GB1558890A - Product and method of printing carpet - Google Patents

Description

(54) PRODUCT AND METHOD OF PRINTING CARPET (71) We, ARMSTRONG CORK COMPANY, a Corporation organized according to the laws of the Commonwealth of Pennsylvania, United States of America of Lancaster, Pennsylvania 17604, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: The invention is primarily directed to a technique for printing carpet, and more particularly, to a printing technique that uses sublimable dyes on a transfer carrier.

This invention provides a method for making a decorative tufted carpet which comprises dyeing at least some of the carpet fibres using one or more sublimable dyes, wherein the dye or dyes are printed on a porous transfer sheet and transfer of the dye(s) is effected by passing a heated gaseous medium through the transfer sheet and then through the face fibres of the.carpet so as to volatilise the dye(s) and bring it or them into contact with the carpet face fibres in the adjacent portion of the carpet to dye the face fibres substantially throughout the depth of the pile of the carpet.

Preferably the transfer sheet is sufficiently porous to permit the passage of the heated gaseous medium at a flow rate of at least 10 standard cubic feet per minute per square foot and the gaseous medium is advantageously passed through the transfer sheet and the carpet at a rate of from 10 to 120 standard cubic feet per minute per square foot.

The heated gaseous medium is preferably supplied at a temperature of from 260"F. to 450"F. and the dye transfer time Is desirably within the range of from 30 seconds to 15 minutes preferably from 30 seconds to 5 minutes.

The gaseous transfer medium is preferably heated air but the invention can also be carried out through the use of superheated steam. Other gases could alternatively be utilized. It would appear that the three primary purposes of the gas utilized are (1) to cause the dye to change to a vapor phase, (2) to move the vapor phase dye through the carpet face yarn from the front to the back of the carpet facing. and (3) to facilitate diffusion of the dye into the fiber.

The invention may be carried out in various ways.

In one way of carrying out the method of the invention the porous transfer sheet is placed adjacent to the face fibres on the upper surface of the carpet and the heated gaseous medium is passed through the transfer sheet and the carpet in a direction towards the carpet backing.

In a second way, the transfer sheet is placed adjacent the carpet backing and the heated gaseous medium is passed through the transfer sheet and the carpet backing towards the face fibres on the upper surface of the carpet. In such a method the transfer sheet may be so positioned that the dye-printed surface thereof faces towards or away from the carept backing.

In a third way the porous transfer sheet is a carpet backing material, the dye(s) are printed on the carpet backing material, the face fibres are tufted into the backing material and the heated gaseous medium is passed through the carpet from the backing towards the face fibres. In such a method the dye(s) are preferably printed on one side only of the carpet backing and the face fibres may be tufted into the backing so that the face fibres extend from the dye-printed suface of the backing or from the side opposite to the dye-printed surface.

When the transfer sheet is the carpet backing and the dye printed surface is the surface away from the face fibres, after the transfer of the dye(s). a coating is preferably applied to the back of the carpet to lock any residual dye(s) to the carpet backing.

Figure I shows the steps of the first embodiment of the process; Figure 2 is a cross-sectional view of the product of Figure 1; Figure 3 shows the steps of the second embodiment of the process; Figure 4 is a cross-sectional view of the product of Figure 3; Figure 5 shows the steps of the third embodiment of the process; Figure 6 is a cross-sectional view of one product of the process of Figure 5; and Figure 7 is a cross-sectional view of a second product of the process of Figure 5.

Referring to Figures 1 and 2, the process herein is carried out by basically the following steps. A porous transfer material is provided with a design printed thereon by a conventional Zimmer printer, utilizing inks containing sublimable dyes. Printing can be carried out by any commercially available printer as long as it places the different inks in position in register. The printed transfer sheet is permitted to dry. A conventional carpet yarn is tufted into a conventional carpet backing by conventional tufting machinery. The piles or loops or face fiber yarns of the finished tufted yarn carpet will be on one side of the carpet backing. The face of the transfer sheet with the design printed thereon is then placed adjacent the carpet face fiber yarns. The transfer sheet may be placed in contact with the face fiber yarns or spaced therefrom.The transfer sheet-carpet assembly is then subjected to a heated air treatment wherein air is passed through the porous transfer paper, through the face fiber yarns and out the back of the carpet backing. At this time, the pattern printed on the transfer paper is transferred therefrom and fully developed throughout the height of the pile of the face fiber yarns of the carpet. A sharp, well-defined image is formed on the face fiber yarns when the transfer sheet contacts the yarns, and at about a 1/8" (.3 cm) spacing a slight change in sharpness of image is noted. Spacings of up to one inch (2.5cm) have been used and at that point the printed image on the face fiber yarns is diffused. This then provides a carpet product which has a backing and yarn tufted into the face thereof with the yarn being dyed in a selected pattern.

Referring to Figures 3 and 4 the second embodiment of the process is carried out by basically the following steps. A porous transfer sheet is provided with a design printed thereon by a conventional Zimmer printer, utilizing inks containing sublimable dyes.

Printing can be carried out by any commercially available printer as long as it places the different inks in position in register. The printed transfer sheet is permitted to dry. A conventional carpet yarn is tufted into a conventional carpet backing by conventional tufting machinery. The piles or loops or face fiber yarns of the finished tufted yarn carpet will be on one side of the carpet backing. The face fiber yarns of the carpet may be in one level, but preferably will be at two or more levels. The face of the transfer sheet with the design printed thereon is then placed adjacent the carpet backing on the side thereof opposite from the side of the carpet backing containing the face fiber yarns. That is, the transfer sheet will be placed in contact with the back of the carpet backing.The transfer sheet-carpet assembly is then subjected to a heated air treatment wherein air is passed through the porous transfer sheet. through the carpet backing and then through the face fiber yarns of the carpet. At this time. the pattern printed on the transfer sheet is transferred therefrom and fully developed throughout the height of the pile of the face fiber yarns of the carpet. This then produces a carpet product which has a backing and yarn tufted into the face thereof with the yarn being dyed in a selected pattern. The design of the product is slightly diffused as compared with the design that one would secure by printing with the technique of the first embodiment.Particularly if the carpet face fiber yarns are tufted into the carpet backing with multi levels, the technique of the second embodiment is preferable in use over the transfer printing technique of the first embodiment since the transfer sheet is placed against the backing of the carpet and thus rests against a uniform level surface. If the printing technique of the first embodiment was carried dust, the transfer sheet would have to be placed against the carpet face fiber yarns which are of different levels and, therefore, the transfer sheet in some spots would be in contact with some of the face fiber yarns, but in other areas spaced from the lower level face fiber yarns. This lack of a uniform spacing on the transfer sheet from the irregular surface of the face fiber yarn can be undesirable in some circumstances because it may result in loss or registration or result in loss of pattern.

With reference to Figures 5 to 7 the third embodiment of the process is carried out by basically the following steps. A conventional carpet backing or scrim material, which is porous in nature, is provided with a design printed thereon by a conventional Zimmer printer utilizing inks containing sublimable dyes. Printing can be carried out by any commercially available printer as long as it places the different dyes in position in register.

The printed carpet backing is then permitted to air dry. A conventional carpet yarn is tufted into the carpet backing by conventional tufting machinery. This may be tufted into the dye printed side of the backing (as shown in Figure 6) or on the opposite side of the backing (as shown in Figure 7). The carpet backing with the tufted yarns is then subjected to a heated air treatment wherein air. is passed through the carpet in the direction from the backing of the carpet through to the face fiber yarns of the carpet. At this time, the pattern printed on the carpet backing is transferred from the carpet backing and fully developed throughout the height of the pile of the face yarns. There is then provided a carpet product which has a backing and yarn tufted into the face thereof with the yarn being dyed in a selected pattern.

A latex or other type of coating material may then be provided to the back side of the carpet product, especially-when as shown in Figure 7 is the side of the carpet backing which contains the printed design so as to lock in excess or residual dye left over from the printed - dyestuffs. The coating also will lock in the tufted fiber yarns so that the tufted fiber yarns cannot be readily separated from the carpet backing.

The following Examples illustrate the invention: Example 1 A carpet product is made with a conventional jute carpet backing with a 19 x 19 count.

The 19 x 19 count is the number of yarns in the warp and woof direction of the backing. The aforesaid jute weighs approximately 6 ounces per square yard (210 g. per square meter).

Nylon 66 yarn, Dupont Type 846, 1300 denier, bulk continuous filament yarn is then tufted into the jute using a 5/16 inch (.2 cm) gauge, 12 tufts per inch, to produce a 1/8 inch (.3 cm) pile level loop carpet weighing 13 ounces per square yard (455 g. per square meter). This then yields the carpet product which is similar to that shown in Figure 2 wherein the carpet backing or scrim 2 is provided with tufted yarn 6. The tufted yarn have their pile loop construction on what may be called the upper side of the carpet backing 2. Porous glass fiber paper is a non-woven material weighing 2.7 ounces per square yard (94.5 g. per square - meter) with an air permeability of 208 standard cubic feet/minute/square foot (70 standard cubic meters/minute/square meter) is then printed on a Zimmer printer with inks containing sublimable dyes.Specifically, the dyes being used are Latyl Cerise NSN, C.I.

Disperse No. Red 60, C.I. Constitution No. 60756: Latyl Violet 2R. C.I Disperse No.

Violet 28, C.I. Constitution No. 61102; and Acetamine Yellow CG, C.I. Disperse No: Yellow 3, C.I. Constitution No. 11855. The design printed on the glass fiber paper may be any type of aesthetic design and, after it is printed on the transfer paper with the above-said sublimable dyes, the dyes are permitted to dry. The printed surface of the transfer paper near or in contact with the upper ends of the face fibers of the carpet. This is shown in Figure 2 wherein the transfer paper 8 is provided with a design 4 and the design 4 is placed in contact with the face fiber loops of the carpet yarn 6.

The above product is then passed through a chamber where air, at 425"F. (218"C.), may be passed through the transfer paper and the carpet in the direction from the transfer paper through the tufted carpet yarn and out through the scrim of the carpet. The air flows at a rate of 15 cubic feet/minute/square foot (5 eubic meters/minute/square meter) and the transfer paper and carpet are subjected to this air flow for 45 seconds: In this time, the pattern printed on the glass paper is transferred to the carpet face fiber and fully developed throughout the depth of the pile of the carpet face fiber. The print is sharply defined and brightly colored.

In addition to using jute as the backing material for the carpet, the invention has been carried out using backing materials of glass fiber and woven and non-woven polypropylene.

In addition to using Nylon 66 as the carpet face yarn, the invention has also been carried out using Nylon 6, acrylic, and polyester fibers as the carpet face yarn. The invention has been carried out with carpeting of a denser construction that that described above and has been utilized with carpet backing having tufted thereinto face yarns of 1/4 (0.6 cm) gauge, 5 tufts per inch, to produce a pile height of 1 inch (2.5 cm) with a carpet face fiber weight up to 48 ounces per square yard (1.6 kg per square meter). Theretofore was just described a shag carpet wherein density was measurable in the pile height direction. The invention has also been practice on a carpet structure having a carpet face fiber weight of 43 ounces per square yard (1.5 kg per square meter), but only a one-half inch (1.2 cm) pile height.The carpet had, 10 tufts per inch and a 3/16 (.4 cm) gauge. This is a denser carpet than the first example given because there is more fiber weight per unit area (square inch). The invention has been carried out using not only glass fiber paper as the transfer sheet, but also transfer sheets made of jute, cellulosic-glass fiber paper, cellulosic paper, and spun-bonded polyester In every case, the transfer paper is a porous material.

The invention has been carried out with an air flow rate of as low as 10 standard cubic feet/minute/square foot (3.3 standard cubic meters/minute/square meter) and as high an air flow as 120 standard cubic feet/minute/square foot (40 standard cubic meters/minute/square meter) for a carpet construction of a pile height of 1 inch (2.5 cm) with a carpet face. weight up to 48 ounces per square yard (1.6 kg per square meter). It would appear that the air flow upper limit is determined by the output capability of the air moving means and the air flow rate is selected based upon the scrim material used, face fiber used, dye used, operating temperature and desired production speed. Naturally, the porosity of the transfer sheet also influences to some extent the air flow.

Successful transfer printing has been carried out with temperatures as low as 2600,,2700F.

(127"-1320C.) for the heated air. This has required printing times of from 7 to 15 minutes with a dye such as Celanthrene Brilliant Blue FFS, C.I. Disperse No. Blue 3, C.I.

Constitution No. 61505. Since sublimable dyes tend to sublime at different temperatures, it is obvious that the temperature used is primarily a function of the dye being utilized.

Three primary dyes have been utilized for most work to date. These dyes are primarily disperse dyes and may be mixed to produce other colors such as are listed in the table below. These three dyes transfer at similar rates.

Table I Trade Name Latyl Latyl Celanthrene Cerise Yellow Brilliant NSN 3G Blue PFS C.I. Disperse No. Red 60 Yellow 54 Blue 3 C.I. Constitution No. 60756 47020 61505 Color Relative Proportion in Printing Ink Red 100% Red-orange 50 50 Orange 25 75 Yellow-orange 10 90 Yellow 100 Yellow-green 90 10 Green 25 75 Blue-green 50 50 Blue 100 Indigo 25 75 Violet 50 50 Red Violet 90 10 The invention herein need not be restricted to the dyes above listed, but may be utilized with the following dyes: C.I. Disperse No. Yellow 3, C.I. Constitution No. 11855; C.I.

Disperse No. Yellow 64, C.I. Constitution No. 47023; C.I. Disperse No. Blue 7, C.I.

Constitution No. 62500; C.I. Disperse No. Blue 56, C.I. Constitution No. 63285; C.I.

Disperse No. Violet 28, C.I. Constitution No. 61102, etc. It is also possible to use solvent dyes such as C.I. Solvent Yellow 77, C.I. Constitution No. 11855; C.I. Solvent Yellow 16, C.I. Constitution No. 12700; and C.I. Solvent Blue 68, C.I. Constitution No. 61110. The invention is also workable with dyes such as C.I. Vat Violet 15, C.I. Constitution No. 6335; C.I. Vat Yellow 26, C.I. Constitution No. 65410 and acid dye Yellow 54, C.I. Constitution No. 47020.

The inks which normally are used for the printing of the backing are prepared as a three-part composition. A thickener is used and it will constitute 80-90 parts by weight of the mix. The disperse dye will constitute 5 to 10 parts of the mix and an accelerator will constitute 0 to 10 parts of the mix. The thickener usually consists of a 3% Chemloid 2245 in water plus 0.1% Dowicide G as preservative. Chemloid 2245 is supplied by the Chemloid Company and it is basically a refined natural ether or gum. Dowicide G is produced by the Dow Chemical Company and is basically a monohydrate of sodium pentachlorophenate, The ink is prepared by dissolving the preservative in water, then slowly addin the Chemloid 2245 while using a high shear mixer to mix. The mix is allowed to stand 2 to 4 hours before final mixing and use. If an accelerator is used, it is added and mixed using a high shear mixer. A typical accelerator that may be used is a polyvinylacetate emulsion.

Some disperse and solvent dyes may be dissolved in solvents to form solvent-based printing inks.

Finally, the disperse dye is added and mixed for 5 to 10 minutes to produce uniform smooth ink. In the ink formulation, the amount of dye is varied depending upon the depth of color desired. The accelerators increase the intensity of color developed with a given amount of dye. Accelerators also have a tendency to reduce the time required to produce a print with a given intensity.

Example 2 A carpet is made the same way as the carpet of Example 1 with a jute backing and a Nylon 66 yarn with a glass fiber paper except for the following differences. The transfer sheet utilized is a jute yarn having a 16 x 16 count and weighing 9 ounces per square yard (305 wg. per square meter) and an air permeability of 590 standard cubic feet/minute/square foot (180 standard cubic meters/minute/square meter). This transfer sheet is used on a Nylon 6 carpet yarn which is 1750 denier and is sold under the trade name "Allied Chemical 15U2XA5". The Nylon 6 material is tufted into the jute carpet backing to provide 43 ounces per square yard (1460 g. per square meter) of face yarn on the carpet scrim, to produce a 13/32 inch (1.03 cm) pile height.During processing, the jute transfer sheet and the Nylon 6 carpet face yarn are processed in a chamber where air, at 390 F. (199"C.) may be passed through the transfer paper and the carpet. The air flow rate is at about 75 cubic feet/minute/square foot (23 cubic meters/minute/square meter) and the transfer paper and carpet arse subjected to this air flow for 60 seconds. In this time, the pattern printed on the transfer sheet is transferred to the carpet face fiber and fully developed throughout the depth of the file of the carpet face fiber. The print is sharply defined and brightly colored.

Example 3.

This example is carried out in Example 1 except for the following differences.

The transfer paper utilized is a "Reemay" paper, a spun bonded polyester of Dupont, weighing 1.8 ounces per square yard (61. g. per square meter) and having an air permeability of 166 standard cubic feet/minute/square foot (51 standard cubic meters/ minute/square meter). This transfer paper is used on a polyester carpet yarn which is 3600 denier and is sold under the trade name "Dupont Type 527". The polyester material is tufted into the jute carpet backing to provide 20 ounces per square yard (678. g. per square meter) of face yarn on the carpet scrim. to produce a 1/4 inch (.6 cm) pile height. During processing, the "Reemay" transfer paper and the polyester carpet face varn are processed in a chamber where air, at 440"F. (226"C.) may be passed through the transfer paper and the carpet.The air flow rate is at about 15 cubic feet/minute/square foot (5 cubic meters/minute/square meter) and the transfer paper and carpet are subjected to this air flow for 75 seconds. In this time, the pattern printed on the transfer sheet is transferred to the carpet face fiber and fully developed throughout the depth of the pile of the carpet face fiber. The print is sharply and brightly colored.

Example 4 This example is carried out in the same way as Example 1 Except for the following differences. The transfer paper utilized is a porous cellulose sheet. from Stratmore Company, Grade 7411-25-52, weighing 1.49 ounces per square yard (51 g. per square meter) and an air permeability of 50 standard cubic feet/minute/square foot (15.2 standard cubic meters/minute/square meter). This transfer paper is used on a Nylon 66 carpet yarn which is 1300 denier and is sold under the trade name "Dupont Type 846". The Nylon 66 material is tufted into the carpet backing to provide 13 ounces per square yard (440 g. per square meter) of face yarn on the carpet scrim, to produce a 1/8 inch (.3 cm) pile height.

During processing, the cellulose transfer paper and the Nylon 66 carpet face yarn are processed in a chamber where air, at 425"F. (218"C.) may be passed through the transfer paper and the carpet. The air flow rate is at about 15 cubic feet/minute/square foot (5 cubic meters/minute/square meter) and the transfer paper and carpet are subjected to this air flow for 120 seconds. In this time, the pattern printed on the transfer paper is transferred to the carpet face fiber and fully developed throughout the depth of the file of the carpet face fiber. The print is sharply defined and brightly colored.

Example 5.

This example is carried out in the same way as Example 1 except for the following differences. The transfer paper utilized is a woven glass scrim, having a 39 x 28 count and weighing 6.3 ounces per square yard (214 g. per square meter) and an air permeability of 60 standard cubic feet/minute/square foot (18.3 standard cubic meters/minute/square meter).

This transfer paper is used on a Nylon 66 carpet yarn which is 1300 denier and is sold under the trade name "Dupont Type 846". The Nylon 66 material is tufted into the carpet backing to provide 13 ounces per square yard (440 g. per square meter) of face yarn on the carpet scrim, to produce a 1/3 inch (.3 cm) pile height. During processing. the woven glass scrim transfer paper and the Nylon 66 carpet face yarn are processed in a chamber where air, at 425 F. (218"C.) may be passed through the transfer paper and the carpet. The air flow rate is at about 15 cubic feet/minute/square foot (5 cubic meters/minute/square meter) and the transfer paper and carpet are subjected to this air flow for 90 seconds.In this time, the pattern printed on the transfer paper and carpet are subjected to this air flow for 90 seconds. In this time, the pattern printed on the transfer sheet is transferred to the carpet face fiber and fully developed throughout the depth of the pile of the carpet face fiber. The print is sharply defined and brightly colored.

Example 6.

This example is carried out in the same way as Example 1 except for the following differences. The transfer paper utilized is a porous glass fiber paper weighing 2.7 ounces per square yard (92 g. per square meter) and an air permeability of 208 standard cubic feet/minute/square foot (64 standard cubic meters/minutelsquare meter). This transfer sheet is used on an acrylic carpet yarn which is 1700 denier and is sold under the trade name "Creslan (Registered Trade Mark) Acrylic CS Type 83" by America Cyanamid. The acrylic material is tufted into the carpet backing to provide 25 ounces per square yard (848 g. per square meter) of face yarn on the carpet scrim, to produce a 13132 inch (1.03 cm) pile height.During processing, the porous glass fiber paper transfer sheet and the acrylic carpet face yarn are processed in a chamber where air, at 425"F. (218"C may be passed through the transfer paper and the carpet. The air flow rate is at about 15 cubic feet/minute/square foot (5 cubic meters/minute/square meter) and the transfer paper and carpet are subjected to this air flow for 60 seconds. In this time, the pattern printed on the transfer paper is transferrred to the carpet face fiber and fully developed throughout the depth of the pile of the carpet face fiber. The print is sharply defined and brightly colored.

Example 7 A carpet product is made with a conventional jute carpet backing with a 19 x 19 count.

The 19 x 19 count is the number of yarns in the warp and woof direction of the backing. The aforesaid jute weighs approximately 6 ounces per square yard. The jute has an air permeability of 650 standard cubic feet per minute per square foot (219 standard cubic meters per minute per square meter). Nylon 66 yarn, Dupont Type 846. 1300 denier, bulk continuous filament yarn is the tufted into the jute using a 5/16 inch (.2 cm) gauge. 12 tufts per inch, to produce a 1/8 inch (.3 cm) pile level loop carpet weighing 13 ounces per square yard (455 g. per square meter). This then yields a carpet product similar to that shown in Figure 4 wherein the carpet backing or scrim 2 is provided with tufted yarn 6.Porous glass fiber paper which is a non-woven material weighing 2.7 ounces per square yard (94.5 g. per square meter) with an air permeability of 208 standard cubic feet per minute per square foot (70 standard cubic meters per minute per square meter). is then printed on a Zimmer printer with inks containing sublimable dyes. Specifically. the dyes being used are Latyl Cerise NSN, C.I. Disperse No. Red 60, C.I. Constitution No. 60756, and Latyl Yellow 3G, C.I. Disperse No. Yellow 54, C.I. Constitution No. 47020. The design printed on the glass fiber paper may be any type of aesthetic design and after it is printed on the transfer paper with the above-said sublimable dyes, the dyes are permitted to dry. The printed paper is then placed adjacent the nylon carpeting with the printed surface of the transfer paper near or in contact with the carpet scrim or backing 2.This is shown in Figure 4 wherein the transfer sheet 8 is provided with a design 4 and the design 4 is placed in contact with the carpet scrim 2. Alternately. the transfer paper is placed in contact with the carpet scrim with the printed design positioned on the back side of the scrim 8 so that the printed design will be facing away from the carpet backing and in the position 4' shown in Figure 4.

The above product is then passed through a chamber where air. at 425"F. (218"C.), may be passed through the transfer sheet and the carpet in the direction from the transfer sheet through the scrim of the carpet and out through the face fiber of the carpet, The air flows at a rate of 15 cubic feet per minute per square foot (5 cubic meters per minute per square meter) and the transfer sheet and carpet are subjected to this air flow for 3 minutes. In this time, the pattern printed on the glass paper is transferred to the carpet face fiber and fully developed through the depth of the pile of the carpet face fiber. The print has a reasonably sharp appearance, but more diffused than one would secure by printing with the technique descrived in Examples, 1 to 6 and is brightly colored.

In addition to using jute as the backing material for the carpet, the invention has been carried out using backing materials of glass fiber and woven and non-woven polypropylene.

In addition to using Nylon 66 as the carpet face yarn, the invention has also been carried out using Nylon 6, acrylic and polyester fibers as the carpet face yarn. The invention has been carried out with carpeting of a denser construction than that described above and has been utilized with carpet backing having tufted thereinto face yarns of as high as 1/4 inch (0.6 cm) gauge, 5 tufts per inch, to produce a pile height of 1 inch (2.5 cm) with a carpet face fiber weight up to 48 ounces per square (1.6 kg per square meter). The invention has been carried out using not only glass fiber paper as the transfer sheet, but also transfer sheets made of jute, cellulosic-glass fiber paper, cellulosic paper, and spun-bonded polyester. In every case, the transfer sheet is a porous material.

The invention has been carried out with an air flow rate of as low as 10 standard cubic feet per minute per square foot (3.3 standard cubic meters per minute per square meter) and as high an air flow as 120 standard cubic feet per minute per square foot (40 standard cubic meters per minute per square meter), for a carpet construction of a pile height of 1 inch (2.5 cm) with a carpet face weight up to 48 ounces per square yard (1.6 kg per square meter). It would appear that the air flow upper limit is determined by the output capability of the air moving means and the air flow rate is selected based upon the scrim material used, face fiber used, dye used, operating temperature and desired production speed. Naturally, the porosity of the transfer sheet also influences to some extent the air flow.

Successful transfer printing has been carried out with temperatures as low as 300"F.

(149"C.) for the heated air. This has required long printing times, in the range of 10 minutes or more. Since the vapor pressure of sublimable dyes is a function of temperature, it is obvious that the temperature used is primarily a function of the dye being utilized, but in some carpet constructions the temperature used may be selected because of a heat-sensitive element in the carpet construction.

Three primary dyes have been utilized for most work to date. Many other dyes may be utilized. As described in Example 1, the three basic dyes may be utilized to form a number of different colors. In addition to the basic dyes, as set forth in the above-mentioned copending application, other dyes may be utilized. The inks containing the dyes are prepared in a conventional manner as described in Example 1. The different dyes which have been utilized or which may be utilized and the forming of the inks which have been utilized are spelled out in detail in Example 1.

Example 8 A carpet product is made with a conventional jute carpet backing with a 19 x 19 count.

The 19 x 19 count is the number of yarns in the warp and woof direction of the backing. The aforesaid jute weights approximately 6 ounces per square yard (210 g. per square meter).

Nylon 6 yarn, 1750 denier spun yarn is then tufted into the jute using a 3/16 inch (.48 cm) gauge, 30.5 stitches per 3 inches (7.5 cm) to produce a 13/32 inch (1.03 cm) sheared pile carpet weighing 43 ounces per square yard (1.43 kg per square meter). Porous glass fiber paper which is a non-woven material weighing 2.7 ounces per square yard (90 g. per square meter) is then printed on a Zimmer printer with inks containing the sublimable dyes above-mentioned in the first example. The printed paper is placed adjacent the nylon carpeting with the printed surface of the transfer sheet near or in contact with the carpet scrim. This is shown in Figure 2 wherein the transfer sheet 8 is provided with a design 4 and the design 4 is placed in contact with the carpet scrim 2.

The above product is then passed through a chamber where air, at 400"F. (204.4"C.) may be passed through the transfer sheet and the carpet in the direction from the transfer sheet through the carpet scrim and out through the face fiber of the carpet. The air flows at a rate of 30 cubic feet per minute per square foot (10 cubic meters per minute per square meter) and the transfer paper and carpet are subjected to this air flow for 3 minutes. In this time, the pattern printed on the glass paper is transferred to the carpet face fibers and fully developed through the depth of the file of the carpet face fiiber. The print has a soft, - diffused appearance and is brightly colored.

Example 9 A carpet product is made with a conventional jute backing with a 13 x 15 count. The 13 x 15 count is the number of yarns in the warp and woof direction of the backing. The aforesaid jute weighs approximately 9 ounces per square yard (300 g. per square meter).

Nylon 6 yarn, Allied Chemical 15U2XA5. 1750 denier. bulk continuous filament yarn is then tufted into the jute using a 3/16 inch (.95 cm) gauge, 30.5 stitches per 3 inches (7.5 cm), tuft length of 1 inch 2.5 cm) and then sheared to produce a carpet with a pile height of 13/32 inch (1.03 cm) weighing 43 ounces per square yard (1.46 kg per square meter). While this product happens to have a level pile construction, it is possible that the product could be made with a multi-level pile construction. By that is meant that the product would be made with some loops (pile) at a level as shown by loops (pile) 11 and other loops (pile) 12 at a higher level. This then provides a carpet structure which has the loops (pile) therein at two different levels. Such a carpet is well known in the carpeting industry and is normally referred to as a multi-level carpet or sometimes sculptured carpet.Porous glass fiber paper which is a non-woven material weighing 2.7 ounces per square yard (90 g. per square meter) and having an air permeability of 208 standard cubic feet per minute per square foot (70 standard cubic meters per minute per square meter), is then printed on a Zimmer printer with inks such as those described in the first above given example. The printed transfer sheet is then placed adjacent the nylon carpeting with the printed surface of the transfer sheet near or in contact with the carpet scrim. This is shown in Figure 4 wherein the transfer sheet 8 is provided with a design 4 and the design 4 is placed in contact with the carpet scrim 2.

The above product is then passed through a chamber where air, at 425"F. (218"C.) may be passed through the transfer sheet and the carpet in the direction from the transfer sheet through the carpet scrim and out through the face fiber of the carpet. The air flows at a rate of 15 cubic feet per minute per square foot (5 cubic meters per minute per square meter) and the transfer sheet and carpet are subjected to this air flow for 3-4 minutes. In this time, the pattern printed on the glass paper is transferred to the carpet face fiber and fully developed throughout the depth of the pile of the carpet face fiber. The print has a soft, diffused appearance and is brightly colored.

Example 10 This example is carried out in the same way as Example 7 except for the following differences. The transfer paper utilized is a porous glass fiber paper weighting 2.7 ounces per square yard (91.5 g. per square meter) and having an air permeability of 208 standard cubic feet per minute per square foot (63.4 standard cubic meters per minute per square meter). This transfer sheet is used on an acrylic carpet yarn which is 1700 denier and is sold under the trade name "Cresland Registered Trade Mark) Acrylic CS Type 83" by American Cyanamid Company. The acrylic material is tufted into the carpet backing to provide 25 ounces per square yard (847.7 g. per square meter) of face yarn on the carpet scrim, to produce a 13/32 inch (1.032 cm) pile height.During processing, the porous glass fiber paper transfer sheet and the acrylic carpet face yarn are processed in a chamber where air, at 4250F. (218"C.) may be passed through the transfer paper and the carpet in the direction from the transfer sheet through the carpet scrim and out through the face fiber of the carpet. The air flow rate is at about 15 cubic feet per minute per square foot (5 cubic meters per minute per square meter) and the transfer paper and carpet are subjected to this air flow for 3 minutes, In this time, the pattern printed on the transfer paper is transferred to the carpet face fiber and fully developed throughout the depth of the pile of carpet face fiber. The print is sharply defined and brightly colored.

Example 11.

Conventional jute carpet backing with a 19 x 19 count is utilized. The 19 x 19 count is the number of yarns in the warp and woof direction. The aforesaid jute weighs approximately 6 ounces per square yard (210 g. per square meter). This material is run across a Zimmer printer and printed with conventional inks containing sublimable dyes. Specifically, the dyes being used are Latyl Cerise NSN, C.I. Disperse No. Red 60, C.I. Constitution No.

60756; Latyl Violet 2R, C.I. Disperse No. Violet 28. C.I. Constitution No. 61102: and Acetamine Yellow CG, C.I. Disperse No. Yellow 3, C.I. Constitution No. 11855. The design printed on the jute may be any type of aesthetic design and after it is printed on the jute with the abovesaid sublimable dyes it is permitted to dry. Nylon 66 yarn, Dupont Type 846, 1300 denier, bulked continuous filament is then tufted into the jute using a 5/64 gauge (.2 cm), 12 tufts per inch to produce a 1/8 inch (.3 cm) pile level looped carpet weighing 13 ounces per square yard (455 g. per square mater). This then yields a product similar to Figure 6 wherein the carpet scrim 2 is provided with a design 4 and tufted yarn 6. The tufted yarns have their pile looped construction on the side of the carpet backing 2, which is the same side of the carpet backing 2 which has the printed design 4.

The above product is then passed through a chamber wherein air, at 425 F. (218"C.), may be passed through the carpet in the direction from the scrim 2 to the face yarn 6 at a rate of 15 standard cubic feet per minute per square foot (5 cubic meters per minute per square meter) for 90 seconds. In this time, the pattern 4 which was printed on the jute with sublimable dyes is transferred and fully developed throughout the height of the pile 6. The print is brightly colored with a soft diffused appearance.

In addition to using jute as the backing material, the invention has been carried out using backing materials of glass fiber and woven and non-woven polypropylene. In addition to using nylon 66 as the carpet face yarn, the invention can be carried out using nylon 6.

acrylic, and polyester fibers as the carpet face yarn. The invention has been carried out without directional heated air with carpet backing having tufted thereinto face yarns of as high as 12 tufts per inch to produce a pile height of 1/8 inches (.3 cm) with a carpet face weight up to 13 ounces per square yard (455 g. per square meter). If directional air is used, the transfer may be carried out with carpet face yarns as high as one inch (2.5 cm) in pile height with a carpet face weight up to 48 ounces per square yard (1.6 kg per square meter).

The invention has been carried out with a directional air flow rate of as low as 10 standard cubic feet per minute per square foot (3.3 cubic meters per minute per square meter) and as high as 120 standard cubic feet per minute per square foot (40 cubic meters per minute per square meter) for a carpet construction of a pile height of 1 inch (2.5 cm) with a carpet face weight up to 48 ounces per square yard (1.6 kg per square meter). It would appear that the air flow upper limit is determined by output capability of the air moving means and the air flow rate is selected based upon the scrim material used, face fiber material used, dye used, operating temperature and desired production speed.

Successful transfer printing has been carried out with temperatures as low as 2600-270"F.

(1270-132"C.) for the heated air. This has required printing times of from 7 to 15 minutes with a dye such as Celanthrene Blue FFS, C.I. Disperse No. Blue 3, C.I. Constitution No.

61505. Since sublimable dyes tend to sublime at different temperatures, it is obvious that the temperature used is primarily a function of the dye being utilized.

Three primary dyes have been utilized for most work to date. These dyes and the method of formulation of links are fully described in Example 1.

Example 12 Conventional woven glass scrim primary carpet backing with a 39 x 28 count is utilized.

The 39 x 28 count is the number of yarns in the warp and woof direction. The aforesaid glass scrim weighs approximately 6.3 ounces per square yars (214 g. per square meter). This material is run across a Zimmer printer and printed with conventional inks containing sublimable dyes. Specifically, the dyes being used are Latyl Cerise NSN. C.I. Disperse No.

Red 60, C.I. Constitution No. 60756; Latyl Violet 2R, C.I. Disperse No. Violet 28, C.I.

Constitution No. 61102; and Acetamine Yellow CG, C.I. Disperse No. Yellow 3, C.I.

Constitution No. 11855. The Design printed on the glass scrim may be any type of aesthetic design and after it is printed on the glass scrim with the abovesaid sublimable dyes, it is permitted to dry. Nylon 66 yarn, Dupont Type 846, 1300 denier, bulked continuous filament is then tufted into the scrim using a 5/64 (.2 cm) gauge, 12 tufts per inch to produce a 1/8 inch (.3 cm) pile level looped carpet weighing 13 ounces per square yard (455 g. per square meter). This then yields a product similar to Figure 6 wherein the carpet scrim 2 is provided with a design 4 and tufted yarn 6. The tufted yarns have their pile looped construction on the side of the carpet backing 2, which is the same side of the carpet backing 2 which has the printed design 4.

The above product is then passed through a chamber wherein air, at 425"F. (218"C.), may be passed through the carpet in the direction from the scrim 2 to the face yarn 6 at a rate of 15 standard cubic feet per minute per square foot (5 cubic meters per minute per square meter) for 2 minutes. In this time, the pattern 4 which was printed on the glass scrim with sublimable dyes is transferred and fully developed throughout the height of the pile 6. The print is brightly colored with a soft diffused appearance.

Example 13 Conventional woven polypropylene scrim primary carpet backing with a 24 x 11 count is utilized. The 24 x 11 count is the number of yarns in the warp and woof direction. The aforesaid polypropylene scrim weighs approximately 3 ounces per square yard (101 g. per square meter). This material is run across a Zimmer printer and printed with conventional inks containing sublimable dyes. Specifically, the dyes being used are Latyl Cerise NSN, C.I. Disperse No. Red 60, C.I. Constitution No. 60756; Latyl Violet 2R, C.I. Disperse No.

Violet 28, C.I. Constitution No. 61102; and Acetamine Yellow CG, C.I. Disperse No.

Yellow 3, C.I. Constitution No. 11855. The design printed on the polypropylene may be any type of aesthetic design and after it is printed on the polypropylene with the abovesaid sublimable dyes, it is permitted to dry. Nylon 66 yarn. Dupont Type 846+ 1300 denier, bulked continuous filament is then tufted into the jute using a 5/64 (.2 cm) gauge, 12 tufts per inch to produce a 1/8 inch (.3 cm) pile level loop carpet weighing 13 ounces per square yard (455 g. per square meter). This then yields a product similar to Figure 2 wherein the carpet scrim is provided with a design 4 and tufted yarn 6. The tufted yarns have their pile looped construction on the side of the carpet backing 2. which is the same side of the carpet backing 2 which has the printed design 4.

This product is further processed as described in Example 11. The print is brightly coloured with a soft diffused appearance.

Example 14.

Conventional jute carpet backing with a 19 x 19 count is utilized. The 19 x 19 count is the number of yarns in the warp and woof direction. The aforesaid jute weighs approximately 6 ounces per square yard (210 g. per square meter). This material has an air permeability of 650 standard cubic feet per minute per square foot (219 cubic meters per minute per square meter). The jute material is run across a Zimmer printer and printed with conventional inks containing sublimable dyes. Specifically. the dyes being used are Latyl Cerise NSN. C.I.

Disperse No. Red 60, C.I. Constitution No. 60756; Latyl Violet 2R, C.I. Disperse No.

Violet 28, C.I. Constitution No. 61102; and Acetamine Yellow CG, C.I. Disperse No.

Yellow 3, C.I. Constitution No. 11855. The design printed on the jute may be any type of aesthetic design and after it is printed on the jute with the abovesaid sublimable dyes, it is permitted to dry. Nylon 66 yarn, Dupont Type 846, 1300 denier, bulk continuous filament is the tufted into the jute using a 5/64 (.2 cm) gauge, 12 tufts per inch to produce a 1/8 inch (.3 cm) pile level looped carpet weighing 13 ounces per square yars (455 g. per square meter).

The Nylon 66 is tufted into the jute so that the face fiber yarns will be on the side of the jute opposite from the side of the jute containing the printed design. The product so formed will look similar to that shown in Figure 7 wherein the carpet backing 2 is provided with a design 4 and a tufted yarn 6. The tufted yarns have their pile loop construction on the side of the carpet backing 2 opposite from the side of the carpet backing which has the printed design 4.

The above product is then passed through a chamber wherein air, at 425"F. (218"C.). may be passed through the carpet in the direction from the scrim 2 to the face yarn 6 at a rate of 15 standard cubic feet per minute per square foot (5 cubic meters per minute per square meter) for 3 minutes. In this time, the pattern 4 which was printed on the jute with sublimable dyes is transferred and fully developed throughout the height of the pile 6. The print is brightly colored with a soft, diffused appearance.

The carpet is then provided with a latex tie coat 8. If one were to take hold of a single one of the loops of the face yarn 6 and tug thereon, it would be possible to pull the yarn completely out of the carpet backing because of the nature of the tufting operation that placed the yarn on the carpet backing 2. In order to prevent this, the latex coating is provided on the back of the carpet backing 2 so as to lock in the yarn segments 10 which are on the back of the carpet backing. The latex forms a film across the back of the carpet backing and holds the elements 10 of the tufted carpet yarn in position on the back of the scrim. It now is no longer easy to pull the carpet yarn out from the carpet backing by grasping hold of one of the loops of the face yarn 6 and pulling thereon.

It has been found that when the dyestuffs is printed on the upper side of the carpet backing, that is, the side of the carpet on which the face fiber piles 6 exist. there is a likelihood of residual or excess dye causing a staining, crocking. or bleeding problem after the carpet is printed and placed in use. If the printed design 4 is on the back side of the carpet backing 2 away from the face fiber 6 of the carpet, the staining, crocking, and bleeding problems are diminished. The coating 8 on the back of the carpet. which is being placed on the side of the backing 2 which has the design thereon, will lock in excess or residual dye on the underside of the carpet backing so that subsequent actions on the carpet will not permit the residual dye to be released and migrate up into the face fiber pile 6.

When the dyestuffs are printed on the back surface of the layer backing it is possible to print the design 4 on the back of the carpet product after the yarn has been tufted into the carpet backing 2. In such a case all processing of the carpet and dye transfer are carried out as above set forth with the only variant being the printing of the design on the carpet backing which has the yarn already tufted thereinto.

In addition to using jute as the backing material. this Example can be carried out using backing materials of glass fiber and woven and non-woven polypropylene. In addition to using Nylon 66 as the carpet face yarn, the Example can be carried out uisng Nylon 6 or polyester fibers as the carpet face yarn. All of variations in the backing materials, carpet face yarn, carpet constructions, dyes. air flow characteristics and temperatures described in Examples 11 to 13 may be utilized, the only diffference being the positioning of the printed design on the carpet backing. that is the printed design is, on the side of the carpet backing opposite from the side of the carpet backing containing the face fiber piles 6.There may however need to be a slight increase in air flow or a slight increase in processing time since the dyes must pass through the carpet backing before they can then pass through the face fiber yarn. In the process described in Example 11 the dyes move directly from the surface of the carpet backing through the face fiber yarns. In practising the method described in this Example, because the dyes are on the back side of the backing, the dyes must initially move through the carpet backing and then through the face fiber yarns. This slightly longer path of travel, plus the slight decrease in air permeability of the scrim/face yarn combination versus just the face yarn structure alone, may require either slightly increased processing time or air flow in order to get the printed design on the face fiber yarns in a brightly colored design with a soft, diffused appearance comparable to the design secured in the process of Example 11.

The latex coating may be applied by conventional roll coating equipment or by other suitable means such as spraying. The application rate generally will be in the range of 5 to 40 ounces per square yard on a dry weight basis. The coating may be dried in conventional ovens, by infra-red heaters, etc. Often it is desirable to incorporate fillers such as calcium carbonate, alumina trihydrate, clays, felspar and other materials in the latex. In this specific Example there was applied at a rate of 30 ounces per square yard a carboxylated styrenebutadiene rubber latex (Lotol (Registered Trade Mark) 520 made by Uniroyal) at 50% solids and containing 300 parts alumina trihydrate and 50 parts limestone per 100 parts latex solids. While the above is a preferred type of latex binder, other compositions such as those disclosed in U.S. Patent 3,756,974 may be used.

Our co-pending Application No. 37785/76 (Serial No. 1558889) describes and claims a carpet dyeing method and the resulting product. In this method, transfer of dye from a porous transfer sheet to the face fibres of a carpet is effected by passing a heated gaseous medium through the sheet to the fibres, the sheet and the face fibres being in contact or adjacent. The medium causes volatilization of the dye and brings it into contact with the fibres in the adjacent portion of the carpet.

WHAT WE CLAIM IS 1. A method for making a decorative tufted carpet which comprises dyeing at least some of the carpet fibres using one or more sublimable dyes, wherein the dye or dyes are printed on a porous transfer sheet and transfer of the dye(s) is effected by passing a heated gaseous medium through the transfer sheet and then through the face fibres of the carpet so as to volatilise the dyes) and bring it or them into contact with the carpet face fibres in the adjacent portion of the carpet to dye the face fibres substantially throughout the depth of the pile of the carpet.

2. A method as claimed in claim 1, wherein the transfer sheet is sufficiently porous to permit the passage of the heated gaseous medium at a flow rate of at least 10 standard cubic feet per minute per square foot.

3. A method as claimed in claim 1 or claim 2, wherein the gaseous medium is passed through the transfer sheet and the carpet at a rate of from 10 to 120 standard cubic feet per minute per square foot.

4. A method as claimed in any one of claims 1 to 3, wherein the heated gaseous medium is supplied at a temperature of from 260"F to 450"F.

5. A method as claimed in any one of claims 1 to 4. wherein the dye transfer time is within the range of from 30 seconds to 15 minutes.

6. A method as claimed in any one of claims 1 to 5, wherein the heated gaseous medium is hot air.

7. A method as claimed in any one of claims 1 to 5, wherein the heated gaseous medium is superheated steam.

8. A method as claimed in any one of claims 1 to 7, wherein the transfer sheet is placed adjacent the carpet backing and the heated gaseous medium passed through the transfer sheet and the carpet backing towards the face fibres on the upper surface of the carpet.

9. A method as claimed in claim 8 wherein the transfer sheet is so positioned that the dye-printed surface thereof is towards the carpet backing.

10. A method as claimed in any one of claims 1 to 7. wherein the porous transfer sheet is a carpet backing material, the dye(s) are printed on the carpet backing material, the face fibres are tufted into the backing material and the heated gaseous medium is passed through the carpet from the backing towards the face fibres.

11. A method as claimed in claim 10, wherein the dye(s) are printed on one side only of the carpet backing.

12. A method as claimed in claim 10, wherein the face fibres are tufted into the backing so that the face fibres extend from the dye-printed surface of the backing.

13. A method as claimed in claim 11, wherein the face fibres are tufted into the backing so that the face fibres extend from the side opposite to the dye-printed surface.

14. A method as claimed in claim 13. wherein, after the transfer of the dye (s), a coating is applied to the back of the carpet to lock any residual dye (s) to the carpet backing.

15. A decorative carpet whenever produced by a method as claimed in any one of claims 1 to 7.

16. A decorative carpet whenever produced by a method as claimed in claim 8 or claim 9.

17. A decorative carpet whenever produced by a method as claimed in claim 10 or claim 11.

18. A decorative carpet whenever produced by a method as claimed in claim 12.

19. A decorative carpet whenever produced by a method as claimed in claim 13 or claim 14.

20. A process for making a decorative carpet through the use of sublimable dyes comprising the steps of: (a) printing sublimable dyes on a porous transfer sheet, (b) preparing a carpet product which has on one side thereof carpet yarn forming the face fiber yarns,

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (34)

**WARNING** start of CLMS field may overlap end of DESC **. carbonate, alumina trihydrate, clays, felspar and other materials in the latex. In this specific Example there was applied at a rate of 30 ounces per square yard a carboxylated styrenebutadiene rubber latex (Lotol (Registered Trade Mark) 520 made by Uniroyal) at 50% solids and containing 300 parts alumina trihydrate and 50 parts limestone per 100 parts latex solids. While the above is a preferred type of latex binder, other compositions such as those disclosed in U.S. Patent 3,756,974 may be used. Our co-pending Application No. 37785/76 (Serial No. 1558889) describes and claims a carpet dyeing method and the resulting product. In this method, transfer of dye from a porous transfer sheet to the face fibres of a carpet is effected by passing a heated gaseous medium through the sheet to the fibres, the sheet and the face fibres being in contact or adjacent. The medium causes volatilization of the dye and brings it into contact with the fibres in the adjacent portion of the carpet. WHAT WE CLAIM IS

1. A method for making a decorative tufted carpet which comprises dyeing at least some of the carpet fibres using one or more sublimable dyes, wherein the dye or dyes are printed on a porous transfer sheet and transfer of the dye(s) is effected by passing a heated gaseous medium through the transfer sheet and then through the face fibres of the carpet so as to volatilise the dyes) and bring it or them into contact with the carpet face fibres in the adjacent portion of the carpet to dye the face fibres substantially throughout the depth of the pile of the carpet.

2. A method as claimed in claim 1, wherein the transfer sheet is sufficiently porous to permit the passage of the heated gaseous medium at a flow rate of at least 10 standard cubic feet per minute per square foot.

3. A method as claimed in claim 1 or claim 2, wherein the gaseous medium is passed through the transfer sheet and the carpet at a rate of from 10 to 120 standard cubic feet per minute per square foot.

4. A method as claimed in any one of claims 1 to 3, wherein the heated gaseous medium is supplied at a temperature of from 260"F to 450"F.

5. A method as claimed in any one of claims 1 to 4. wherein the dye transfer time is within the range of from 30 seconds to 15 minutes.

6. A method as claimed in any one of claims 1 to 5, wherein the heated gaseous medium is hot air.

7. A method as claimed in any one of claims 1 to 5, wherein the heated gaseous medium is superheated steam.

8. A method as claimed in any one of claims 1 to 7, wherein the transfer sheet is placed adjacent the carpet backing and the heated gaseous medium passed through the transfer sheet and the carpet backing towards the face fibres on the upper surface of the carpet.

9. A method as claimed in claim 8 wherein the transfer sheet is so positioned that the dye-printed surface thereof is towards the carpet backing.

10. A method as claimed in any one of claims 1 to 7. wherein the porous transfer sheet is a carpet backing material, the dye(s) are printed on the carpet backing material, the face fibres are tufted into the backing material and the heated gaseous medium is passed through the carpet from the backing towards the face fibres.

11. A method as claimed in claim 10, wherein the dye(s) are printed on one side only of the carpet backing.

12. A method as claimed in claim 10, wherein the face fibres are tufted into the backing so that the face fibres extend from the dye-printed surface of the backing.

13. A method as claimed in claim 11, wherein the face fibres are tufted into the backing so that the face fibres extend from the side opposite to the dye-printed surface.

14. A method as claimed in claim 13. wherein, after the transfer of the dye (s), a coating is applied to the back of the carpet to lock any residual dye (s) to the carpet backing.

15. A decorative carpet whenever produced by a method as claimed in any one of claims 1 to 7.

16. A decorative carpet whenever produced by a method as claimed in claim 8 or claim 9.

17. A decorative carpet whenever produced by a method as claimed in claim 10 or claim 11.

18. A decorative carpet whenever produced by a method as claimed in claim 12.

19. A decorative carpet whenever produced by a method as claimed in claim 13 or claim 14.

20. A process for making a decorative carpet through the use of sublimable dyes comprising the steps of: (a) printing sublimable dyes on a porous transfer sheet, (b) preparing a carpet product which has on one side thereof carpet yarn forming the face fiber yarns,

(c) placing the transfer sheet adjacent the back of the carpet product on the side of the carpet product opposite from the side of the carpet product having the face fiber yarns so that the transfer sheet with the sublimable dyes printed thereon will be adjacent the back of the carpet product, and (d) transferring the sublimable dyes from the transfer sheet to the carpet face yarn through the application of a directional flow. heated gaseous medium passing through the transfer sheet and the carpet product in the direction from the transfer sheet towards the back of the carpet product and out the face fiber yarn side of the carpet product.

21. A process for making a decorative carpet according to claim 20 wherein the directional flow, heated gaseous medium is supplied at a flow rate as low as about 10 standard cubic feet per minute per square foot and the porosity of the transfer sheet and carpet product is sufficient to permit the passage of the gaseous medium therethrough as the aforesaid flow rates.

22. A process as claimed in claim 21, wherein the gaseous medum is supplied at a flow rate of 10 to 120 standard cubic feet per minute per square foot.

23. A process for making a decorative carpet as claimed in any one of claims 20 to 22 wherein the gaseous medum is supplied at a temperature ranging from 300"F. to 450"F. and the dye transfer time ranges from 30 seconds to 15 minutes.

24. A product made according to the process of any one of claims 20 to 23.

25. A process for making a decorative carpet through the use of sublimable dyes comprising the steps of: (a) printing sublimable dyes on one side of the carpet backing prior to the time the carpet face yarns are tufted into the carpet backing, (b) tufting the carpet face yarns into the carpet backing with the carpet face yarn pile being on the opposite side of the carpet backing from that side of the carpet backing which contains the sublimable dyes.

(c) transferring the sublimable dyes from the carpet backing to the carpet face yarn through the application of a heated gaseous medium passing through the carpet from the carpet backing side of the carpet to the carpet face yarn side of the carpet, and (d) applying a coating to the back of the carpet backing on that side of the backing which is the side of the carpet backing that had the design printed thereon with sublimable dyes to lock in excess or residual dyes to the back side of the carpet backing.

26. A process according to claim 25 wherein the gaseous medium is supplied at an air flow rate of as low as 10 standard cubic feet per minute per square foot.

27. A process as claimed in claim 26. wherein the gaseous medium is supplied at an air flow rate of from 10 to 120 standard cubic feet per minute per square foot.

28. A process as claimed in any one of claims 25 to 27 wherein the gaseous medium is supplied at a temperature ranging from 260 F. to 450"F. and dye transfer time ranges from 30 seconds to 15 minutes.

29. A product made according to the process of any one of claims 25 to 28.

30. A process for making a decorative carpet through the use of sublimable dyes comprising the steps of: (a) printing sublimable dyes on the carpet backing prior to the time and carpet face yarns are tufted into the carpet backing.

(b) tufting the carpet face yarn into the carpet backing with the carpet face yarn pile being on the side of the carpet backing which contains the sublimable dyes, and then (c) transferring the sublimable dyes from the carpet backing to the carpet face yarn through the application of a heated gaseous medium passing through the carpet product from the carpet backing side of the carpet to the carpet face yarn side of the carpet.

31. A process according to claim 30 wherein the gaseous medium is supplied at an air flow rate as low as 10 standard cubic feet per minute per square yard.

32. A process as claimed in claim 31 wherein the gaseous medium is supplied at an air flow rate of from 10 to 120 standard cubic feet per minute per square foot.

33. A process according to any one of claims 30 to 32 wherein the gaseous medium is supplied at a temperature ranging from 2600F. to 450"F. and dye transfer time ranges from 30 seconds to 15 minutes

34. A product made according to the process of any one of claims 30 to 33.