CA1097460A - Continuous carpet dyeing process - Google Patents
Continuous carpet dyeing processInfo
- Publication number
- CA1097460A CA1097460A CA257,397A CA257397A CA1097460A CA 1097460 A CA1097460 A CA 1097460A CA 257397 A CA257397 A CA 257397A CA 1097460 A CA1097460 A CA 1097460A
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- CA
- Canada
- Prior art keywords
- carpet
- length
- foam mixture
- dye
- foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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- Treatment Of Fiber Materials (AREA)
- Coloring (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A continuous dyeing process for use in dyeing material, such as carpet, a selected one of a number of colors. The process is performed by providing at least two dye applicator means, advancing a length of material to be dyed along a predetermined path adjacent the applicator means, operating one of the applicator means a predetermined period of time to apply one color dye to the length of material moving along the predetermined path, fixing the first color dye to the length of material. operating the other one of the dye applicator means for a predetermined period of time to apply a second color dye to a length of material moving along the predetermined path, and fixing the second color dye to the length of material.
The dye is applied in a foam mixture having predetermined amounts of dye material, predetermined amounts of a thickening material, predetermined amounts of water and predetermined amounts of air processed in a mixing apparatus to develop a foam mixture. The foam mixture containing dye is applied only to one surface of material moving along a predetermined path by either extruding the foam material onto the length of material being dyed, creating a puddle of the foam material on the length of material and doctoring the foam material to a predetermined height, or by introducing the foam dye material into a container applicator means having an edge operable for doctoring the foam material to a predetermined height.
A continuous dyeing process for use in dyeing material, such as carpet, a selected one of a number of colors. The process is performed by providing at least two dye applicator means, advancing a length of material to be dyed along a predetermined path adjacent the applicator means, operating one of the applicator means a predetermined period of time to apply one color dye to the length of material moving along the predetermined path, fixing the first color dye to the length of material. operating the other one of the dye applicator means for a predetermined period of time to apply a second color dye to a length of material moving along the predetermined path, and fixing the second color dye to the length of material.
The dye is applied in a foam mixture having predetermined amounts of dye material, predetermined amounts of a thickening material, predetermined amounts of water and predetermined amounts of air processed in a mixing apparatus to develop a foam mixture. The foam mixture containing dye is applied only to one surface of material moving along a predetermined path by either extruding the foam material onto the length of material being dyed, creating a puddle of the foam material on the length of material and doctoring the foam material to a predetermined height, or by introducing the foam dye material into a container applicator means having an edge operable for doctoring the foam material to a predetermined height.
Description
~7~66) CONTINUOUS_CARPET DYEING PROCESS
BACKGROUND OF THE INVENTION
This invention relates to a continuous process of dyeing carpet and is more particularly concerned with a process for selectively dyeing a carpet ally one oE a numbcl- of ~olors.
One prior art continuous dyeing process is performed by advancing material to be dyed along a predetermined path through a vat containing liquid dye material, with the material leaving the vat, then being advanced through a steam oven for fixing the dye to the material. Another prior art carpet dyeing process is performed by lowering a batch of carpet ln a vat containing dye and then transferring the carpet to a steam oven for fixation.
In the vat applicator process, when -the dyeing apparatus is being changed for applying a second color of dye material, the complete dyeing process must be stopped, the vat and dye applicator means must be thoroughly cleaned beEore a second color dyeing process can be started.
The above disadvantages of the vat dye applicator process increased the cost of dyeing carpet since the complete dyeing line must be shut down during the change-over from one color dye to a second color dye. Further, due to the e~treme ..c~
cost of changing from one color dye -to a second color dye, it is not economically feasible to dye short runs or small amounts of carpet.
SUMMARY OF THE INVENTION
The above disadvantages have been overcome by the present invention which basically includes in one broad aspect a process Eor use in dyeing carpet with a pile surEace, ~QC~ 6~
i.nclud:ing acivancing a length of caxpet to be dyed along a predetermined path with its pile fibers facing upwardly, applying a foam mixture containing dye material to the pile fibers of length of carpet moving ~long the predetermined path, applying a vacuum to the side of the length of carpet opposite to the side thereof to which the foam mixture is applied at a pressure sufficient to draw the foam into the pile fibers and fixing the dye material to the pile fibers of the length of carpet.
The invention also comprehends a process for use in dyeing carpet with a pile surface a selected one of a number of colors including providing at least two applicator means operable for applying a foam mixture containing dye material, advancing a length of carpet to be dyed along a predetermined path adjacen-t the applicator means with the pile~ fibers facing the applicator means, operating one of the applicator means a predetermined period of time to apply a foam mixture containing one color of dye to the pile fibers o the length of carpet moving along the predetermined path, fixing the first color dye to the ~ile fibers of the len~th of carpet, operating the other one oE
the applicator means a predetermined period of time to apply a foam mixture containing a second color dye to the pile fibers of the length of carpet moving along the predetermined `: path and fixing the second color dye to the pile fibers of the length of carpet.
A still further aspect of the inventioll pertaills to a process of dyeing carpet wi-th a pile surface comprising the steps of moving a length of carpet to be dyed along its length in an approximately horizontal attitude -through a predetermined path with its pile fibers facing upwardly, progressively applying a first foam mixture containing dye to the top surface of the length of carpet as the length ~7~
of carpet moves along the preclcterMinecl patll, pro~.rossively applying a second foam mixture containing a dye to the top surface of the length of carpet as the length of carpet movès along the predetermined path after~the step of applying the first oam mixture to the length of carpet has been completed, and progressively fixing the dyes to the length of carpet as the length of carpet moves along its path.
~lore particularly, in usin9 thc COllt.inllOUS d~o~
proeess of the present invention for dyeing a lenc]th of carpet with a number of colors, the two dye applieator means are used, with a dye applicator means being easily moved from a position adjaeent the upper surfaee of the earpet movi.ng along the prede-termined path to an adjus-ted position located remotely from the earpet for eleaning. One oE the clye applieator means may be eleaned while the seeond dye applieator meal~s is applying a seeond eolor to the length of material moving al.ong the predetermined path thus allowing the remaini.ng apparatus assoeiated with a carpet dyeing proeess to continue : to run without a long period of shutdown.
A further aspeet of the invention is that by providing means for applying a foam mi~ture containing dye material through a number of applicator means, with the applicator means being selectively operable, a short run of earpet can be eeonomieally dyed -thus offering a much more diversified color eombination of earpet material.
It is therefore a primary object of the present invention to provide a continuous dyeing process for use in dyeing earpet a seleeted one of a number of colors.
.
- 2a - `
6~
An additional objec-t of the present invention is to provide a process for use in dyeing carpet a selected one of a number of colors which is simple in operation, economical to use and reliable in performance.
These and other aspects and advantages of the details of construction will become apparent after reading the following description of th~e illustrative embodiments with reference to the attached drawings wherein like reference numerals have been used to refer to like parts throughout the several figures and wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic view of a carpet dyeing process embodying the principles of the present invention;
Figure 2 is an elevational schematic view of one ~ :
applicator means;
Figure 3 is an elevational schematic view of a second applicator means;
Figure 4 is an horizontal schematic view showing .
material confining means; and ., , Figure 5 is a schematic view showing a further embodiment of a carpet dyeing process embodying the principles of the present invention.
~' ' .
i ~
, ~7~6~) DESCRIPTION OF THE ILLUST~ATIVE E~BODI~ENTS
Referring to the drawing, the continuous carpet dyeing process of the present invention will be described wi'_h reference to the apparatus required to carry out the process, including alternate applicator means and arrangements, followed by the description of the steps of the process.
As shown in Figure 1, a length of carpet to be dyed is generally represented by the reference numeral 10 and is conveyed along a predetermined path by conventional carpet conveying apparatus (not shown). Carpet support means 11 is positioned beneath carpet 10 with a pair of foam mixture dye applicators 12, 13 supported above carpet 10. A foam mixture containing carpet dye is supplied to applicators 12, 13 by conventional individual foam machines 14, 15, respectively.
Foam machines 14 and 15 are independently operable, with both of the foam machines being connected to a common air supply means 16 which is used ir. developing a foam mixture. E'oam machine 14 is supplied with a mixture of material from batch means 17.
satch means 17 contains a mixture of predetermined amounts of water, powder or liqiud thickner material, such as gum tragacanth and selected color dye material supplied from supply sources 18, 19 and 20, respectively.
Foam machine 15 is supplied with a mixture of material ` from batch means 21, which contains a mixture of predetermined amounts of water, thickner material and another selected color dye material. Batch means 21 is supplied from a water source 22, thickner material source 23 and dye material source 24.
~7g6~
As shown in Figure 1, the carpet material 10 being advanced along the predeterm~ned path beneath applicators 12, 13 and above support 11 ls then advanced through a conventional steam oven 30. Carpet 10 is guided through oven 30 by a plurality of roller guide means 31, with oven 30 including a steam supply source 32 operable for developing sufficient temperature and moisture conditions to cause fixation of dye material contained in a foam mixture to the carpet pile or nap.
The applicators 12, 13 can be constructed in a number of embodiments. One embodiment of an applicator is shown in Figure 2 and generally represented by number 40. Applicator 40 includes an elongated tray or container having a longitudinal dimension equal to the width of the carpet being dyed. The applicator tray is provided with a vertical side wall 41 and a sloping wall 42 and includes a pair of end walls (not shown).
Applicator 40 has a top entrance opening 43 and a bottom discharge opening 44. Vertical wall 41 includes an adjustable bottom edge 45 adjacent discharge opening 44. Adjustable edge 45 is adapted to be held in a selected adjusted position by conventional locking screw means 46 so that the height or amount of foam mixture being applied to carpet 10 can be varied. The foam mixture containing dye is supplied to applicator tray 40 through conduit 48. In operation~ the foam mixture containing dye is ~ ;
supplied through conduit 48 from one of the foam machines 14, 15 in a sufficient amount and in a matter to reach a predetermined height in the applicator tray. As carpet 10 is advanced beneath applicator 40 the foam mixture containing dye will be applied to the upper or the pile surface of the carpet. The amount of foam mixture will be controlled by adjustable edge 45, with edge 45 being operable to doctor the foam mixture evenly across the width of the carpet and evenly along the length of the carpet.
~Q~7~6~
Figure 3 shows a second embodiment of a foam mixture applicator which is generally represented by number 50. Appli-cator 50 includes an elongated doctoriny blade 51 supported across the width of carpet 10. Blade 51 is adjustably supported adjacent its opposite ends by a crank and threaded screw adjust-ment mechanism 52. A foam mixture is supplied from one of the foam machines 14, 15 through conduit means 53 which discharges the foam mixture on the upper carpet surface. Conduit means 53 is supported by conventional carriage means (not shown) for r ; 10 reciprocating movement across the width of the carpet to form -~
a puddle of the foam mixture on the carpet with the puddle being doctored to a predetermined height by doctoring blade 51 during advancement of the carpet beneath blade 51. The puddle of the foam mixture is confined to the width of the carpet by lateral confining blade 55, 56. Blades 55, 56 can be adjusted by a conventional threaded shaft support means to acccm~odate various width carpet.
Figure 5 shows a third modification of a foam mixture applicator generally represented by number 60, with applicator 60 being associated with an alternate arrangement of a carpet dyeing process. Applicator 60 is constructed in the form of an extruder 61 entending across the width carpet. Applicator extruder 61 is connected in closed conveying relationship to conduit 62. Conduit 62 is connected to one of the foam machines 14, 15. Applicator extruder 61 is provided with one adjustable wall portion 63 which is held in a selected adjusted position by conventional locking screw means 64. Adjustable wall portion 63 will permit the amount of foam mixture extruded to be varied.
Applicator extruder 61 can be supported above carpet 10, as a7~
shown in Figure 1, or can be supported adjacent an angled pile opening portion of carpet 10, as shown in Figure 5~
The alternate arrangement of the carpet dyeing process shown in Figure 5 includes means for advancing the carpet around a roller guide 70 and along an upwardly angled path adjacent guide means 71 and beneath pre heat means 72. Guide means 71 includes an upwardly angled portion 71a and a horizontal guide portion 71b joined to form an apex adjacent applicator extruder 61. As shown in Figure 5, vacuum conduit means 80 having an elongated slot 81 is supported beneath carpet 10. Vacuum means 80 can be used to aid in effecting penetration of the foam mixture into the carpet pile. Additional heating means 85, 86 is supported above carpet 10 as it moves along the upper surface of horizontal guide portion 71b and prior to movement into the steam oven 30.
Either of the above described applicator means 40, 50 or 60 can be used in a carpet dyeing process embodying the principles of the present invention. In a carpet dyeing process, `1 a first amount of material containing a first carpet dye color ~, is mixed to form one of the batches 17, 21. The batch of material is calculated for the amount of carpet to be dyed. The batch of material is then introduced to one of the foam machines 14, 15 with air being mixed therein to form a foam mixture. The foam mixture is then applied to carpet 10 through one of the appli- `
cator means 12, 13 as the carpet is advanced therebeneath. After the foam mixture containing dye has been applied to the carpet, the carpet is then advanced through steam oven 30 for fixation , of the dye material to the carpet.
~, 7~6~) While a first length of carpet is being dyed, a second batch of materlal containing calculated amounts of water, thickner and another color dye material is mixed to form the second batch. After the first length of carpet is dyed, the first applicator means and foam machine is cleaned. While the first applicator means and foam machine is being cleaned the second batch of material is introduced to the second foam machine, mixed with air to form a foam mixture and then applied to a second length of carpet through the second applicator means.
By using two foam machines and two applicator means, one foam machine and one applicator means can be cleaned while the others are in use. Thus, providing for a continuous carpet dyeing process to obtain maximum utilization of the carpet conveying means, carpet guiding means and the steam oven. The use of the foam mixture containing clye which is applied pro-gressively to only the upper surface oE the carpet being advanced along a predetermined path will permit calculated mixture of small amounts of dye material and wi.ll provide a carpet dyeing process which can be economically used for dyeing short runs of carpet material.
It now becomes apparent that the above described -process and apparatus are capable of obtaining the above stated objects and advantages. It is obvious that those skilled in the art may make modifications in the details of construction without departing from the spirit of the invention which is to be limited only by the scope of the appended claims.
BACKGROUND OF THE INVENTION
This invention relates to a continuous process of dyeing carpet and is more particularly concerned with a process for selectively dyeing a carpet ally one oE a numbcl- of ~olors.
One prior art continuous dyeing process is performed by advancing material to be dyed along a predetermined path through a vat containing liquid dye material, with the material leaving the vat, then being advanced through a steam oven for fixing the dye to the material. Another prior art carpet dyeing process is performed by lowering a batch of carpet ln a vat containing dye and then transferring the carpet to a steam oven for fixation.
In the vat applicator process, when -the dyeing apparatus is being changed for applying a second color of dye material, the complete dyeing process must be stopped, the vat and dye applicator means must be thoroughly cleaned beEore a second color dyeing process can be started.
The above disadvantages of the vat dye applicator process increased the cost of dyeing carpet since the complete dyeing line must be shut down during the change-over from one color dye to a second color dye. Further, due to the e~treme ..c~
cost of changing from one color dye -to a second color dye, it is not economically feasible to dye short runs or small amounts of carpet.
SUMMARY OF THE INVENTION
The above disadvantages have been overcome by the present invention which basically includes in one broad aspect a process Eor use in dyeing carpet with a pile surEace, ~QC~ 6~
i.nclud:ing acivancing a length of caxpet to be dyed along a predetermined path with its pile fibers facing upwardly, applying a foam mixture containing dye material to the pile fibers of length of carpet moving ~long the predetermined path, applying a vacuum to the side of the length of carpet opposite to the side thereof to which the foam mixture is applied at a pressure sufficient to draw the foam into the pile fibers and fixing the dye material to the pile fibers of the length of carpet.
The invention also comprehends a process for use in dyeing carpet with a pile surface a selected one of a number of colors including providing at least two applicator means operable for applying a foam mixture containing dye material, advancing a length of carpet to be dyed along a predetermined path adjacen-t the applicator means with the pile~ fibers facing the applicator means, operating one of the applicator means a predetermined period of time to apply a foam mixture containing one color of dye to the pile fibers o the length of carpet moving along the predetermined path, fixing the first color dye to the ~ile fibers of the len~th of carpet, operating the other one oE
the applicator means a predetermined period of time to apply a foam mixture containing a second color dye to the pile fibers of the length of carpet moving along the predetermined `: path and fixing the second color dye to the pile fibers of the length of carpet.
A still further aspect of the inventioll pertaills to a process of dyeing carpet wi-th a pile surface comprising the steps of moving a length of carpet to be dyed along its length in an approximately horizontal attitude -through a predetermined path with its pile fibers facing upwardly, progressively applying a first foam mixture containing dye to the top surface of the length of carpet as the length ~7~
of carpet moves along the preclcterMinecl patll, pro~.rossively applying a second foam mixture containing a dye to the top surface of the length of carpet as the length of carpet movès along the predetermined path after~the step of applying the first oam mixture to the length of carpet has been completed, and progressively fixing the dyes to the length of carpet as the length of carpet moves along its path.
~lore particularly, in usin9 thc COllt.inllOUS d~o~
proeess of the present invention for dyeing a lenc]th of carpet with a number of colors, the two dye applieator means are used, with a dye applicator means being easily moved from a position adjaeent the upper surfaee of the earpet movi.ng along the prede-termined path to an adjus-ted position located remotely from the earpet for eleaning. One oE the clye applieator means may be eleaned while the seeond dye applieator meal~s is applying a seeond eolor to the length of material moving al.ong the predetermined path thus allowing the remaini.ng apparatus assoeiated with a carpet dyeing proeess to continue : to run without a long period of shutdown.
A further aspeet of the invention is that by providing means for applying a foam mi~ture containing dye material through a number of applicator means, with the applicator means being selectively operable, a short run of earpet can be eeonomieally dyed -thus offering a much more diversified color eombination of earpet material.
It is therefore a primary object of the present invention to provide a continuous dyeing process for use in dyeing earpet a seleeted one of a number of colors.
.
- 2a - `
6~
An additional objec-t of the present invention is to provide a process for use in dyeing carpet a selected one of a number of colors which is simple in operation, economical to use and reliable in performance.
These and other aspects and advantages of the details of construction will become apparent after reading the following description of th~e illustrative embodiments with reference to the attached drawings wherein like reference numerals have been used to refer to like parts throughout the several figures and wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic view of a carpet dyeing process embodying the principles of the present invention;
Figure 2 is an elevational schematic view of one ~ :
applicator means;
Figure 3 is an elevational schematic view of a second applicator means;
Figure 4 is an horizontal schematic view showing .
material confining means; and ., , Figure 5 is a schematic view showing a further embodiment of a carpet dyeing process embodying the principles of the present invention.
~' ' .
i ~
, ~7~6~) DESCRIPTION OF THE ILLUST~ATIVE E~BODI~ENTS
Referring to the drawing, the continuous carpet dyeing process of the present invention will be described wi'_h reference to the apparatus required to carry out the process, including alternate applicator means and arrangements, followed by the description of the steps of the process.
As shown in Figure 1, a length of carpet to be dyed is generally represented by the reference numeral 10 and is conveyed along a predetermined path by conventional carpet conveying apparatus (not shown). Carpet support means 11 is positioned beneath carpet 10 with a pair of foam mixture dye applicators 12, 13 supported above carpet 10. A foam mixture containing carpet dye is supplied to applicators 12, 13 by conventional individual foam machines 14, 15, respectively.
Foam machines 14 and 15 are independently operable, with both of the foam machines being connected to a common air supply means 16 which is used ir. developing a foam mixture. E'oam machine 14 is supplied with a mixture of material from batch means 17.
satch means 17 contains a mixture of predetermined amounts of water, powder or liqiud thickner material, such as gum tragacanth and selected color dye material supplied from supply sources 18, 19 and 20, respectively.
Foam machine 15 is supplied with a mixture of material ` from batch means 21, which contains a mixture of predetermined amounts of water, thickner material and another selected color dye material. Batch means 21 is supplied from a water source 22, thickner material source 23 and dye material source 24.
~7g6~
As shown in Figure 1, the carpet material 10 being advanced along the predeterm~ned path beneath applicators 12, 13 and above support 11 ls then advanced through a conventional steam oven 30. Carpet 10 is guided through oven 30 by a plurality of roller guide means 31, with oven 30 including a steam supply source 32 operable for developing sufficient temperature and moisture conditions to cause fixation of dye material contained in a foam mixture to the carpet pile or nap.
The applicators 12, 13 can be constructed in a number of embodiments. One embodiment of an applicator is shown in Figure 2 and generally represented by number 40. Applicator 40 includes an elongated tray or container having a longitudinal dimension equal to the width of the carpet being dyed. The applicator tray is provided with a vertical side wall 41 and a sloping wall 42 and includes a pair of end walls (not shown).
Applicator 40 has a top entrance opening 43 and a bottom discharge opening 44. Vertical wall 41 includes an adjustable bottom edge 45 adjacent discharge opening 44. Adjustable edge 45 is adapted to be held in a selected adjusted position by conventional locking screw means 46 so that the height or amount of foam mixture being applied to carpet 10 can be varied. The foam mixture containing dye is supplied to applicator tray 40 through conduit 48. In operation~ the foam mixture containing dye is ~ ;
supplied through conduit 48 from one of the foam machines 14, 15 in a sufficient amount and in a matter to reach a predetermined height in the applicator tray. As carpet 10 is advanced beneath applicator 40 the foam mixture containing dye will be applied to the upper or the pile surface of the carpet. The amount of foam mixture will be controlled by adjustable edge 45, with edge 45 being operable to doctor the foam mixture evenly across the width of the carpet and evenly along the length of the carpet.
~Q~7~6~
Figure 3 shows a second embodiment of a foam mixture applicator which is generally represented by number 50. Appli-cator 50 includes an elongated doctoriny blade 51 supported across the width of carpet 10. Blade 51 is adjustably supported adjacent its opposite ends by a crank and threaded screw adjust-ment mechanism 52. A foam mixture is supplied from one of the foam machines 14, 15 through conduit means 53 which discharges the foam mixture on the upper carpet surface. Conduit means 53 is supported by conventional carriage means (not shown) for r ; 10 reciprocating movement across the width of the carpet to form -~
a puddle of the foam mixture on the carpet with the puddle being doctored to a predetermined height by doctoring blade 51 during advancement of the carpet beneath blade 51. The puddle of the foam mixture is confined to the width of the carpet by lateral confining blade 55, 56. Blades 55, 56 can be adjusted by a conventional threaded shaft support means to acccm~odate various width carpet.
Figure 5 shows a third modification of a foam mixture applicator generally represented by number 60, with applicator 60 being associated with an alternate arrangement of a carpet dyeing process. Applicator 60 is constructed in the form of an extruder 61 entending across the width carpet. Applicator extruder 61 is connected in closed conveying relationship to conduit 62. Conduit 62 is connected to one of the foam machines 14, 15. Applicator extruder 61 is provided with one adjustable wall portion 63 which is held in a selected adjusted position by conventional locking screw means 64. Adjustable wall portion 63 will permit the amount of foam mixture extruded to be varied.
Applicator extruder 61 can be supported above carpet 10, as a7~
shown in Figure 1, or can be supported adjacent an angled pile opening portion of carpet 10, as shown in Figure 5~
The alternate arrangement of the carpet dyeing process shown in Figure 5 includes means for advancing the carpet around a roller guide 70 and along an upwardly angled path adjacent guide means 71 and beneath pre heat means 72. Guide means 71 includes an upwardly angled portion 71a and a horizontal guide portion 71b joined to form an apex adjacent applicator extruder 61. As shown in Figure 5, vacuum conduit means 80 having an elongated slot 81 is supported beneath carpet 10. Vacuum means 80 can be used to aid in effecting penetration of the foam mixture into the carpet pile. Additional heating means 85, 86 is supported above carpet 10 as it moves along the upper surface of horizontal guide portion 71b and prior to movement into the steam oven 30.
Either of the above described applicator means 40, 50 or 60 can be used in a carpet dyeing process embodying the principles of the present invention. In a carpet dyeing process, `1 a first amount of material containing a first carpet dye color ~, is mixed to form one of the batches 17, 21. The batch of material is calculated for the amount of carpet to be dyed. The batch of material is then introduced to one of the foam machines 14, 15 with air being mixed therein to form a foam mixture. The foam mixture is then applied to carpet 10 through one of the appli- `
cator means 12, 13 as the carpet is advanced therebeneath. After the foam mixture containing dye has been applied to the carpet, the carpet is then advanced through steam oven 30 for fixation , of the dye material to the carpet.
~, 7~6~) While a first length of carpet is being dyed, a second batch of materlal containing calculated amounts of water, thickner and another color dye material is mixed to form the second batch. After the first length of carpet is dyed, the first applicator means and foam machine is cleaned. While the first applicator means and foam machine is being cleaned the second batch of material is introduced to the second foam machine, mixed with air to form a foam mixture and then applied to a second length of carpet through the second applicator means.
By using two foam machines and two applicator means, one foam machine and one applicator means can be cleaned while the others are in use. Thus, providing for a continuous carpet dyeing process to obtain maximum utilization of the carpet conveying means, carpet guiding means and the steam oven. The use of the foam mixture containing clye which is applied pro-gressively to only the upper surface oE the carpet being advanced along a predetermined path will permit calculated mixture of small amounts of dye material and wi.ll provide a carpet dyeing process which can be economically used for dyeing short runs of carpet material.
It now becomes apparent that the above described -process and apparatus are capable of obtaining the above stated objects and advantages. It is obvious that those skilled in the art may make modifications in the details of construction without departing from the spirit of the invention which is to be limited only by the scope of the appended claims.
Claims (19)
1. A process for use in dyeing carpet with a pile surface, including:
(a) advancing a length of carpet to be dyed along a predetermined path with its pile fibers facing upwardly;
(b) applying a foam mixture containing dye material to the pile fibers of length of carpet moving along said pre-determined path;
(c) applying a vacuum to the side of the length of carpet opposite to the side thereof to which the foam mixture is applied at a pressure sufficient to draw the foam into the pile fibers; and (d) fixing said dye material to the pile fibers of said length of carpet.
(a) advancing a length of carpet to be dyed along a predetermined path with its pile fibers facing upwardly;
(b) applying a foam mixture containing dye material to the pile fibers of length of carpet moving along said pre-determined path;
(c) applying a vacuum to the side of the length of carpet opposite to the side thereof to which the foam mixture is applied at a pressure sufficient to draw the foam into the pile fibers; and (d) fixing said dye material to the pile fibers of said length of carpet.
2. A process as defined in Claim 1 further characterized in that said foam mixture containing dye is applied only to the pile fibers of the length of carpet moving along said pre-determined path.
3. A process as defined in Claim 1 further characterized in that said foam mixture containing dye is applied by extruding said foam mixture onto the pile fibers of said length of carpet.
4. A process as defined in Claim 1 further characterized in that said foam mixture containing dye is applied to the upper surface of said length of carpet moving along said predetermined path in an amount to create a puddle of said foam mixture and wherein said foam mixture is doctored to a predetermined level by an adjustable doctoring blade.
5. A process as defined in Claim 4 further characterized in that said doctoring blade includes means for confining the lateral dimensions of said puddle of said foam mixture to the width of said length of carpet, wherein said confining means includes a confining element located adjacent each of the lateral side edges of the length of carpet, with confining elements being adjustable in a vertical plane.
6. A process as defined in Claim 1 further characterized in that said foam mixture containing dye is applied to said length of carpet in an applicator container, and wherein said applicator container includes a doctoring edge located at a predetermined elevation above said length of carpet.
7. A process as defined in Claim 1 further characterized in that said length of carpet is advanced in a first direction of movement along said predetermined path and is then angularly adjusted for movement in a second direction along said pre-determined path, and wherein said foam mixture is applied to the pile fibers of said length of carpet at said angular change in direction of said length of carpet moving along said pre-determined path.
8. A process as defined in Claim 1 further characterized in that the pile fibers of said length of carpet are preheated prior to application of said foam mixture.
9. A process as defined in Claim 1 further characterized in that said length of carpet is heated to a predetermined temperature after application of said foam mixture.
10. A process as defined in Claim 1 further characterized in that said foam mixture is made by mixing predetermined amounts of dye material, predetermined amounts of thickening material, predetermined amounts of water, and predetermined amounts of air.
11. A process as defined in Claim 1 further characterized in that said dye is fixed to the pile fibers of said length of carpet by applying a steam heating medium to said length of carpet containing said foam mixture.
12. A process for use in dyeing carpet with a pile surface a selected one of a number of colors including:
(a) providing at least two applicator means operable for applying a foam mixture containing dye material;
(b) advancing a length of carpet to be dyed along a predetermined path adjacent said applicator means with the pile fibers facing said applicator means;
(c) operating one of said applicator means a predetermined period of time to apply a foam mixture containing one color of dye to the pile fibers of said length of carpet moving along said predetermined path;
(d) fixing said first color dye to the pile fibers of said length of carpet;
(e) operating said other one of said applicator means a predetermined period of time to apply a foam mixture containing a second color dye to the pile fibers of said length of carpet moving along said predetermined path; and (f) fixing said second color dye to the pile fibers of said length of carpet.
(a) providing at least two applicator means operable for applying a foam mixture containing dye material;
(b) advancing a length of carpet to be dyed along a predetermined path adjacent said applicator means with the pile fibers facing said applicator means;
(c) operating one of said applicator means a predetermined period of time to apply a foam mixture containing one color of dye to the pile fibers of said length of carpet moving along said predetermined path;
(d) fixing said first color dye to the pile fibers of said length of carpet;
(e) operating said other one of said applicator means a predetermined period of time to apply a foam mixture containing a second color dye to the pile fibers of said length of carpet moving along said predetermined path; and (f) fixing said second color dye to the pile fibers of said length of carpet.
13. A process as defined in Claim 12 further characterized in that said foam mixture containing dye is applied only to the pile fibers of the length of carpet moving along said pre-determined path.
14. A process as defined in Claim 12 further characterized in that said foam mixture containing dye is applied by extruding said foam mixture onto said length of carpet.
15. A process as defined in Claim 12 further characterized in that said foam mixture containing dye is applied to the upper surface of said length of carpet moving along said pre-determined path in an amount to create a puddle of said foam mixture and wherein said foam mixture is doctored to a pre-determined level by an adjustable doctoring blade.
16. A process of dyeing carpet with a pile surface comprising the steps of moving a length of carpet to be dyed along its length in an approximately horizontal attitude through a predetermined path with its pile fibers facing upwardly, progressively applying a first foam mixture containing dye to the top surface of the length of carpet as the length of carpet moves along the predetermined path, progressively applying a second foam mixture containing a dye to the top surface of the length of carpet as the length of carpet moves along the predetermined path after the step of applying the first foam mixture to the length of carpet has been completed, and progressively fixing the dyes to the length of carpet as the length of carpet moves along its path.
17. The process as defined in Claim 16 and further characterized in that the foam mixture containing dye is applied to the length of carpet by extruding the foam mixture onto the length of carpet.
18. The process as defined in Claim 16 and further including the step of heating the foam on the top surface of the length of carpet.
19. The process as defined in Claim 16 further including the step of preheating the pile fibers of the top surface of the carpet prior to the application of the foam to the carpet.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA257,397A CA1097460A (en) | 1976-07-20 | 1976-07-20 | Continuous carpet dyeing process |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA257,397A CA1097460A (en) | 1976-07-20 | 1976-07-20 | Continuous carpet dyeing process |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1097460A true CA1097460A (en) | 1981-03-17 |
Family
ID=4106467
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA257,397A Expired CA1097460A (en) | 1976-07-20 | 1976-07-20 | Continuous carpet dyeing process |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1097460A (en) |
-
1976
- 1976-07-20 CA CA257,397A patent/CA1097460A/en not_active Expired
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| MKEX | Expiry |