Compositions for Treating Textiles and Carpet and Applications Thereof

Abstract

The present invention provides compositions for treating textiles, including carpet and other floor coverings. Compositions of the present invention, in some embodiments, can impart flame resistant and/or stain resistant properties to fibers, including synthetic fibers comprising polyolefins, polyamides, and polyesters such as polytrimethylene terephthalate.

That which is claimed is: 
     
         1 . An aqueous dispersion comprising:
 at least one dye leveler compound; and   a compound of Formula (I):   
       
         
           
           
               
               
           
         
       
       wherein R 1 , R 2  and R 3  are independently selected from the group consisting of -hydrogen, -alkyl, -alkenyl, -alkynyl, -cycloalkyl, -fluoroalkyl, -chloroalkyl, -bromoalkyl, -fluoroalkenyl, -chloroalkenyl, -bromoalkenyl, -cycloalkyl, -heterocyclyl, -aryl, -heteroaryl, -alkyl-aryl, -alkyl-heteroaryl, -alkenyl-aryl, -alkenyl-heteroaryl, -aryl-alkyl, -heteroaryl-alkyl, -aryl-alkenyl, -heteroaryl-alkenyl, alkyl-OH, alkenyl-OH, -aryl-OH and -heteroaryl-OH
 wherein the alkyl, alkenyl, alkynyl, cycloalkyl, aryl and heteroaryl groups of R 1 -R 3  are optionally and independently substituted one or more times with a substituent selected from the group consisting of -alkyl, -alkenyl, -fluoroalkyl, -chloroalkyl, -bromoalkyl, -aryl, —O-alkyl, —O-alkenyl, —O-aryl, —O-alkylene-aryl, -carboxyl, -hydroxyl, -halo and -nitro. 
 
     
     
         2 . The aqueous dispersion of  claim 1 , wherein the compound of Formula (I) comprises tris(1,3-dichloroisopropyl)phosphate, triphenyl phosphate, tricresyl phosphate or diphenyl phosphate or mixtures thereof. 
     
     
         3 . The aqueous dispersion of  claim 1 , wherein the compound of Formula (I) is present in an amount ranging from about 10 weight percent to about 80 weight percent. 
     
     
         4 . The aqueous dispersion of  claim 1 , further comprising a dye component. 
     
     
         5 . The aqueous dispersion of  claim 4 , wherein the dye component comprises an acid dye, cationic dye, disperse dye, fiber reactive dye, sulfur dye, vat dye or mixtures thereof. 
     
     
         6 . A composition comprising:
 a synthetic fiber substrate treated with an aqueous dispersion comprising at least one dye leveler compound and a compound of Formula (I):   
       
         
           
           
               
               
           
         
       
       wherein R 1 , R 2  and R 3  are independently selected from the group consisting of -hydrogen, -alkyl, -alkenyl, -alkynyl, -cycloalkyl, -fluoroalkyl, -chloroalkyl, -bromoalkyl, -fluoroalkenyl, -chloroalkenyl, -bromoalkenyl, -cycloalkyl, -heterocyclyl, -aryl, -heteroaryl, -alkyl-aryl, -alkyl-heteroaryl, -alkenyl-aryl, -alkenyl-heteroaryl, -aryl-alkyl, -heteroaryl-alkyl, -aryl-alkenyl, -heteroaryl-alkenyl, alkyl-OH, alkenyl-OH, -aryl-OH and -heteroaryl-OH,
 wherein the alkyl, alkenyl, alkynyl, cycloalkyl, aryl and heteroaryl groups of R 1 -R 3  are optionally and independently substituted one or more times with a substituent selected from the group consisting of -alkyl, -alkenyl, -fluoroalkyl, -chloroalkyl, -bromoalkyl, -aryl, —O-alkyl, —O-alkenyl, —O-aryl, —O-alkylene-aryl, -carboxyl, -hydroxyl, -halo and -nitro. 
 
     
     
         7 . The composition of  claim 6 , wherein the synthetic fiber substrate comprises a polyamide, polyolefin, polyester, polyacrylonitrile or combinations thereof. 
     
     
         8 . The composition of  claim 7 , wherein the polyolefin comprises polyethylene, polypropylene, polybutene or combinations thereof. 
     
     
         9 . The composition of  claim 7 , wherein the polyester comprises polytrimethylene terephthalate, polyethylene terephthalate, polybutylene terephthalate or combinations thereof. 
     
     
         10 . The composition of  claim 7 , wherein the compound of Formula (I) comprises tris(1,3-dichloroisopropyl)phosphate, triphenyl phosphate, tricresyl phosphate or diphenyl phosphate or mixtures thereof. 
     
     
         11 . The composition of  claim 6 , wherein the synthetic fiber substrate is further treated with an aqueous solution of a compound of Formula (II): 
       
         
           
           
               
               
           
         
       
       wherein R 4 , R 5  and R 6  are independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, cycloalkyl, alkoxy, heterocycl, aryl, heteroaryl, -alkyl-aryl, -aryl-alkyl, halo, —OH, —C(O)OR 16 , 
       —SH, 
       
         
           
           
               
               
           
         
       
       wherein R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 13 , R 14 , R 15  and R 16  are independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, heterocycl, aryl, heteroaryl, -alkyl-aryl, and -aryl-alkyl, —OH; and 
       wherein X −  is independently selected from the group consisting of fluoride, chloride, bromide, iodide, hydroxide, carboxylate, phosphate, sulfate, and sulfide. 
     
     
         12 . The composition of  claim 6 , wherein the synthetic fiber substrate is further treated with a fluorochemical. 
     
     
         13 . The composition of  claim 12 , wherein the fluorochemical comprises a fluoropolymer of Formula (III):
   R f —(CH 2 ) n -P  (III)
   
       wherein P is a polymerizable moiety, R f  is a straight chained or branched perfluoroalkyl group and n is an integer from 0 to 3. 
     
     
         14 . The composition of  claim 6 , wherein the aqueous dispersion further comprises a dye component. 
     
     
         15 . The aqueous dispersion of  claim 14 , wherein the dye component comprises an acid dye, cationic dye, disperse dye, fiber reactive dye, sulfur dye, vat dye or mixtures thereof. 
     
     
         16 . A floor covering construction comprising:
 a backing; and   a plurality of fibers coupled to the backing, wherein the plurality of fibers have associated therewith a compound of Formula (I):   
       
         
           
           
               
               
           
         
       
       wherein R 1 , R 2  and R 3  are independently selected from the group consisting of -hydrogen, -alkyl, -alkenyl, -alkynyl, -cycloalkyl, -fluoroalkyl, -chloroalkyl, -bromoalkyl, -fluoroalkenyl, -chloroalkenyl, -bromoalkenyl, -cycloalkyl, -heterocyclyl, -aryl, -heteroaryl, -alkyl-aryl, -alkyl-heteroaryl, -alkenyl-aryl, -alkenyl-heteroaryl, -aryl-alkyl, -heteroaryl-alkyl, -aryl-alkenyl, -heteroaryl-alkenyl, alkyl-OH, alkenyl-OH, -aryl-OH and -heteroaryl-OH,
 wherein the alkyl, alkenyl, alkynyl, cycloalkyl, aryl and heteroaryl groups of R 1 -R 3  are optionally and independently substituted one or more times with a substituent selected from the group consisting of -alkyl, -alkenyl, -fluoroalkyl, -chloroalkyl, -bromoalkyl, -aryl, —O-alkyl, —O-alkenyl, —O-aryl, —O-alkylene-aryl, -carboxyl, -hydroxyl, -halo and -nitro. 
 
     
     
         17 . The floor covering construction of  claim 16 , wherein the compound of Formula (I) comprises tris(1,3-dichloroisopropyl)phosphate, triphenyl phosphate, tricresyl phosphate or diphenyl phosphate or mixtures thereof. 
     
     
         18 . The floor covering construction of  claim 16 , wherein the plurality of fibers comprises natural fibers, synthetic fibers or combinations thereof. 
     
     
         19 . The floor covering construction of  claim 18 , wherein the synthetic fibers comprise a polyamide, polyolefin, polyester, polyacrylonitrile or combinations thereof. 
     
     
         20 . The floor covering construction of  claim 19 , wherein the polyester comprises polytrimethylene terephthalate, polyethylene terephthalate, polybutylene terephthalate or combinations thereof. 
     
     
         21 . The floor covering construction of  claim 16 , wherein the plurality of fibers have associated therewith a fluorochemical. 
     
     
         22 . The floor covering construction of  claim 21 , wherein the fluorochemical comprises a fluoropolymer of Formula (III):
   R f —(CH 2 ) n -P  (III)
   
       wherein P is a polymerizable moiety, R f  is a straight chained or branched perfluoroalkyl group and n is an integer from 0 to 3. 
     
     
         23 . The floor covering construction of  claim 16 , wherein the backing comprises a latex composition comprising the compound of Formula (I). 
     
     
         24 . The floor covering construction of  claim 23 , wherein the backing further comprises particles of a fluoropolymer. 
     
     
         25 . The floor covering construction of  claim 16 , wherein the floor covering construction passes the flammability requirements set for in the Department of Commerce FF1-70. 
     
     
         26 . The floor covering construction of  claim 16 , wherein the floor covering construction has a critical radiant flux of at least 0.45 watts/cm 2  according to ASTM E-648. 
     
     
         27 . The floor covering construction of  claim 16 , wherein the floor covering construction has a critical radiant flux of at least 0.45 watts/cm 2  according to ASTM E-648. 
     
     
         28 . The floor covering construction of  claim 26 , wherein the plurality of fibers comprise polytrimethylene terephthalate. 
     
     
         29 . A method of enhancing the flammability resistance of a substrate comprising:
 providing an aqueous dispersion comprising at least one dye leveler compound and a compound of Formula (I):   
       
         
           
           
               
               
           
         
       
       wherein R 1 , R 2  and R 3  are independently selected from the group consisting of -hydrogen, -alkyl, -alkenyl, -alkynyl, -cycloalkyl, -fluoroalkyl, -chloroalkyl, -bromoalkyl, -fluoroalkenyl, -chloroalkenyl, -bromoalkenyl, -cycloalkyl, -heterocyclyl, -aryl, -heteroaryl, -alkyl-aryl, -alkyl-heteroaryl, -alkenyl-aryl, -alkenyl-heteroaryl, -aryl-alkyl, -heteroaryl-alkyl, -aryl-alkenyl, -heteroaryl-alkenyl, alkyl-OH, alkenyl-OH, -aryl-OH and -heteroaryl-OH,
 wherein the alkyl, alkenyl, alkynyl, cycloalkyl, aryl and heteroaryl groups of R 1 -R 3  are optionally and independently substituted one or more times with a substituent selected from the group consisting of -alkyl, -alkenyl, -fluoroalkyl, -chloroalkyl, -bromoalkyl, -aryl, —O-alkyl, —O-alkenyl, —O-aryl, —O-alkylene-aryl, -carboxyl, -hydroxyl, -halo and -nitro; and 
 applying the aqueous dispersion to the substrate. 
 
     
     
         30 . The method of  claim 30 , wherein the substrate comprises one or more natural fibers, synthetic fibers or a combination thereof. 
     
     
         31 . The method of  claim 29 , wherein the synthetic fibers comprise a polyamide, polyolefin, polyester, polyacrylonitrile or combinations thereof. 
     
     
         32 . The method of  claim 31 , wherein the polyester comprises polytrimethylene terephthalate, polyethylene terephthalate, polybutylene terephthalate or combinations thereof.