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Abstract:
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This thesis research comprised the development of a
strongly active catalyst system based on magnesium fluoborate
to replace the conventional magnesium chloride and zinc salt
catalysts used in resin finishing. Textile finishers have
questioned the use of chloride-containing catalysts, which
may form carcinogens in the presence of methylolamide crosslinking
agents. Discharges into the waste disposal system of
heavy metal compounds, such as zinc salts, have been banned
or severely restricted in several states. Increasing fuel
costs necessitate the investigation of catalysts which can
permit curing of fabrics with substantial reduction in the
curing temperature, thereby saving energy.
The purpose of this investigation was to study the
effects of a magnesium fluoborate catalyst on the properties
of cotton printcloth cross-linked with two popular resins:
a DMDHEU permanent-press resin, which requires a high curing
temperature; and a DMEU wash-wear resin, which cures at lower
temperatures. Variables in the experiments were catalyst
concentration and cure temperature. A magnesium chloride
catalyst was also evaluated so that the properties of the
fabrics resin-treated with the two catalyst systems could be
compared. The experimental work performed on laboratory scale
equipment was divided into two parts: a) preliminary trials,
and b) final trials. Preliminary trials were undertaken for
each of the four resin-catalyst systems to establish the cure
temperature ranges in which the resin and catalyst concentration
recommended by the manufacturers for commercial use would
produce conditions of undercuring, curing, and overcuring.
From the final runs, results from a comparison of the fabric
properties produced with each catalyst system would determine:
a) whether the magnesium fluoborate catalyst could be substituted
for magnesium chloride, and b) whether low temperature curing
with the fluoborate catalyst could be achieved.
Results from the final runs indicated that magnesium
fluoborate can be an alternative chloride-free, heavy metal-free
catalyst for cross-linking cotton fabrics with a DMEU resin.
Fabrics finished with a DMEU resin and both the magnesium
fluoborate and magnesium chloride catalyst exhibited a comparable
relationship in crease recovery angle/breaking strength loss.
Calculations of energy requirements for a curing oven demonstrated
that a thirty percent reduction in energy consumption in curing
can be achieved from lowering the cure temperature by 300 C.
From the results of the final runs, it was concluded
that the magnesium fluoborate can be substituted for a magnesium
chloride catalyst, provided strict control of catalyst concentration is maintained. No energy savings would be realized
by using a magnesium fluoborate catalyst with a DMDHEU resin
because the higher catalyst concentration required for curing
at low temperatures produced unacceptable strength losses.
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