CA1181606A - Method for producing space-dyed yarn - Google Patents
Method for producing space-dyed yarnInfo
- Publication number
- CA1181606A CA1181606A CA000384829A CA384829A CA1181606A CA 1181606 A CA1181606 A CA 1181606A CA 000384829 A CA000384829 A CA 000384829A CA 384829 A CA384829 A CA 384829A CA 1181606 A CA1181606 A CA 1181606A
- Authority
- CA
- Canada
- Prior art keywords
- prefabric
- yarn
- dye
- printing
- rolls
- 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
Links
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
- D06B11/00—Treatment of selected parts of textile materials, e.g. partial dyeing
- D06B11/002—Treatment of selected parts of textile materials, e.g. partial dyeing of moving yarns
- D06B11/0036—Treatment of selected parts of textile materials, e.g. partial dyeing of moving yarns specially disposed for a local treatment
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
- D06B11/00—Treatment of selected parts of textile materials, e.g. partial dyeing
- D06B11/0056—Treatment of selected parts of textile materials, e.g. partial dyeing of fabrics
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Textile Engineering (AREA)
- Coloring (AREA)
- Treatment Of Fiber Materials (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
Yarn is space dyed in a plurality of tones of one color, by a single set of printing rolls having an intermittent relief pattern of different depths.
The yarn is formed into a prefabric before passing through the nip of the printing rolls and the novel space dyed yarn is recovered from the prefabric.
Yarn is space dyed in a plurality of tones of one color, by a single set of printing rolls having an intermittent relief pattern of different depths.
The yarn is formed into a prefabric before passing through the nip of the printing rolls and the novel space dyed yarn is recovered from the prefabric.
Description
~ D~ ~
METHOD FO~ PRODUCING SP~CE-DYED YARN
AND RESU~TING PRODUCT
The invention relates to an improved method for produciny space-dyed yarn and particularly to a method for producing yaxn space-dyed in different tones.
More particularly, khe invention relates to a method for producing space-dyed yarn dyed with different tones of the same color using only one set of printing rolls for each color.
It is ~nown that when a continuous yarn dyed in a multicolored pattern, in which the pattern is repea~ed frequently r is utili~ed to prepar~ a knitted, woven or tufted material, the finished article tends to develop undersirable striations or streaking. The phenomenon is particularly noticeable when multicolored yarn is utilized for preparing tufted carpeting o~ upholstery fabric.
To overcome the difficulty wi-th streaking, a te~hnique known as space-dyeing was developed to provide a yarn which was dyed with multiple colors but the pattern of the multiple colors is repeated at only long intervals along the yarn. The long intervals between repeating patterns prevented the development of streaking or striations in the finished article.
Gihson et al in U.S. Patent 3,605,225 discloses forming a woven fabric and then printing diagonal stripes of various colors on the fabric followed by disassembling the fabric by deweaving it to produce a multiplicity of multicolored yarns.
,,~
Gibson et al disclose that the process may be combined with pad dyeing to provide the yarn with an overall background color but even with this additional step, the number of colors which can be applied to the yarn is limited.
U.S. Patent 4,058,848 to Whitaker discloses a novel method for space dyeing a woven fabric wherein the fabric is prepared by utilizing a sacrificial filling which is dissolved after the s~ace dyeing opera-tion to recover the multicolored yarn.
Knitted tubing may be subjected to similar processes as disclosed in U.S. Patents 3,012,303, 3,543,359, 4,033,717, 3,701,315, 3,919,749 and 4,185,3~4.
The concept of psaced dyeing has been ap~lied to individual yarns as disclosed in U.S. 3,871,196 and U.S. 3,803,880.
It has also been disclosed to knit textile yarn into a tube and -to freely distribute dyes-tuffs onto the knitted tube in order to im~art various colors to the yarn. The tube is passed through rollers which press the tube flat and force differential migration of the dyestuff. The dyestuff is set, and the tube deknitted. However, the free distribution of the dye-stuff onto the knitted textile yarn presents a severe limitation to the number of colors which may be applied to the yarn and prohibits precise control of the specific areas and location to which the colors are applied. The method is disclosed in U~S. Patenk No.
3,828,405~
The prior art processes which space dye woven or knitted fabrics or space dye the individual yarns suffer from the disadvantage that not only are different printing rolls re~uired for different colors but different printing rolls are required for different tones or shades of a particular color. When a large number of colors and shades are re~uired in a multicolored yarn, the number of printing stations becomes large and the process becomes difficult to control and economically unattractive.
` It is the object of the present invention to provide a method for producing space dyed yarn wherein two or more tones or shades of a color can be applied to the yarn with one set Gf printing rolls.
BRIEF DESCRIPTION OF THE INVENTION
According to the present invention, space dyed yarns are ~repared by a process which comprises forming a prefabric from the yarn, providing two printing rolls to form a nip wherein at least one of said prin-ting rolls is provided with a relief pattern having at least two depths; filling the relief pattern with dye;
passing the prefabric through the nip of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones and recovering the space dyed yarn.
The pair of printing rolls can each contain a matching relief pattern one of which is the mirror image of the other, having portions of the relie pattern in different depths, so that when the dye is transferred from the relief pattern to the prefabric, the color is deposited in different tones or shades on the prefabric.
The tone or shade can further be contr~lled by registration of the matching patterns on the matching printing roll5. The deepest tones are producecl when the relief patterns are in exact registrat;on. When the relief patterns are sli~htly out of registratioll, the edges of the pattern show a gradation in ~one.
The prefabric may be passed serially thro~gh two or more sets of printing rolls where multiple colors in at least two tones for each color can be printed on the prefabric.
BRIEF l)ESCRIPTION OF TIIE DRAWINGS
FIGURE 1 is a diagrammatic representation of a preferred embodiment of the lnvention.
FIGURE 2 is a diagrammatic representation of the straightening, paddin~, printing and dye setting operations of the present invention.
FIGIJRE 3 is a perspective view of two printin~
rolls having matching patterns.
FIGURE 4 is the layout for the pattern of the two sets of matching printing rolls shown ln Fig. 2.
DETAILED DESCRIPTION OF TIIE lNVENTION
As llsed herein, space dyein~ refers to applyinc~
dye interlnittently to a yarn or fabric. Colored dyec;
may be applied intermittently to a fabric or yarn which has been dyed a solid color and the cdyes may be applied intermittently with some overlap of colors tc>
provide an additional cc~lor. q~h~ clye can ~ applied intermittently to an undyccl yarn or fabric and i:ne fabric subsequently overclyecl with a solid c~olc)r to provide a multicolored yarn.
The process of the present invention can be utilized to prepare space dyed yarns prepared from continuous multifilament or staple yarns. Yarns can be prepared from synthetic or na~ural materials.
Continuous multifilament or staple yarns prepared from nylon (polyamides), polyesters and acrylic polymers can be space dyed by the process of the present inven-tion. The process of the present invention can also be applied to yarn prepared ~rom natural materials such as cotton, wool, linen and the like. The space dyed yarns prepared according to the process of the present invention can be utilized to prepare cloth, upholstery fabric, carpeting (particularly tufted carpeting) and knitted goods. The space dyed yarn prepared according to the present invention overcomes the problem of streaking and provides colors in a mul~iplicity of tones or shades with a minimum of printing stations req~ired for the processO
Fic~3ure 1 is a diagrammatic representation of the preferred embodiment of a complete process of the present invention.
The yarn which is to be space dyed is formed into a prefabricO The prefabric can be in the form of a knitted sock such as disclosed in U.S. 3,701,315 or U.S. 3,012,303, can be formed from a woven fabric such as disc:losed in U.S. 4,0~5,34~3 or can be il~ the form of parallel strands of yarn haviny a tempOrAry entraillin~3 :~ ld.~ ?~
strand oE yarn woven int:o an array o~ warps ~s dis-elosed in U.S. 3,908,24~ ny c]oth-like array i-;
suitable for processiny in the present invention.
Ho~ever, a prefabric in the form of a knitt~d tube or sock has been ounc] to be particularly useful for space dyeing by the process of the present invention.
A knitted flat cloth suc~ as disclosed in ll.~,.
3,919,749 is also useful in the practice of t:he pres~nt invention. The prefabrics useful in the practice of the present invention are charaeterized in that they maintain the forrn of the prefabric as they proceed through the process but can be easily separated into the individual strands of yarn aEter the process has been completed. Methods for fabricating prefabrics useful in the proeess of the present invention are well known in the art and wi:Ll not be described further hereinO
The prefabrie is generally straightened to remove any wrinkles and kinks to insure that the fabric is lying flat so that it may be evenly clyed and printed in the proeess. When a knitted sock is utilizec~ as the prefabric, the straightening and levelling of the knitted soek can be readily accomplished by the use of lease rods.
The prefabric can be clyed an overall solid baekground eolor in a paddinc~ operation. The prefabric is eontaeted with the dye for a suffieient length of time for the fibers in the yarn to take up the requirecl amount of dye to provide the hackground color. The 3~ excess liyuid from the dye bath is then separated from the prefabric and the preabric is passed to the printing station.
Xt is preferred that the preFabric frolll the dyeing operation be damE) whell it is passecl through the printing stations. I'he dalllp prefabric is more receptive to the d~e applied from the printing rolls and the patl:ern can be applied in a more uniform manner.
The prefabric however need not first be dyed a solid background color. 'I'he preFabric can be overdyed after printing, can be left as a white background or can be dyed after being incorporated in-to a finished article. The overall dyeincl if used~ may be incorpoc-^
ated into the process to suit the requirements c~f the equipment available and ~he finished product required by the operator.
The prefabric is then passed to the printing station where the prefabric is passed through the nip of at least one pair of printing rolls and preferably at least two pairs of printing rolls. The pairs of printiny rolls have the desired intermittent pattern formed in relief on the face of at least one of the printing rolls. It is preferred that each pair of printing rolls have matching or mirror image patterns formed in relief thereon. In printing, the relief pattern on the printing roll is filled with dye, the excess dye removed from the outermost surface of the printing roll by means of a device such as a doctor blade and the dye transferred to the prefabric as it passes through the nip o~ the printing rolls. The excess dye is removed Erom the outermost surface of the printing roll to ensure that the dye contained in the relief pattern on the printing roll is transferred to the prefabric as it passes through the nip of the printing rolls and not from the outermost surface of the rolls.
Thc~ intermittent relief pattern on the prirltin~^~
rolls is ~ormed to differerlt deE)ths. q'he dif~erent deE)ths oF the relief pattern holding the dye provide, varying amounts of dye fc)r transfer to the prefabric at the point where the pattern is brought adj~cent to the prefabric at the nip of the rolls. Where the relief pattern on the printed roll is deepest) the largest amount of dye is transferred to the acljacent portion of the prefabric. By varyin~ the depth of the relief pattern, the dye can be transferred to the prefabric to Eorm different tones or shades oE a single color on the prefabric. The penetration ol- the dye into the prefabric can be controlled by the depth of the relief pattern at a particular point, the pressure of the rolls and where the rolls have matching patterns, the registration of the pattern on the rolls.
When the rolls of one prin~ing roll set have matching or mirror image patterns, registration of the patterns on the rol~s increases the penetration of the color. If the matchin~ rolls aré not in re~istration, the tone of the color at the edges of the pattern will be of different tone or shade than the portion where registration occ~rs.
The relief pattern is formed of an intermittent pattern at two or more depths. A pattern havin~ at least two different depths is necessary to provide at least two tones in the space-dyed printed pattern on the prefabric and yarn. ~ach portion of the relief pattern having a different clepth provides color c3eposited on the prefabric having a different tone or shade. The tone or shade of color can also be modi-fied by the combination of the color of the d~e prinled on the prefabric and an overa]l baclcgrounc] color to which the prefabric has been previousl~ dyed.
The relief pattern on the printin~ rol3s can be in any random form for depositing areas or splotches of dye on the prefabric as it passes thro~gh the nip of the printing rolls. However, it has been founcl preferable to provide a pattern in the form of stripes which are printed on the preEabric at an angle to the longitudinal axis of the prefabric. An angle oE from about 15 to about 40 with the longitudinal axis of the prefabric has been found to be suitable.
A flat layout of the pattern for two sets of printing rol;Ls which print different colors in differ-ent tones or shades is shown in Fig. 4. Rolls 6 and 6' show a striped pattern at an angle of abo~lt 30 with the longitudinal axis of the prefabric. The patt:ern contains relief portions oE two different depths noted by a and b. The relief portion area a is the shallowest portion of the pattern and would approximately correspond to a half tone printing plate.
Area b is greater in depth than area a. Area b is the deeper relief portion of the pattern and would therefore transfer the largest portion of the dye to the prefabric and therefore provide the darkest tone or shade. The mating roll can be plain but preferabLy has a pattern which is the mirror image of the pattern on the roll with which it mates.
The pattern for the rol~s 15 and 15' of the second printing station is a~so shown in Fig. 4. ~rhe pattern for the second printing station is in the forrn of stripes having relief areas d and e. Relief area d jc the' shallower clepth; rclief area e is the deeper relief portion ol~ lhe pat:tern. The pattern is in the form of stripes at an ancJle of about 30 with the lon~itudinal axis of the prefabric. The 30 angle with the longitudinal axis of the preabric is in the opposite direction from the angle at ~hich the pat:tern on rolls 6 and 6'was formecl. The patterns therefore cross each other on the printed prefabric. The matin~
roll can be plain or have a pattern which is a matching pattern or a mirror imacle oE the pattern O~ he roll with which it mates.
Since the stripes in the relief pattern on the two sets of printing ro]ls (6, 6' and 15, 15') are at different angles to the longitudinal axis of the pre-fabric, the stripes in the pattern when impressed onthe prefabric cross each otherO Since the patterns are of different colors, a third color is introduced into the prefabric at the point where the patterns over print each other. By this method, a third color can be printec~ on the prefabric by the use of only two prir-ting stations. In addition to the two or three colors introduced onto the prefabric, the three colors are in different tones or shades since the dye is t:ransferred to the prefabric in different amounts due to the different depths of the relief pattern and the amount of dye which can be held therein. The depth of the relieE pattern can vary from about 0.0005 inches to about 0.070 inches to provide the various tones ancl shades of color to thc? yarn in the prefabric. The depth of the relief pattern is also determined hy the denier of the yarn and the tone required.
'6 When the printin~3 stations are disposed horizorl-tally wi~h orle roll of a pair of printing rolls mountecl above the other, it is advantageous to form the matchin~
portions of the relief pattern in differe~t depths on the top and bottom rolls to insure printing the same tone or shade on the bottom and top surfaces of the prefabric. Gravity aids in transferrin~J the dye from the relief pattern on the upper roll to the prefabric and therefore the transfer of dye to the pre~abric occurs at a faster rate than ~rom the relief pattern on the lower roll. The relief pattern in the upper roll can therefore be formed to a slightly shallower depth than the matching relief pattern in the loweL
rol:L to obtain substantially the same tone transferrecl to the fabric. As an example, if the deep relief pattern in the upper roll has a depth of 0.016 inches, the depth of the matching pattern in the lower roll sho~ld be about 0.018 inches to insure transfer of a pattern of equal shade o. tone to the prefabric. I,ike--~ise, if the relief pattern in the upper roll has a depth of 0.004 inches, the depth of the pattern in the lower roll should be about 0.005 inches to insure that the tone or shade of the color transferred to the prefabric is about the same on both surfaces. This novel aspect of the invention is useful when the printin~
stations are disposed hori~ontally with one of the matched pair of printing rolls disposed above the other. If the printing stations are disposed vertical~y with the matchin~ printing rolls disposed side by side, the depth of the matchil-lg portions of the relie~' patterns should be the same.
The pressure applied to the printin~ rolls at:
the nip can be varied to modify the penetration of the 3~
dye illtO the prefabric. ln additiorl, the sh~cle anc~jor tone of the pattern cleposite(l on the pre~abric Ccln be varied to some extent by modifying the regis~ration of the matching patternC on the printing rolls. The deepest ~one or darkest shades are obtained when the matching patterns are in perfect registration. When the matching patterns are not in perfect registration, the edges of the patterns become blurred and the tone or shade of the color changes. The gradation o~ tone or shade can provide a pleasing effect to the yarn produced by the present process.
Although the printing rolls shown have a stripecl pattern which prints in dif~erent directions for the different printing stations or colors, other forms of intermittent patterns can be utilized in the present process. Irregular shapes, geometric forms, crosses, stars, random splotches, amoeba like forms, don~lt like profiles and the like may be utilized a~ the relief pattern on the printin~ rolls. A striped pattern can be engraved on two or more sets of printing rolls at the same angle so that the colored stripes on one set of printing rolls are printed in the vacant space hetween the stripes on another set of printing rolls.
The patterns can be varied by a combination of geometric or irregular figures to provide intermittently colored yarns and prefabrics ~ith interesting visual appearances. The patterns in two or more printing stations can be arranged so that portions of the patt:erns print over each other to form additional intermittent:
colors in the prefabric and the yarn produced by the process.
The prefabric leaving I:he printing stations proceeds to a means for settirlg the dye in the yarn.
The dye i5 l~SUally Get ~y confining the prefabric in heated zone where the pre~abric is heated hy steam or dry yases. In the heating zone, the dye is set and any loops or crimps irnparted to the yarn in making the prefabric can be partially set in the yarn~
After the dye is set, the prefabric is passed through a scouring and drying zone wherein the prefabric is washed and dried. In the washing or scouring ~one, the prefabric is contacted with water or so~ne other solvent to remqve the dye materials which have not been set in the prefabric. In addition, conditioning agents can be imparted to the prefabric to improve the hand, lubricity or other properties of the yarn.
The washed and dried prefabric is then passe~
to a zone wherein the yarn is recovered and wound on bobbins, spools or the like. If the prefabric has been knitted in the form of a tube or sock, the prefahlic is unravelled to recover the yarn and the yarn is wound on a supporting means which can be transferred to a process in which the yarn is utilized. If the prefabric is of a woven type, the weft is removed and individucll warp yarns recovered on a windup means and support.
The yarn prepared according to the process o~
the present invention has imparted thereto colors in a ranclom intermittent pattern wherein each color is present in at least two shades or tones on the yarn.
Fiyure ~ is a diagrammatic representation showing some of the major operations which can he combined with the multip]e tone printing rolls to provide the intermittently dyed multicolored ~pace dyecl yarn oi: the presenl: invellt-ioll.
As shown in ~ig. 2, prefat)ric 1 which can b~
in the form of a woven cloth, a knitted cloth or l:u~e is straightened by pa~-~ing over lease rods 2 wherein S wrinkles or kinks in the prefabric are removed. I'he straightene(~ and level prefabric passes into pac~di.ng bath 4 and proceeds through the battl over ro~.e:rs or rods 3 in a tortuous pat:h~ The tortuous path provide:;
a sufficient residence time of the prefahric i.n the dye bath to provide the color required. The overall solid background color i.mparted to the yarn alld pre-fabric in the pad~ing bath can be controlled by ad-justing the concentration of dye in the padding bath and the length of time which the yarn or prefabric is in contact with the dye solution in the bath. rrhe prefabric 1 passes between the nip of padding rollers 5 wherein the excess dye is moved from the prefabric.
The wet prefabric thell proceecls to printing station 30 where it passes between the nip of printing rolls 6 and 6' and 15 and 15'. Printing rolls 6 and 6' have matching intermittent patterns in relie~ on their surface. Relief patterns can be formed by known means such as engraving, rotogravure and the like. It is essential however that relief patterns be formecl at at least two different depths on the rolls. Since the rolls as shown .in printing station 30 are on a horizorl-tal stand, to ensure even color tones and hues on both sides of the prefabric, the matching portions of the pattern in the lower roll 6'should be slightly deeper than the ~quivalent portioll of the matching pattern ir ~pper roll 6. The slight differences in depth of the relief pattern is necessary to ensure even tones from 6~
the upE~er prillting roll ancl the lower prirltin(~ rol,l since the fLow of dy~: Erom the uE~per print-,ing roll is assistecl by the effects of gravity and therefore permeat~;
the prefabric at a Easter rate than the dye held in the relieE pattern on the lower roll.
The upper printing roll 6 is supplied with dye from dye trough 7. The excess ink from the ~ rfa~e o~
printing roll 6 is removed by doctor blade 8 which is a part of dye trough 7. The doctor blade 8 removes lQ the dye from the surface of printing roll 6 and leaves the relief portions of the pattern filled with dye.
Lower prin~ing roll 6' rotates in a pool of clye con-tained in a dye trough ~0. The excess dye is removec1 from the surface of the printing roll by doct:or blade 9. As the prefabric 1 passes between the nips of printing rolls 6 and 6l, the dye contairled in the intermittent relief patterns on the rolls is transferred to the prefabric. The dye penetration of the fabric can be adj~lsted by adjusting the pressure applied to the prefabric at the nip of the printing rolls.
If only one of the printing rolls 6 or 6' has the relief pat~ern of different depths, then only one dye supply would be requirecl and only one doctor blade would be needed.
The prefabric 1 which has passed thro~lgh the nip of printing rolls 6 and 6' has printed thereon an intermittent color pattern havin~ different tones of the color which was applied at the nip between the printing rolls. The prefabric then passes to the nip between printing rolls 15 and 15'. ~t the nip hetween printing rolls 15 and 15', a second color in two or more shades or tones is applied to the prefabric in an intermittent pattern. ])ye i5 supplied to printinc) roll 15 from dye trough 11 and excess dye :is lemoved from the surface of the printing ro:ll by doctor blade 12 which is a part of dye trough llo Lower printing roll 15~ rotates in a pool of dye in dye trough 14. ~he excess dye is removed from the surface of printing roll lS' by means of doctor blade 13. The surface of the roll is wiped substanticlLlv clean of dye and the dye is carried to the prefabric in the relief pattern formed on the printing ro:lls.
The matching pattern in roll 15' is of a slightly deeper depth than the relief pattern in roll 15 since t:he flow of dye from the relief pattern on the upper printing roll is assisted by the forces of gravity. The flow of dye Erom the relief pattern in roll 15' is retarded by the forces of gravity and therefore more dye is supplied to the lower roll than to the upper printing roll.
The prefabric 1 then passes from printinc3 station 30 to dye setting zone 16. Dye setting zone 16 is a chamber in which the prefabric is raised to an elevated temperature to set the dye and ~o partially set any crimps or loops which have been formed in the yarn.
The prefabric enters the dye setting zone 16 througl inlet 20, passes through the dye setting zone in a tortuous path over rollers 17. The tortuous path provides a sufficient amount of residence ~ime for th~
prefabric to reach the temperature of the gases in the dye setting zone and to pernlit the dye to set. Elea~ecl gases are admitted into the clye setting zone through inlet means 18 ancl are removed through outlet means 1 to provide a flow oE super heated steam or hot gase through the dye setting zone.
The dyed prefabric leaves the dye setting zonf-throuc3h out1et means ~1 and pass to a scol~r:ing, clryiIl~, unravell.ing and windup mearls to form the multicolorecI
intermittent.ly dyed yarn which is useful For forming fabrics, carpets, Icnitted goods and the like The straightening, dyeing, clye setting, scouring~ drying unravell;ng and windup means are not discussccI in detail herein since they are well known in the ar~ ancl Eorm no critical portion of the present invention.
The present inventioIl is the novel and unobvious confiyuration of the printinc3 rolls which permits the intermittent dyeing of the yarn in two or more shades or ~ones of the same color by one set oE printing rolls. The conformation and configuxation of tIle printing rolls is extremely useful since the number o:E
printinq stations in a printing stand can be substan-tially reduced when forming ~he multicolored intermittently dyed yarn of the present invention.
Figure 3 is a view in perspective of the essential features of the configuration of printiny rolls 6 and 6' in printing station 30. The essential features of the printing rolls 6 and 6' are shown without reyard to supporting structure or means for rotating the rolls or means to transport the prefabric between the nip o the rolls. Fa~ric printing machines are well known in the art and the supporting structure and operating means for the printing machine will not be cliscussed in detail herein since ~he present invent:ion is concerned with ~he form of the pattern carried by the printing rolls rather than any structure or operat::irI~3 means which aid them in carrying out their functioll~
Print.ing rolls 6 and 6' carry an intermittent rel:ief pattern on the rolls. ~s shown in Fiy. 3, the rel:ief pattern is formed as stripes in two depths which provide two differellt tones or shades to the 3~U~
color deposited on the ~refabric l. The relief pc~tte3n can be formec1 by engr~lvil1c~ or other means known in t~le art for forming relief patterns on printing rollsr In operation, the dye is deposited in relief patterns a and b on roll 6 Erom dye trough 7. Th* dye is removed f:rom the surface 25 of printing rol] 6 by means of doctor blade 8 shown as a part of dye trouyh 7. Doctor blade 8 can be a means separate from dye trough 7 but must perform the function of removing the excess ink from the surface 25 of printing roll 6.
Printing roll 6' revolves in a pool of dye present in dye tro~gh lO. The dye is deposited in the intermittent relief patterns a and b of roll 6' and the excess dye .is wiped from the surface 25 of printing roll 6 ' by doctor blade means 9. A doctor blade is shown in Fig. 3 but other means for eEfectively removing the excess dye from the surface of printing roll 6' may be utilized. Means for supplying dye to a relief pattern on a printing roll and removing the excess d~e rom the surface of the printing roll are well known in the art and means other than those shown can be efiect-ively employed in the process of the present invention.
As shown in Eig. 3, printing rolls 6 and S' have matching random patterns and contact the prefabrit l in registration to provide the intermit~ent color in sharp reyistration on the prefabric. The printing rolls 6 and 6' can be out of register to some degree and provide additional tones at the edges of the relie-f patterns on the prefabric. By providing a s~all degree of misregister of the printing rolls which should not exceed about 5 degrees, an interesting and visually pleasing effect can be imparted to the yarn.
As shown in lig. 3 rollc; 6 and 6' have matchil~(3 relief patterns on their sllrtace. I-lowever, the multiple tone effect. can t)e achi.eved if only one rol.l that i.s either 6 or 6 ' has the rel:ief pattern of diffe.r--ent depth. ~owever, it is preferred that -the printincJ
rolls have matching reliei patterns of vclrying depth.
The depth of the relief pattern on bottom printing roll 6' should be from about 2~ to about 35% cleeper than the matching portion of the relief pattern in upper roll 6. The difference in the depth of the relief pattern provides for more even tones to the pattern imprinted on the prefabric. However, if the printing rolls are in a vertical stand where the rolls are side by side the deE)th of the relief pattern in each roll should be the same.
lt is clear that more than two tones or shades oE
a color can be space-dyed on a prefabric or yarn by providing printing rolls having a relief pattern with more than two difEerent depths.
The dyes utilized in the process of the present invention are well known in the art of printing colors in fabrics and yarns and need not be described in detail herein. The dyes correspond to the colors required and should have physical properties which permit them to be retained in the relief pattern on the roll and to be readily -transferred to the prefabr:ic.
The invention has been set forth in sufficient detail for one skilled in the art to practice ttle invention. ~lowever many modifications of a minor natul.c can be utilized without afEectin~ the novel use of the printing rolls havin~ the relief patterns of different dept.hs thereon. The relief patterns can ~e provided by enc3ravin(3 or other means known to those skilled in the art.
METHOD FO~ PRODUCING SP~CE-DYED YARN
AND RESU~TING PRODUCT
The invention relates to an improved method for produciny space-dyed yarn and particularly to a method for producing yaxn space-dyed in different tones.
More particularly, khe invention relates to a method for producing space-dyed yarn dyed with different tones of the same color using only one set of printing rolls for each color.
It is ~nown that when a continuous yarn dyed in a multicolored pattern, in which the pattern is repea~ed frequently r is utili~ed to prepar~ a knitted, woven or tufted material, the finished article tends to develop undersirable striations or streaking. The phenomenon is particularly noticeable when multicolored yarn is utilized for preparing tufted carpeting o~ upholstery fabric.
To overcome the difficulty wi-th streaking, a te~hnique known as space-dyeing was developed to provide a yarn which was dyed with multiple colors but the pattern of the multiple colors is repeated at only long intervals along the yarn. The long intervals between repeating patterns prevented the development of streaking or striations in the finished article.
Gihson et al in U.S. Patent 3,605,225 discloses forming a woven fabric and then printing diagonal stripes of various colors on the fabric followed by disassembling the fabric by deweaving it to produce a multiplicity of multicolored yarns.
,,~
Gibson et al disclose that the process may be combined with pad dyeing to provide the yarn with an overall background color but even with this additional step, the number of colors which can be applied to the yarn is limited.
U.S. Patent 4,058,848 to Whitaker discloses a novel method for space dyeing a woven fabric wherein the fabric is prepared by utilizing a sacrificial filling which is dissolved after the s~ace dyeing opera-tion to recover the multicolored yarn.
Knitted tubing may be subjected to similar processes as disclosed in U.S. Patents 3,012,303, 3,543,359, 4,033,717, 3,701,315, 3,919,749 and 4,185,3~4.
The concept of psaced dyeing has been ap~lied to individual yarns as disclosed in U.S. 3,871,196 and U.S. 3,803,880.
It has also been disclosed to knit textile yarn into a tube and -to freely distribute dyes-tuffs onto the knitted tube in order to im~art various colors to the yarn. The tube is passed through rollers which press the tube flat and force differential migration of the dyestuff. The dyestuff is set, and the tube deknitted. However, the free distribution of the dye-stuff onto the knitted textile yarn presents a severe limitation to the number of colors which may be applied to the yarn and prohibits precise control of the specific areas and location to which the colors are applied. The method is disclosed in U~S. Patenk No.
3,828,405~
The prior art processes which space dye woven or knitted fabrics or space dye the individual yarns suffer from the disadvantage that not only are different printing rolls re~uired for different colors but different printing rolls are required for different tones or shades of a particular color. When a large number of colors and shades are re~uired in a multicolored yarn, the number of printing stations becomes large and the process becomes difficult to control and economically unattractive.
` It is the object of the present invention to provide a method for producing space dyed yarn wherein two or more tones or shades of a color can be applied to the yarn with one set Gf printing rolls.
BRIEF DESCRIPTION OF THE INVENTION
According to the present invention, space dyed yarns are ~repared by a process which comprises forming a prefabric from the yarn, providing two printing rolls to form a nip wherein at least one of said prin-ting rolls is provided with a relief pattern having at least two depths; filling the relief pattern with dye;
passing the prefabric through the nip of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones and recovering the space dyed yarn.
The pair of printing rolls can each contain a matching relief pattern one of which is the mirror image of the other, having portions of the relie pattern in different depths, so that when the dye is transferred from the relief pattern to the prefabric, the color is deposited in different tones or shades on the prefabric.
The tone or shade can further be contr~lled by registration of the matching patterns on the matching printing roll5. The deepest tones are producecl when the relief patterns are in exact registrat;on. When the relief patterns are sli~htly out of registratioll, the edges of the pattern show a gradation in ~one.
The prefabric may be passed serially thro~gh two or more sets of printing rolls where multiple colors in at least two tones for each color can be printed on the prefabric.
BRIEF l)ESCRIPTION OF TIIE DRAWINGS
FIGURE 1 is a diagrammatic representation of a preferred embodiment of the lnvention.
FIGURE 2 is a diagrammatic representation of the straightening, paddin~, printing and dye setting operations of the present invention.
FIGIJRE 3 is a perspective view of two printin~
rolls having matching patterns.
FIGURE 4 is the layout for the pattern of the two sets of matching printing rolls shown ln Fig. 2.
DETAILED DESCRIPTION OF TIIE lNVENTION
As llsed herein, space dyein~ refers to applyinc~
dye interlnittently to a yarn or fabric. Colored dyec;
may be applied intermittently to a fabric or yarn which has been dyed a solid color and the cdyes may be applied intermittently with some overlap of colors tc>
provide an additional cc~lor. q~h~ clye can ~ applied intermittently to an undyccl yarn or fabric and i:ne fabric subsequently overclyecl with a solid c~olc)r to provide a multicolored yarn.
The process of the present invention can be utilized to prepare space dyed yarns prepared from continuous multifilament or staple yarns. Yarns can be prepared from synthetic or na~ural materials.
Continuous multifilament or staple yarns prepared from nylon (polyamides), polyesters and acrylic polymers can be space dyed by the process of the present inven-tion. The process of the present invention can also be applied to yarn prepared ~rom natural materials such as cotton, wool, linen and the like. The space dyed yarns prepared according to the process of the present invention can be utilized to prepare cloth, upholstery fabric, carpeting (particularly tufted carpeting) and knitted goods. The space dyed yarn prepared according to the present invention overcomes the problem of streaking and provides colors in a mul~iplicity of tones or shades with a minimum of printing stations req~ired for the processO
Fic~3ure 1 is a diagrammatic representation of the preferred embodiment of a complete process of the present invention.
The yarn which is to be space dyed is formed into a prefabricO The prefabric can be in the form of a knitted sock such as disclosed in U.S. 3,701,315 or U.S. 3,012,303, can be formed from a woven fabric such as disc:losed in U.S. 4,0~5,34~3 or can be il~ the form of parallel strands of yarn haviny a tempOrAry entraillin~3 :~ ld.~ ?~
strand oE yarn woven int:o an array o~ warps ~s dis-elosed in U.S. 3,908,24~ ny c]oth-like array i-;
suitable for processiny in the present invention.
Ho~ever, a prefabric in the form of a knitt~d tube or sock has been ounc] to be particularly useful for space dyeing by the process of the present invention.
A knitted flat cloth suc~ as disclosed in ll.~,.
3,919,749 is also useful in the practice of t:he pres~nt invention. The prefabrics useful in the practice of the present invention are charaeterized in that they maintain the forrn of the prefabric as they proceed through the process but can be easily separated into the individual strands of yarn aEter the process has been completed. Methods for fabricating prefabrics useful in the proeess of the present invention are well known in the art and wi:Ll not be described further hereinO
The prefabrie is generally straightened to remove any wrinkles and kinks to insure that the fabric is lying flat so that it may be evenly clyed and printed in the proeess. When a knitted sock is utilizec~ as the prefabric, the straightening and levelling of the knitted soek can be readily accomplished by the use of lease rods.
The prefabric can be clyed an overall solid baekground eolor in a paddinc~ operation. The prefabric is eontaeted with the dye for a suffieient length of time for the fibers in the yarn to take up the requirecl amount of dye to provide the hackground color. The 3~ excess liyuid from the dye bath is then separated from the prefabric and the preabric is passed to the printing station.
Xt is preferred that the preFabric frolll the dyeing operation be damE) whell it is passecl through the printing stations. I'he dalllp prefabric is more receptive to the d~e applied from the printing rolls and the patl:ern can be applied in a more uniform manner.
The prefabric however need not first be dyed a solid background color. 'I'he preFabric can be overdyed after printing, can be left as a white background or can be dyed after being incorporated in-to a finished article. The overall dyeincl if used~ may be incorpoc-^
ated into the process to suit the requirements c~f the equipment available and ~he finished product required by the operator.
The prefabric is then passed to the printing station where the prefabric is passed through the nip of at least one pair of printing rolls and preferably at least two pairs of printing rolls. The pairs of printiny rolls have the desired intermittent pattern formed in relief on the face of at least one of the printing rolls. It is preferred that each pair of printing rolls have matching or mirror image patterns formed in relief thereon. In printing, the relief pattern on the printing roll is filled with dye, the excess dye removed from the outermost surface of the printing roll by means of a device such as a doctor blade and the dye transferred to the prefabric as it passes through the nip o~ the printing rolls. The excess dye is removed Erom the outermost surface of the printing roll to ensure that the dye contained in the relief pattern on the printing roll is transferred to the prefabric as it passes through the nip of the printing rolls and not from the outermost surface of the rolls.
Thc~ intermittent relief pattern on the prirltin~^~
rolls is ~ormed to differerlt deE)ths. q'he dif~erent deE)ths oF the relief pattern holding the dye provide, varying amounts of dye fc)r transfer to the prefabric at the point where the pattern is brought adj~cent to the prefabric at the nip of the rolls. Where the relief pattern on the printed roll is deepest) the largest amount of dye is transferred to the acljacent portion of the prefabric. By varyin~ the depth of the relief pattern, the dye can be transferred to the prefabric to Eorm different tones or shades oE a single color on the prefabric. The penetration ol- the dye into the prefabric can be controlled by the depth of the relief pattern at a particular point, the pressure of the rolls and where the rolls have matching patterns, the registration of the pattern on the rolls.
When the rolls of one prin~ing roll set have matching or mirror image patterns, registration of the patterns on the rol~s increases the penetration of the color. If the matchin~ rolls aré not in re~istration, the tone of the color at the edges of the pattern will be of different tone or shade than the portion where registration occ~rs.
The relief pattern is formed of an intermittent pattern at two or more depths. A pattern havin~ at least two different depths is necessary to provide at least two tones in the space-dyed printed pattern on the prefabric and yarn. ~ach portion of the relief pattern having a different clepth provides color c3eposited on the prefabric having a different tone or shade. The tone or shade of color can also be modi-fied by the combination of the color of the d~e prinled on the prefabric and an overa]l baclcgrounc] color to which the prefabric has been previousl~ dyed.
The relief pattern on the printin~ rol3s can be in any random form for depositing areas or splotches of dye on the prefabric as it passes thro~gh the nip of the printing rolls. However, it has been founcl preferable to provide a pattern in the form of stripes which are printed on the preEabric at an angle to the longitudinal axis of the prefabric. An angle oE from about 15 to about 40 with the longitudinal axis of the prefabric has been found to be suitable.
A flat layout of the pattern for two sets of printing rol;Ls which print different colors in differ-ent tones or shades is shown in Fig. 4. Rolls 6 and 6' show a striped pattern at an angle of abo~lt 30 with the longitudinal axis of the prefabric. The patt:ern contains relief portions oE two different depths noted by a and b. The relief portion area a is the shallowest portion of the pattern and would approximately correspond to a half tone printing plate.
Area b is greater in depth than area a. Area b is the deeper relief portion of the pattern and would therefore transfer the largest portion of the dye to the prefabric and therefore provide the darkest tone or shade. The mating roll can be plain but preferabLy has a pattern which is the mirror image of the pattern on the roll with which it mates.
The pattern for the rol~s 15 and 15' of the second printing station is a~so shown in Fig. 4. ~rhe pattern for the second printing station is in the forrn of stripes having relief areas d and e. Relief area d jc the' shallower clepth; rclief area e is the deeper relief portion ol~ lhe pat:tern. The pattern is in the form of stripes at an ancJle of about 30 with the lon~itudinal axis of the prefabric. The 30 angle with the longitudinal axis of the preabric is in the opposite direction from the angle at ~hich the pat:tern on rolls 6 and 6'was formecl. The patterns therefore cross each other on the printed prefabric. The matin~
roll can be plain or have a pattern which is a matching pattern or a mirror imacle oE the pattern O~ he roll with which it mates.
Since the stripes in the relief pattern on the two sets of printing ro]ls (6, 6' and 15, 15') are at different angles to the longitudinal axis of the pre-fabric, the stripes in the pattern when impressed onthe prefabric cross each otherO Since the patterns are of different colors, a third color is introduced into the prefabric at the point where the patterns over print each other. By this method, a third color can be printec~ on the prefabric by the use of only two prir-ting stations. In addition to the two or three colors introduced onto the prefabric, the three colors are in different tones or shades since the dye is t:ransferred to the prefabric in different amounts due to the different depths of the relief pattern and the amount of dye which can be held therein. The depth of the relieE pattern can vary from about 0.0005 inches to about 0.070 inches to provide the various tones ancl shades of color to thc? yarn in the prefabric. The depth of the relief pattern is also determined hy the denier of the yarn and the tone required.
'6 When the printin~3 stations are disposed horizorl-tally wi~h orle roll of a pair of printing rolls mountecl above the other, it is advantageous to form the matchin~
portions of the relief pattern in differe~t depths on the top and bottom rolls to insure printing the same tone or shade on the bottom and top surfaces of the prefabric. Gravity aids in transferrin~J the dye from the relief pattern on the upper roll to the prefabric and therefore the transfer of dye to the pre~abric occurs at a faster rate than ~rom the relief pattern on the lower roll. The relief pattern in the upper roll can therefore be formed to a slightly shallower depth than the matching relief pattern in the loweL
rol:L to obtain substantially the same tone transferrecl to the fabric. As an example, if the deep relief pattern in the upper roll has a depth of 0.016 inches, the depth of the matching pattern in the lower roll sho~ld be about 0.018 inches to insure transfer of a pattern of equal shade o. tone to the prefabric. I,ike--~ise, if the relief pattern in the upper roll has a depth of 0.004 inches, the depth of the pattern in the lower roll should be about 0.005 inches to insure that the tone or shade of the color transferred to the prefabric is about the same on both surfaces. This novel aspect of the invention is useful when the printin~
stations are disposed hori~ontally with one of the matched pair of printing rolls disposed above the other. If the printing stations are disposed vertical~y with the matchin~ printing rolls disposed side by side, the depth of the matchil-lg portions of the relie~' patterns should be the same.
The pressure applied to the printin~ rolls at:
the nip can be varied to modify the penetration of the 3~
dye illtO the prefabric. ln additiorl, the sh~cle anc~jor tone of the pattern cleposite(l on the pre~abric Ccln be varied to some extent by modifying the regis~ration of the matching patternC on the printing rolls. The deepest ~one or darkest shades are obtained when the matching patterns are in perfect registration. When the matching patterns are not in perfect registration, the edges of the patterns become blurred and the tone or shade of the color changes. The gradation o~ tone or shade can provide a pleasing effect to the yarn produced by the present process.
Although the printing rolls shown have a stripecl pattern which prints in dif~erent directions for the different printing stations or colors, other forms of intermittent patterns can be utilized in the present process. Irregular shapes, geometric forms, crosses, stars, random splotches, amoeba like forms, don~lt like profiles and the like may be utilized a~ the relief pattern on the printin~ rolls. A striped pattern can be engraved on two or more sets of printing rolls at the same angle so that the colored stripes on one set of printing rolls are printed in the vacant space hetween the stripes on another set of printing rolls.
The patterns can be varied by a combination of geometric or irregular figures to provide intermittently colored yarns and prefabrics ~ith interesting visual appearances. The patterns in two or more printing stations can be arranged so that portions of the patt:erns print over each other to form additional intermittent:
colors in the prefabric and the yarn produced by the process.
The prefabric leaving I:he printing stations proceeds to a means for settirlg the dye in the yarn.
The dye i5 l~SUally Get ~y confining the prefabric in heated zone where the pre~abric is heated hy steam or dry yases. In the heating zone, the dye is set and any loops or crimps irnparted to the yarn in making the prefabric can be partially set in the yarn~
After the dye is set, the prefabric is passed through a scouring and drying zone wherein the prefabric is washed and dried. In the washing or scouring ~one, the prefabric is contacted with water or so~ne other solvent to remqve the dye materials which have not been set in the prefabric. In addition, conditioning agents can be imparted to the prefabric to improve the hand, lubricity or other properties of the yarn.
The washed and dried prefabric is then passe~
to a zone wherein the yarn is recovered and wound on bobbins, spools or the like. If the prefabric has been knitted in the form of a tube or sock, the prefahlic is unravelled to recover the yarn and the yarn is wound on a supporting means which can be transferred to a process in which the yarn is utilized. If the prefabric is of a woven type, the weft is removed and individucll warp yarns recovered on a windup means and support.
The yarn prepared according to the process o~
the present invention has imparted thereto colors in a ranclom intermittent pattern wherein each color is present in at least two shades or tones on the yarn.
Fiyure ~ is a diagrammatic representation showing some of the major operations which can he combined with the multip]e tone printing rolls to provide the intermittently dyed multicolored ~pace dyecl yarn oi: the presenl: invellt-ioll.
As shown in ~ig. 2, prefat)ric 1 which can b~
in the form of a woven cloth, a knitted cloth or l:u~e is straightened by pa~-~ing over lease rods 2 wherein S wrinkles or kinks in the prefabric are removed. I'he straightene(~ and level prefabric passes into pac~di.ng bath 4 and proceeds through the battl over ro~.e:rs or rods 3 in a tortuous pat:h~ The tortuous path provide:;
a sufficient residence time of the prefahric i.n the dye bath to provide the color required. The overall solid background color i.mparted to the yarn alld pre-fabric in the pad~ing bath can be controlled by ad-justing the concentration of dye in the padding bath and the length of time which the yarn or prefabric is in contact with the dye solution in the bath. rrhe prefabric 1 passes between the nip of padding rollers 5 wherein the excess dye is moved from the prefabric.
The wet prefabric thell proceecls to printing station 30 where it passes between the nip of printing rolls 6 and 6' and 15 and 15'. Printing rolls 6 and 6' have matching intermittent patterns in relie~ on their surface. Relief patterns can be formed by known means such as engraving, rotogravure and the like. It is essential however that relief patterns be formecl at at least two different depths on the rolls. Since the rolls as shown .in printing station 30 are on a horizorl-tal stand, to ensure even color tones and hues on both sides of the prefabric, the matching portions of the pattern in the lower roll 6'should be slightly deeper than the ~quivalent portioll of the matching pattern ir ~pper roll 6. The slight differences in depth of the relief pattern is necessary to ensure even tones from 6~
the upE~er prillting roll ancl the lower prirltin(~ rol,l since the fLow of dy~: Erom the uE~per print-,ing roll is assistecl by the effects of gravity and therefore permeat~;
the prefabric at a Easter rate than the dye held in the relieE pattern on the lower roll.
The upper printing roll 6 is supplied with dye from dye trough 7. The excess ink from the ~ rfa~e o~
printing roll 6 is removed by doctor blade 8 which is a part of dye trough 7. The doctor blade 8 removes lQ the dye from the surface of printing roll 6 and leaves the relief portions of the pattern filled with dye.
Lower prin~ing roll 6' rotates in a pool of clye con-tained in a dye trough ~0. The excess dye is removec1 from the surface of the printing roll by doct:or blade 9. As the prefabric 1 passes between the nips of printing rolls 6 and 6l, the dye contairled in the intermittent relief patterns on the rolls is transferred to the prefabric. The dye penetration of the fabric can be adj~lsted by adjusting the pressure applied to the prefabric at the nip of the printing rolls.
If only one of the printing rolls 6 or 6' has the relief pat~ern of different depths, then only one dye supply would be requirecl and only one doctor blade would be needed.
The prefabric 1 which has passed thro~lgh the nip of printing rolls 6 and 6' has printed thereon an intermittent color pattern havin~ different tones of the color which was applied at the nip between the printing rolls. The prefabric then passes to the nip between printing rolls 15 and 15'. ~t the nip hetween printing rolls 15 and 15', a second color in two or more shades or tones is applied to the prefabric in an intermittent pattern. ])ye i5 supplied to printinc) roll 15 from dye trough 11 and excess dye :is lemoved from the surface of the printing ro:ll by doctor blade 12 which is a part of dye trough llo Lower printing roll 15~ rotates in a pool of dye in dye trough 14. ~he excess dye is removed from the surface of printing roll lS' by means of doctor blade 13. The surface of the roll is wiped substanticlLlv clean of dye and the dye is carried to the prefabric in the relief pattern formed on the printing ro:lls.
The matching pattern in roll 15' is of a slightly deeper depth than the relief pattern in roll 15 since t:he flow of dye from the relief pattern on the upper printing roll is assisted by the forces of gravity. The flow of dye Erom the relief pattern in roll 15' is retarded by the forces of gravity and therefore more dye is supplied to the lower roll than to the upper printing roll.
The prefabric 1 then passes from printinc3 station 30 to dye setting zone 16. Dye setting zone 16 is a chamber in which the prefabric is raised to an elevated temperature to set the dye and ~o partially set any crimps or loops which have been formed in the yarn.
The prefabric enters the dye setting zone 16 througl inlet 20, passes through the dye setting zone in a tortuous path over rollers 17. The tortuous path provides a sufficient amount of residence ~ime for th~
prefabric to reach the temperature of the gases in the dye setting zone and to pernlit the dye to set. Elea~ecl gases are admitted into the clye setting zone through inlet means 18 ancl are removed through outlet means 1 to provide a flow oE super heated steam or hot gase through the dye setting zone.
The dyed prefabric leaves the dye setting zonf-throuc3h out1et means ~1 and pass to a scol~r:ing, clryiIl~, unravell.ing and windup mearls to form the multicolorecI
intermittent.ly dyed yarn which is useful For forming fabrics, carpets, Icnitted goods and the like The straightening, dyeing, clye setting, scouring~ drying unravell;ng and windup means are not discussccI in detail herein since they are well known in the ar~ ancl Eorm no critical portion of the present invention.
The present inventioIl is the novel and unobvious confiyuration of the printinc3 rolls which permits the intermittent dyeing of the yarn in two or more shades or ~ones of the same color by one set oE printing rolls. The conformation and configuxation of tIle printing rolls is extremely useful since the number o:E
printinq stations in a printing stand can be substan-tially reduced when forming ~he multicolored intermittently dyed yarn of the present invention.
Figure 3 is a view in perspective of the essential features of the configuration of printiny rolls 6 and 6' in printing station 30. The essential features of the printing rolls 6 and 6' are shown without reyard to supporting structure or means for rotating the rolls or means to transport the prefabric between the nip o the rolls. Fa~ric printing machines are well known in the art and the supporting structure and operating means for the printing machine will not be cliscussed in detail herein since ~he present invent:ion is concerned with ~he form of the pattern carried by the printing rolls rather than any structure or operat::irI~3 means which aid them in carrying out their functioll~
Print.ing rolls 6 and 6' carry an intermittent rel:ief pattern on the rolls. ~s shown in Fiy. 3, the rel:ief pattern is formed as stripes in two depths which provide two differellt tones or shades to the 3~U~
color deposited on the ~refabric l. The relief pc~tte3n can be formec1 by engr~lvil1c~ or other means known in t~le art for forming relief patterns on printing rollsr In operation, the dye is deposited in relief patterns a and b on roll 6 Erom dye trough 7. Th* dye is removed f:rom the surface 25 of printing rol] 6 by means of doctor blade 8 shown as a part of dye trouyh 7. Doctor blade 8 can be a means separate from dye trough 7 but must perform the function of removing the excess ink from the surface 25 of printing roll 6.
Printing roll 6' revolves in a pool of dye present in dye tro~gh lO. The dye is deposited in the intermittent relief patterns a and b of roll 6' and the excess dye .is wiped from the surface 25 of printing roll 6 ' by doctor blade means 9. A doctor blade is shown in Fig. 3 but other means for eEfectively removing the excess dye from the surface of printing roll 6' may be utilized. Means for supplying dye to a relief pattern on a printing roll and removing the excess d~e rom the surface of the printing roll are well known in the art and means other than those shown can be efiect-ively employed in the process of the present invention.
As shown in Eig. 3, printing rolls 6 and S' have matching random patterns and contact the prefabrit l in registration to provide the intermit~ent color in sharp reyistration on the prefabric. The printing rolls 6 and 6' can be out of register to some degree and provide additional tones at the edges of the relie-f patterns on the prefabric. By providing a s~all degree of misregister of the printing rolls which should not exceed about 5 degrees, an interesting and visually pleasing effect can be imparted to the yarn.
As shown in lig. 3 rollc; 6 and 6' have matchil~(3 relief patterns on their sllrtace. I-lowever, the multiple tone effect. can t)e achi.eved if only one rol.l that i.s either 6 or 6 ' has the rel:ief pattern of diffe.r--ent depth. ~owever, it is preferred that -the printincJ
rolls have matching reliei patterns of vclrying depth.
The depth of the relief pattern on bottom printing roll 6' should be from about 2~ to about 35% cleeper than the matching portion of the relief pattern in upper roll 6. The difference in the depth of the relief pattern provides for more even tones to the pattern imprinted on the prefabric. However, if the printing rolls are in a vertical stand where the rolls are side by side the deE)th of the relief pattern in each roll should be the same.
lt is clear that more than two tones or shades oE
a color can be space-dyed on a prefabric or yarn by providing printing rolls having a relief pattern with more than two difEerent depths.
The dyes utilized in the process of the present invention are well known in the art of printing colors in fabrics and yarns and need not be described in detail herein. The dyes correspond to the colors required and should have physical properties which permit them to be retained in the relief pattern on the roll and to be readily -transferred to the prefabr:ic.
The invention has been set forth in sufficient detail for one skilled in the art to practice ttle invention. ~lowever many modifications of a minor natul.c can be utilized without afEectin~ the novel use of the printing rolls havin~ the relief patterns of different dept.hs thereon. The relief patterns can ~e provided by enc3ravin(3 or other means known to those skilled in the art.
Claims (24)
1. A method for space dyeing a yarn which comprises:
a) providing a prefabric from the yarn to be space dyed;
b) providing two printing rolls to form a nip, wherein at least one of said printing rolls is provided with a relief pattern having at least two depths;
c) filling the relief pattern with dye;
d) passing the prefabric through the nip of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones;
and e) recovering the yarn.
a) providing a prefabric from the yarn to be space dyed;
b) providing two printing rolls to form a nip, wherein at least one of said printing rolls is provided with a relief pattern having at least two depths;
c) filling the relief pattern with dye;
d) passing the prefabric through the nip of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones;
and e) recovering the yarn.
2). The method of claim 1 wherein the two printing rolls have matching relief patterns.
3. The method of claim 2 wherein the depths of the matching relief patterns in the two printing rolls are different.
4. The method of claim 1 wherein the prefabric is serially passed through the nip of at least two sets of printing rolls whereby at least two colors are space dyed on the prefabric.
5. The method of claim 2 wherein the prefabric is serially passed through the nip of at least two sets of printing rolls whereby at least two colors are space dyed on the prefabric.
6. The method of claim 3 wherein the prefabric is serially passed through the nip of at least two sets of printing rolls whereby at least two colors are space dyed on the prefabric.
7. The method of claim 2 wherein the matching relief patterns on the printing rolls are in registration.
8. The method of claim 3 wherein the matching relief patterns on the printing rolls are in registration.
9. The method of claim 4 wherein at least one of said sets of printing rolls has matching patterns which are in registration.
10. The method of claim 4 which comprises:
a) preparing a prefabric from the yarn to be space dyed;
b) passing the prefabric through a dyeing zone containing an aqueous dyeing medium to provide a pre-fabric with a solid background color;
c) passing the wet prefabric through the nips of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones by each set of rolls;
d) setting the dye;
e) scouring and drying the prefabric;
f) unravelling the prefabric; and winding the yarn on a support means.
a) preparing a prefabric from the yarn to be space dyed;
b) passing the prefabric through a dyeing zone containing an aqueous dyeing medium to provide a pre-fabric with a solid background color;
c) passing the wet prefabric through the nips of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones by each set of rolls;
d) setting the dye;
e) scouring and drying the prefabric;
f) unravelling the prefabric; and winding the yarn on a support means.
11. The method of claim 4 wherein the prefabric is in the form of a knitted sock.
12. The method of claim 7 wherein the prefabric is in the form of a knitted sock.
13. The method of claim 5 wherein at least one of said sets of printing rolls has matching patterns which are in registration.
14. The method of claim 5 which comprises:
a) preparing a prefabric from the yarn to be space dyed;
b) passing the prefabric through a dyeing zone containing an aqueous dyeing medium to provide a pre-fabric with a solid background color;
c) passing the wet prefabric through the nips of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones by each set of rolls;
d) setting the dye, e) scouring and drying the prefabric;
f) unravelling the prefabric; and winding the yarn on a support means.
a) preparing a prefabric from the yarn to be space dyed;
b) passing the prefabric through a dyeing zone containing an aqueous dyeing medium to provide a pre-fabric with a solid background color;
c) passing the wet prefabric through the nips of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones by each set of rolls;
d) setting the dye, e) scouring and drying the prefabric;
f) unravelling the prefabric; and winding the yarn on a support means.
15. The method of claim 5 wherein the prefabric is in the form of a knitted sock.
16. The method of claim 14 wherein the prefabric is in the form of a knitted sock.
17. The method of claim 6 wherein at least one of said sets of printing rolls has matching patterns which are in registration.
18. The method of claim 6 which comprises:
a) preparing a prefabric from the yarn to be space dyed;
b) passing the prefabric through a dyeinq zone containing an aqueous dyeing medium to provide a pre-fabric with a solid background color;
c) passing the wet prefabric through the nips of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones by each set of rolls;
d) setting the dye;
e) scouring and drying the prefabric;
f) unravelling the prefabric; and winding the yarn on a support means.
a) preparing a prefabric from the yarn to be space dyed;
b) passing the prefabric through a dyeinq zone containing an aqueous dyeing medium to provide a pre-fabric with a solid background color;
c) passing the wet prefabric through the nips of the printing rolls to transfer dye from the relief pattern to the prefabric in at least two tones by each set of rolls;
d) setting the dye;
e) scouring and drying the prefabric;
f) unravelling the prefabric; and winding the yarn on a support means.
19. The method of claim 6 wherein the prefabric is in the form of a knitted sock.
20. The method of claim 18 wherein the prefabric is in the form of a knitted sock.
21. A space dyed yarn having intermittent portions dyed in shades of a single color.
22. The product of the process of claims 4, 5 or 6.
23. The product of the process of claims 7 or 8.
24. The product of the process of claims 10, 14 or 18.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US19242280A | 1980-09-29 | 1980-09-29 | |
| US192,422 | 1980-09-29 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1181606A true CA1181606A (en) | 1985-01-29 |
Family
ID=22709582
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000384829A Expired CA1181606A (en) | 1980-09-29 | 1981-08-28 | Method for producing space-dyed yarn |
Country Status (3)
| Country | Link |
|---|---|
| CA (1) | CA1181606A (en) |
| DE (1) | DE3127154A1 (en) |
| GB (1) | GB2084515A (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6120560A (en) * | 1999-03-08 | 2000-09-19 | Milliken & Company | Process and apparatus for pattern dyeing of textile substrates |
-
1981
- 1981-07-09 DE DE19813127154 patent/DE3127154A1/en not_active Ceased
- 1981-07-17 GB GB8122091A patent/GB2084515A/en not_active Withdrawn
- 1981-08-28 CA CA000384829A patent/CA1181606A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| DE3127154A1 (en) | 1982-05-13 |
| GB2084515A (en) | 1982-04-15 |
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| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |