Method of durably sizing textile yarns, durable sizing composition, and durably sized yarns and fabrics produced therefrom

Claim 1

A method of producing textile yarns suitable for forming textile fabrics therefrom, said yarns being characterized by having a durable size coating which remains bound to the yarn throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarn, said method comprising providing a supply package containing a plurality of textile yarns, advancing the plurality of textile yarns from the supply package along a predetermined path of travel to and through a coating station and applying to the yarns an aqueous sizing composition comprising an aqueous self-crosslinking copolymer produced by emulsion polymerization of one or more ethylenically unsaturated monomers in the presence of a latent-crosslinking comonomer comprising an N-alkylolamide of an alpha, beta ethylenically unsaturated carboxylic acid having 3 to 10 carbon atoms, directing the coated yarns from the coating station to and through a drying zone and heating the yarns to dry the aqueous sizing composition and to crosslink and insolubilize the self-crosslinking copolymer, and directing the thus coated yarns from the drying zone to a take-up station and winding the coated yarns on a take-up roll.

Claim 2

A method of producing textile yarns suitable for forming textile fabrics therefrom, said yarns being characterized by having a durable size coating which remains bound to the yarn throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarn, said method comprising providing a supply package containing a plurality of textile yarns, advancing the plurality of textile yarns from the supply package along a predetermined path of travel to and through a coating station and applying to the yarns an aqueous sizing composition comprising an aqueous self-crosslinking copolymer produced by emulsion polymerization of one or more ethylenically unsaturated monomers in the presence of a latent-crosslinking comonomer comprising an N-alkylolamide of an alpha, beta ethylenically unsaturated carboxylic acid having 3 to 10 carbon atoms, directing the coated yarns from the coating station to and through a drying zone and heating the yarns to dry the aqueous sizing composition and to crosslink and insolubilize the self-crosslinking copolymer, and directing the thus coated yarns from the drying zone to a take-up station and winding the coated yarns on a take-up roll.

Claim 4

A method of producing textile yarns suitable for forming textile fabrics therefrom, said yarns being characterized by having a durable size coating which remains bound to the yarn throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarn, said method comprising providing a supply package containing a plurality of textile yarns, advancing the plurality of textile yarns from the supply package along a predetermined path of travel to and through a coating station and applying to the yarns an aqueous sizing composition comprising an aqueous self-crosslinking copolymer produced by emulsion polymerization of one or more ethylenically unsaturated monomers in the presence of a latent-crosslinking comonomer comprising an N-alkylolamide of an alpha, beta ethylenically unsaturated carboxylic acid having 3 to 10 carbon atoms; a water soluble or dispersible film forming detackifying polymer selected from the group consisting of starch, polyvinyl alcohol, carboxy acrylic polymers and sulfonated polyesters; and a reactive resin selected from the group consisting of aminoplast resins, glyoxal resins, aziridines, aldehydes, dialdehydes, epoxy resins and diepoxides; directing the coated yarns from the coating station to and through a drying zone and heating the yarns to dry the aqueous sizing composition and to crosslink and insolubilize the self-crosslinking copolymer, and directing the thus coated yarns from the drying zone to a take-up station and winding the coated yarns on a take-up roll.

Claim 5

A method of producing textile yarns suitable for forming textile fabrics therefrom, said yarns being characterized by having a durable size coating which remains bound to the yarn throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarn, said method comprising providing a supply package containing a plurality of textile yarns, advancing the plurality of textile yarns from the supply package along a predetermined path of travel to and through a coating station and applying to the yarns an aqueous sizing composition comprising an aqueous self-crosslinking copolymer produced by emulsion polymerization of one or more ethylenically unsaturated monomers in the presence of a latent-crosslinking comonomer comprising an N-alkylolamide of an alpha, beta ethylenically unsaturated carboxylic acid having 3 to 10 carbon atoms; a water soluble or dispersible film forming detackifying polymer selected from the group consisting of starch, polyvinyl alcohol, carboxy acrylic polymers and sulfonated polyesters; and a reactive resin selected from the group consisting of aminoplast resins, glyoxal resins, aziridines, aldehydes, dialdehydes, epoxy resins and diepoxides; directing the coated yarns from the coating station to and through a drying zone and heating the yarns to dry the aqueous sizing composition and to crosslink and insolubilize the self-crosslinking copolymer, and directing the thus coated yarns from the drying zone to a take-up station and winding the coated yarns on a take-up roll.

Claim 10

A method of durably sizing textile yarns comprising applying to the yarns a coating of an aqueous sizing composition comprising an aqueous self-crosslinking emulsion copolymer having a T g of -30° C. to 0° C. and consisting essentially of (a) at least one primary monomer selected from the group consisting of aliphatic and aromatic vinyl monomers; (b) 5 to 100 parts per 1000 parts of said primary monomer of an N-alkylolamide of an alpha, beta ethylenically unsaturated carboxylic acid having 3 to 10 carbon atoms; (c) 1 to 100 parts per 1000 parts of said primary monomer of an ethylenically unsaturated carboxylic acid; and (d) 1 to 20 parts per 1000 parts of said primary monomer of a polyfunctional active crosslinking monomer; and drying and curing the aqueous sizing composition on the yarns to crosslink and insolubilize the emulsion copolymer and produce a yarn coating having a size coating which remains durably bound to the yarn throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarn.

Claim 11

A method of durably sizing textile yarns comprising applying to the yarns a coating of an aqueous sizing composition comprising an aqueous self-crosslinking emulsion copolymer having a T g of -30° C. to 0° C. and consisting essentially of (a) at least one primary monomer selected from the group consisting of aliphatic and aromatic vinyl monomers; (b) 5 to 100 parts per 1000 parts of said primary monomer of an N-alkylolamide of an alpha, beta ethylenically unsaturated carboxylic acid having 3 to 10 carbon atoms; (c) 1 to 100 parts per 1000 parts of said primary monomer of an ethylenically unsaturated carboxylic acid; and (d) 1 to 20 parts per 1000 parts of said primary monomer of a polyfunctional active crosslinking monomer; and drying and curing the aqueous sizing composition on the yarns to crosslink and insolubilize the emulsion copolymer and produce a yarn coating having a size coating which remains durably bound to the yarn throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarn.

Claim 27

A method of producing a textile fabric formed of textile yarns having a size coating which is durably bound to the yarns, comprising applying to the yarns a coating of an aqueous sizing composition comprising an aqueous self-crosslinking copolymer produced by emulsion polymerization of one or more ethylenically unsaturated monomers in the presence of a latent-crosslinking comonomer comprising an N-alkylolamide of an alpha, beta ethylenically unsaturted carboxylic acid having 3 to 10 carbon atoms, drying and curing the sizing composition on the yarns to crosslink and insolubilize the aqueous self-crosslinking copolymer and to produce yarns having a size coating which remains durably bound to the yarns throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarns, forming the yarns into a fabric, and thereafter subjecting the fabric to wet finishing operations without prior removal of the size coating from the yarns.

Claim 28

A method of producing a textile fabric formed of textile yarns having a size coating which is durably bound to the yarns, comprising applying to the yarns a coating of an aqueous sizing composition comprising an aqueous self-crosslinking copolymer produced by emulsion polymerization of one or more ethylenically unsaturated monomers in the presence of a latent-crosslinking comonomer comprising an N-alkylolamide of an alpha, beta ethylenically unsaturted carboxylic acid having 3 to 10 carbon atoms, drying and curing the sizing composition on the yarns to crosslink and insolubilize the aqueous self-crosslinking copolymer and to produce yarns having a size coating which remains durably bound to the yarns throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarns, forming the yarns into a fabric, and thereafter subjecting the fabric to wet finishing operations without prior removal of the size coating from the yarns.

Claim 29

A method of producing a textile fabric formed of textile yarns having a size coating which is durably bound to the yarns, comprising applying to the yarns a coating of an aqueous sizing composition comprising an aqueous self-crosslinking copolymer produced by emulsion polymerization of butyl acrylate and methyl methacrylate in the presence of a latent-crosslinking comonomer comprising an N-alkylolamide of an alpha, beta ethylenically unsaturated carboxylic acid having 3 to 10 carbon atoms, drying and curing the sizing composition on the yarns to crosslink and insolubilize the aqueous self-crosslinking copolymer and to produce yarns having a size coating which remains durably bound to the yarns throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarns, forming the yarns into a fabric, and thereafter subjecting the fabric to wet finishing operations without prior removal of the size coating from the yarns.

Claim 30

A method of producing a textile fabric formed of textile yarns having a size coating which is durably bound to the yarns, comprising applying to the yarns a coating of an aqueous sizing composition comprising an aqueous self-crosslinking copolymer produced by emulsion polymerization of butyl acrylate and methyl methacrylate in the presence of a latent-crosslinking comonomer comprising an N-alkylolamide of an alpha, beta ethylenically unsaturated carboxylic acid having 3 to 10 carbon atoms, drying and curing the sizing composition on the yarns to crosslink and insolubilize the aqueous self-crosslinking copolymer and to produce yarns having a size coating which remains durably bound to the yarns throughout wet finishing operations and subsequent use and which beneficially contributes to the physical and aesthetic properties of the yarns, forming the yarns into a fabric, and thereafter subjecting the fabric to wet finishing operations without prior removal of the size coating from the yarns.