this process. Common salts which
may be employed include, for example, the halides, sulfates, acetates,
phosphates, carboxylates, oxalates, lactates, formates, sulfonates, and
nitrates. The most often used salts are, however, the halides and
the sulfates.
The solvent may be water or an appropriate non-aqueous solvent such
as alcohol, N,N-dimethyl formamide, dimethyl acetamide, and mixtures
thereof and the like. Alternatively, the solution may be in the form of
, 30 an emulsion. Furthermore, the solution may be a reaction product of the
;`l poly(hydroxymethyl) phosphonium cation with an appropriate nitrogen
containing material such as urea, guanidines, substituted ureas, mel-
_ g _
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108Z05~
amines, or other amino or amido function containing organic materials or
the reaction product of the previously mentioned nitrogen containing
materials with aldehydes, preferably formaldehyde. Especially preferred
~` bases for reaction with the salt are alkaline metal hydroxides, alka-
line earth hydroxides, salts of weak acids and strong bases, monoalk-
aline metal salts of dibasic acids, organic tertiary amines such as
triethyl~mine,trimethylamine, and the like. The pH of the final sol-
ution is adjusted to from about 2 to about 9, preferably to from about
5.0 to about 8.l. For the purpose of this invention, the active com-
lo ponent of the solution or emulsion is considered to be the poly (hy-
droxymethyl) phosphonium cation. Hereinafter, the active component will
be expressed in terms of this component, although it is probable that
there is present a mixture of poly (hydroxymethyl) phosphine and poly ~ ~
;~ (hydroxymethyl) phosphonium cation. -
The treating solution may be applied to the t¢xtile in.
any convenient manner. For example, the solution may be applied by
padding, dipping, spraying, and the like. After impregnation, the
excess solution is preferably removed from the material by passing the
material through squeeze rolls, centrifuging, wringing, or other meth-
ods. Although a wet pick-up of from about 50 to about 200 percent may
suitably be used, preferably the material contains about an equal
weight, i.e., about 100 percent pick-up, of the treating solutions.
The impregnated material is then dried to a residual content of
about 0 to about 8 percent and preferably from about 0 to about 3
percent. The drying is carried out in air or in drying oven at temp-
eratures which may vary from ambient to about l25 centigrade. Ex-
i cessive drying temperatures and times are to be avoided. The drying
-~1 time may vary according to the drying temperature and also the weight
and fibrous nature of the material, as will be obvious to those skilled
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in this art. The solvent content of the material may be measured by a
suitable meter.
The dried material is then aerated by passing a current of air
through the material as soon as possible or convenient after leaving the
drier. The aeration step can be carried out by passing the material,
after drying, over a perforated plate or pipe through which a strong
current of air is continuously blown or sucked. Preferably, the air
current is moved by suction. Conveniently, this aeration means is
located as close as possible and/or convenient to the material exit of
the drier. The material is passed over the perforated or slotted air
distribution means, a plate, pipes, or series of pipes extending over
the width of the fabric and a current of air, flowing at about lO00 to
3000 cubic feet per minute, is caused to pass through the material. The
time required for this operation is not critical, and, in general, the
material is exposed to the current of air for about 0.5 to about 2.0
seconds or more. As will be apparent, the speed of the material running
through the processing equipment will determine the exposure time, and
is a function of the volume of air and speed of the material. By this
means, any formaldehyde present in the dried material is rapidly removed
by the current of air and also the material is rapidly cooled thereby
reducing the formation of additional formaldehyde occaisioned by the
probable decomposition of the phosphonium compounds.
The aerated impregnated material next is exposed to gaseous ammonia
in an enclosed chamber wherein the resin monomer reacts rapidly and
substantially completely to form an insoluble polymer within the mater-
ial. The gaseous atmosphere which comprises at least about 50 percent
of gaseous ammonia, and preferably from about 70 to about 95 percent or
more of gaseous ammonia provides an effective, efficient, and supris-
ingly rapid reactant for the resin curing step. It has been found that
the curing step is completed, under these conditions, in less than
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about 60 seconds and generally less than about 45 seconds, and as low as
5 seconds; whereas, in prior art procedures from about 1 to about 6
minutes were required for substantially complete polymerization and
curing of the impregnated composition. Under optimum conditions, the
procedure of this invention proceeds with the efficient utilization of
the gaseous ammonia charged to the process, whereas prior art processes
often preferred up to a 15 fold excess of the ammonia reactant. This
huge excess of ammonia presented a serious air pollution problem, which
in the present process and apparatus has been eliminated by the highly
lo efficient utilization of the ammonia.
A particularly effective, and hence preferred, apparatus for
carrying out the curing step of this process is illustrated by the
attached drawing which shows a schematic view of the enclosed cabinet
apparatus of thi-s invention. In this drawing the housing, 1, contains a
gas inlet, 2, and a gas outlet, 3, which is conviently connected to a
suction means, not shown. The housing is provided also with a material
/ inlet, 4, and material outlet, 5, for admitting the dried impregnated
- material and exiting the cured material. Material guides, 6, are
provided for conveying the impregnated material through the cabinet.
Partitioning means, 7, extending across the interior of the housing
serves to form a chamber in which the material is contacted with the
gas. The partitioning means includes flaps, 8 and 9, which permits the - -
material to be treated to enter the gas treatment chamber and the
treated material to exit from said chamber, while minimizing the passage
' 25 of gas into and from the said chamber. A gas distribution device, shown
. here as a perforated plate, 10, is provided to assist in the distribu-
tion of the enter1ng gas stream evenly throughout the gas treatment
chamber. Sensing ports, 11, are provided in the gas treatment chamber
for removal of samples of the gaseous atmosphere for analysis to monitor
the concentration of the treatment gas. Water inlet means, 12, with
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connecting application means, l3, are provided in the gas treatment
chamber for the water treatment step.
The housing may be provided with cooling means, not shown, to cool
the treatment chamber and to regulate the temperature of the gaseous
atmosphere within the treatment chamber. A liquid condensate discharge
port, not shown, may be positioned at a convenient place in the housing
` for removal of condensate from the chamber. Such port should be at a
lower point than the material inlet or outlet and the gas outlet, 3.
The housing can be fabricated from conventional materials of
construction such as wood, metal, glass, plastic, and the like or any
combination thereof.
The partition means, 7, may be constructed from like materials or
from rubber. The flaps, 8 and 9, are fabricated from flexible materials
such as rubber, leather, plastic film and are attached to the partition
means in any convenient manner. It is important that the flaps do not
impede the passage of the material therethrough but do substantially
prevent the free flow of gas into and out of the treatment chamber.
In operating this apparatus, ammonia gas is fed into the unit
through gas inlet, l, at a rate sufficient to provide an ammonia at-
mosphere within the gas treatment chamber having at least about 50
percent by volume of ammonia, and preferably from about 70 percent to
about 90 percent ammonia by volume. Textile material which has been
impregnated with the poly (hydroxymethyl) phosphonium cation and dried
to contain from about 0 to about 8 percent moisture is admitted to the
apparatus, preferably in a continuous manner, at inlet, ~, and is passed
over material guides, 6, through partitioning means, 7, through flap, 8,
into the gas treatment chamber wherein the impregnated material is
exposed to the am~onia atmosphere. After exposure to the a~monia at-
mosphere for the requisite time, it is water treated with water appli-
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cation means 13. The material is again exposed to the ammonia at-
mosphere and thereafter leaves the gas treatment chamber passing through
flap, 9, of partitioning means, 7, and exits from the housing, 1, at
material outlet, 5. The passage of air into the gas treatment chamber
: 5 is minimized in part by the partitioning means and in part by the
withdrawal of gas from the housing through gas outlet, 3, which is
connected to a mild suction means e.g., a vacuum pump.
The rate of flow of ammonia gas into the apparatus is adjusted to
provide at least one mol of ammonia per mole of tetrakis (hydroxymethyl)
lo phosphonium hydroxide available for reaction, i.e., curing, on the
impregnated material. Preferably about a 20 percent molar excess of
ammonia is supplied. This amount of ammonia can be approximated by the
following calculation:
Lbs. of impregnated material X Yds. X % THPOH X % Wet pick-up
Yard of material Min. 100 100
X 1 = Mols of THPOH/min.
172
Mols THPOH 359 ft.3
X X 1.2 = cu. ft. NH3 gas/m~n.
min. mol.
The material is preferably contacted with water within the enclosed
chamber. Any convenient method of water application means may be utilized, such
as a trough, stream, spray, etc., or any co~bination thereof, and any
convenient location within the chamber would be appropriate; for ex- -
ample, referring to the drawing, a trough may be located above or below
the partitioning means or may be an integral portion thereof through
which the material is guided with or without an additional material
guiding means. In a like manner, a stream or, as illustrated in the
` drawing, a spray may also be utili~ed. A combination of means may also be used in application of the water treatment. A
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preferred method, however, is the application of water in the form of a
fine spray. Several means for accomplishing this step will be obvious
to those skilled in this art. For example, a spray head or several
heads may be positioned convenient to the material exit means from the
curing cabinet. Most preferably, the spraying means is one or several
air atomizing water spray heads which are used to supply the water in
the form of an atomized spray to the material before exiting from the
ammonia curing cabinet. Sufficient water should be added to the mater-
ial to provide a pick-up of about lO to about 60 percent by weight and
preferably from about 20 to about 30 percent by weight pick-up of water.
This water not only cools the hot material but also results in the
immobilization of formaldehyde and, thus, prevents its further reaction
with the phosphonium salt polymer.
It is believed that the water supplied at this stage of the process
provides a reaction medium for the formaldehyde to react with ammonia
which may be present to form hexamethylene tetramine, which latter
product does not react with the phosphonium salt polymer present in and
on the material.
It has been found that further treatment with gaseous ammonia,
after contact with water, has a further beneficial effect upon the
polymerized material. Treatment with gaseous ammonia for from about
less than l to about lO seconds and preferable about less than l to
about 6 seconds reduce further the substantially reduced odor of for-
maldehyde so that such odor is no longer readily apparent. To gain such
further treatment, placement of the water treatment means at a point
away from the material exit, so that the material will remain in the
enclosed chamber for a time after water treatment, has been found to be
a convenient method of achieving this end. Alternatively, the further
gaseous ammonia treatment may be accomplished in a separate chamber.
Where additional ammonia treatment is desired within the chamber
after the water treatment step, it might be desirable to maintain a nip
roll doctor
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blade or similarly functioning means immediately after the water treat-
ment means to decrease the amount of water maintained on the material when
undergoing the additional ammonia cure. Such means have been found to
be effective but are not necessary to the operation of the instant process.
Thereafter, the wetted material which contains about lO to about 60
percent by weight of moisture pick-up is preferably oxidized or scoured,
or washed to remove unpolymerized materials and the like. Where the
present invention is carried out on yard goods using mill apparatus, this
scouring operation may be effected using any of the conventional scour-
lo ing, and the like. The scouring may be conveniently carried out using,
an aqueous soap solution containing small amounts of sodium carbonate,
perborate, or peroxide and synthetic detergents. Preferably this scour-
ing is carried out immediately after the step of contacting the material
with water.
Alternatively, the wetted material can be batched ln rolls or in
trucks and held for extended periods. When so handled, i.e., batched,
the material does not develop significant formaldehyde odors nor does a
I significant exotherm develop. Thus, following the water wetting step of
-~ this process, the material is essentially completely processed, except
fnr the normal and conventional scouring, etc. treatments and the flame
retardant character is durably imparted thereto. Since in many mills the
scouring and other final operations are carried out at points remote
from the impregnation drying and curing operations, it is usual in this
industry to batch the polymerized or cured materials to the area where the ~-
scouring and other finishing operations are carried out. Since hours or
days may elapse, it can be seen that the process of this invention pro-
vides an efficient and economical means for preventing the deterioration
of the flame retardant treatment prior to finishing the material.
The scouring step may be followed by conventional washing and drying
operations and thereafter the dried treated material may be
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subjected to any normal finishing operation such as sanforizing, calen-
dering, and the like.
The flame retardant cellulose-containing materials treated in
accordance with the procedures set forth above have been found to be
durably flame retardant, even after 50 or more home laundering and
drying cycles. Additionally, such materials are substantially free from
dust and have a tear resistance, tensile strength, and hand which are
substantially unchanged from those of untreated materials.
The process of this invention is readily adaptable to modern high
lo speed commercial textile processing equipment. Substantial savings of
time and of consumption of ammonia gas, in the range of about 100 to 200
percent, are effected by this improved process. Additionally, the
present process prevents the deterioration of the flame retardant char-
acter imparted to the material which may occur between the curing step
and the scouring and other finishing steps.
The following examples will illustrate the process of the present
invention. In these examples, as well as in the above specification and
the claims hereinafter set out, parts and percentages are by weight and
temperatures are given in degrees Fahrenheit, unless otherwise speci-
fied. The durability of the flame retardancies reported by accelerated
boil test and the 50 home washes test were determined in accordance with
the procedure of the United States Department of Commerce test procedure
i No. DOC FF-3-71.
EXAMPLE I
An aqueous solution containing about 32 percent tetrakis (hydroxy-
i methyl) phosphonium cation and having a pH of 7.4 was used to impregnate
6000 yards of white cotton sheeting material, (3 yards/lb.), at the rate
of 60 yards per minute. The impregnated material was passed through
squeeze rolls to give~a wet pick-up of about 100 percent. The impreg-
nated material was dried in a 225~ oven for 30 seconds and then within
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about 20 seconds exposed in an enclosed cabinet for about 15 seconds to
an atmosphere consisting of 95 percent by volume of ammonia and 5 per-
cent by volume of air. The treated material after emanating from the
ammonia treatment cabinet was batched in a roll. After being held in
the roll for about 24 hours, the material was tested for flame retard-
ance, after being subjected to the usual oxidation, washing, and drying
steps, and failed both the accelerated boil test and the 50 home washes
test.
The "accelerated boil test", as a measure of the flame retardant
lo character of the material, is carried out by heating the dried cured
material for 45 minutes in a solution containing 90 parts of soap, 90
parts soda ash, and 10 parts of a synthetic anionic detergent in about
50,000 parts of water and rinsed in hot (145) water for 15 minutes,
repeating the heating and rinsing nine times ("9 boil cycles"). This
"accelerated boii" test is roughly equivalent to at least fifty home
washing and drying cycles.
EXAMPLE II
A multi-yard run of 35 percent polyester, 65 percent cotton flannel
material was continuously processed at the rate of about 60 yards/ min.
by running into an aqueous bath containing about 28 percent tetrakis
; (hydroxymethyl) phosphonium cation and having a pH of 7.4. The im-
pregnated material was passed through squeeze rolls to give a wet pick-
up of about 110 percent and into a 250~ oven (residence time about 30
seconds). The dried material was passed from the oven over a slotted
plate about 36 inches long through which air at the rate of about 2,000
cfm was being moved upwardly through the material by suction. The dwell
time of the fabric moving at the rate of 60 yards/min. over the slotted
plate is about one second. The aerated material was passed into an
enclosed cabinet where it was exposed for about 8 seconds to an atmos-
phere consisting of about 85 percent by volume of ammonia and 15 percent
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by volume of air. The treated material was contacted substantially
immediately after exiting from the cabinet with an air atomized water
spray sufficient to result in a pick-up of about 25 percent water. The
material was batched in rolls and held for about twenty-four hours, then
subject to the usual oxidation, washing, and drying steps. The fabrics
were tested according to Federal Regulation FF-3-71 after 50 home washes
and 50 tumble dryings with the following result:
No. of Samples No. of Samples Avg. Char Length
Run No. Tested Burning (in.)
lo A 18 3 3.7
B 19 4 3.8
C 15 5 4.0
D 21 1 2.3
~ E 10 0 2.0
- 15 F 1? 1 3.2
EXAMPLE III
A multi-yard run of 35 percent polyester, 65 percent cotton flannel
was continually processed by the method of Example II with the exception
that the ammonia exposed material was sprayed with water and exposed to
an additional atmosphere consisting of about 85 percent by volume of
ammonia and 15 percent by volume of air for about 2 seconds. Both of
the ammonia gas exposure steps and the water spray were accomplished in
the enclosed cabinet. The following results were obtained:
No. of Samples No. of Samples Avg. Char Length
Run No. Tested Burning (in.)
G 17 0 2.0
H 19 0 1.9
I 3 0 1.6
`~ J 10 0 2.3
K 6 0 1.9
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Each of the fabrics in both Example II and III were sampled
approximately every 1,000 yards with five specimens tested for each
sample.
A significant difference was observed in the formaldehyde odor
apparent from the batched rolls of Examples I, II, and III. The batched
rolls of Example I had an intensive odor, Example II had a significantly
reduced odor, and Example III had such a reduced odor as to be not
readily apparent.
EXAMPLE IV
A precondensate reaction product was prepared by refluxing 1,000
grams of tetrakis(hydroxymethyl) phosphonium chloride and 125 grams of
urea in 545 grams of water. The reaction product was thereafter diluted
with water to form an aqueous bath containing 36% tetrakis(hydroxymethyl)
phosphonium cation concentration.
Cotton flannel material was immersed in the aforesaid aqueous bath
and thereafter passed through squeeze rolls to give a wet pickup of
about 110 percent. The so impregnated material was oven dried at about
~ 200F. for a time sufficient to dry the material to a moisture content
: of less than about 1 percent and thereafter aerated by the process of
Example II. Samples A-D were prepared from the dried and aerated
material and subjected to gaseous ammonia cure. Each of the samples
were exposed to an atmosphere containing 90 percent by volume ammonia
~ and 10 percent by volume air for varying time periods in an enclosed
-~ chamber. In addition, Sample D was also sprayed with water and further
exposed to a 90 percent by volume gaseous ammonia atmosphere, all
occuring within the enclosed chamber. Each of the samples were subjected
to the usual oxidation, washing and drying steps and thereafter tested
, according to Federal Regulation FF-3-71. After 50 home washings and 50
.!` tumble dryings the results were as follows:
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Exposure Additional Char
to WaterExposure Resin Length
Sample NH3(Sec.~ ~e~3~to NH~(Sec.) Add-on (in.3
A 9 None ---- l9.0 Burn
B l8 None ---- l9.l Burn
C 36 None ---- 21.4 Burn
D 9 Yes 3 26.7 1.8
As can be seen from the aforesaid, Sample D, wherein the material
was water sprayed and re-exposed to an ammonia atmosphere, showed an increase
in resin add-on and an increased resistance in flammability.
EXAMPLE V
An aqueous bath was prepared by diluting tetrakis(hydroxymethyl)
phosphonium sulfate with sufficient water to provide a tetrakis(hydroxy-
methyl) phosphonium cation concentration of 36 percent and thereafter
neutralizing with sodium hydroxide to a pH of 7.5
Cotton flannel material was immersed in the aqueous bath, squeezed
dried and aerated by the method of Example IV. Samples A and B were
prepared and each was exposed to an atmosphere containing 90 percent by
volume ammonia and lO percent by volume air in an enclosed chamber.
Sample A was exposed to the ammonia atmosphere for lO seconds and
thereafter subjected to the usual oxidation, washing and drying steps.
Sample B was exposed to the ammonia atmosphere for 7 seconds, then
`~ water sprayed and re-exposed to the same ammonia atmosphere for 3
seconds in an enclosed chamber. Sample B was thereafter subjected to
the usual oxidation, washing and drhing steps. After 50 home washings ~-~
and 50 tumble dryings FF-3-71 results were as follows:
Char Length
Sample % Resin Add-On (in )
A l7.9 Burn
B 19.4 1.7
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EXAMPLE VI
A multi-yarn run of cotton flannel fabric was processed by passing
it through an aqueous bath containing about 30% tetrakis(hydroxymethyl)
phosphonium cation and having a pH of 7.2. The impregnated
S fabric was passed through squeeze rolls to a wet pickup of about 110percent then into a 250F oven (residence time about 30 seconds) and
dried to a moisture content of about 0.5%. The fabric was aerated
and continually passed into an enclosed ammonia cabinet where it was
exposed for about 8 seconds to an atmosphere consisting of about 85
percent by volume gaseous ammonia and 15 percent by volume of air.
The fabric was then passed through a kiss roll, contacted with a doctor
blade to remove excess water, and passed again through a gaseous
ammonia atmosphere as above described for about 2 seconds. Each of
the aforesaid steps was accomplished within the enclosed ammonia
cabinet. Upon exit from the ammonia cabinet, the material was batched
- in rolls and held for about twenty-four hours, then subjected to the
usual oxidation, washing and drying steps. The fabric was tested
according to Federal Regulation FF-3-71 and was found to be durably
flame retardant as measured by that test.
EXAMPLE VII
A tetrakis(hydroxymethyl) phosphonium sulfate urea precondensate
was prepared by refluxing 1200 gram of tetrakis(hydroxymethyl) phosphonium ;
sulfate (86% sollds), 500 grams of water and 75 grams of urea for 2 hours.
The resulting solution was diluted with 1300 grams of water and 77 grams
of sodium acetate was added thereto.
Cotton flannel material was immersed in the aforesaid aqueous bath
then passed through squeeze rolls to a wet pickup of about 105%.
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108~054
The so impregnated material was oven dried at about 200F. for a time
sufficient to dry the material to a moisture content of about 3-5% and
thereafter aerated by the process of Example II. The material was
exposed to an atmosphere containing 80 percent by volume ammonia and
20 percent by volume air for 10 seconds, then passed directly into a
second chamber, wherein it was immediately sprayed with water and
thereafter exposed to an atmosphere containing about 40 percent by
volume ammonia gas and 60 percent by volume air for about 3 seconds.
The material was then subjected to the usual oxidation, washing and
lo drying steps. The resin add-on was found to be 23 percent and the
fabric was durably flame retardant as measured by Federal Regulation
FF-3-71.
The above process was repeated on a cotton flannel material with
the exception that no second chamber was ut~lized ar;d the material was
not subjected to a spray and further exposure to gaseous ammonia. The -
final resin add-on was found to be 16 percent and the fabric burned
initially and after testing under FF-3-71.
EXAMPLE VIII
A pad bath was prepared containing 600 pounds of tetrakis
(hydroxymethyl) phosphonium sulfate, 758 pounds of water and 105 pounds
of a 50 percent aqueous sodium hydroxide solution.
A desized, scoured 8 oz. sateen material was impregnated with the
above solution and squeezed to a wet pickup of about 60 percent. The
material was dried at about 200F to a moisture content of about 5 percent
and thereafter aerated by the process of Example II. The material was
then passed to an ammoniating chamber where it was exposed for about 20
seconds to an atmosphere containing 90 percent gaseous ammonia and 10 percent
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~0~320S4
air, sprayed w;th water to a wet pick-up of about 40 percent then exposed
to the atmosphere containing about 50 percent gaseous ammonia and 50
percent air for about 6 seconds. Each of these steps occurred in the
ammoniating chamber. The material was then subjected to the usual
oxidation, washing and drying steps. The resin add-on was found to be
13 percent and the fabric was durably flame retardant as measured by
Federal Regulation FF-3-71.
EXAMPLE IX
A desized, scoured and bleached, 5 oz. jean cloth was treated
lo with the solution and process of Example VIII with the exception that
wet-pick-up after imgregnation was 95%. The final resin add-on was
22% and the jean cloth was found to be durably flame retardant as
Feasured by Federal Regulation FF-3-71.
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