CA2129960A1

CA2129960A1 - Method and apparatus for dyeing carpet

Info

Publication number: CA2129960A1
Application number: CA002129960A
Authority: CA
Inventors: Benjamin Franklin Fuller
Original assignee: Individual
Current assignee: Individual
Priority date: 1992-02-14
Filing date: 1992-12-01
Publication date: 1993-08-19
Also published as: KR950700450A; AU3236993A; JPH08500397A; EP0626021A1; WO1993016224A1; AU682303B2

Abstract

2129960 9316224 PCTABS00025 A method and apparatus which utilizes a novel dye solution for dyeing carpet in which the dye solution is heated to a temperature higher than the boiling point of water thus allowing fixation of the dye on the carpet without the need for a steam fixator.

Description

WOg3/16~24PCT~U~92/tO443 1- 2l`~!996~

MET~OD A~D APPARATUS ~OR DYEI~G CARPET

sAc~GRouND OF THE INVE~TION
Fiela of the Inve~tion This invention relates to the dyeing of carpets and, more particularly, ~o a method and apparatus for dyeing carpets which, through the use of a dye bath which has a much higher boiling point than water, does not require the steaming o~ the carpet to set or fix the dye 10 to the carpet.
Prior Art Currently known and used methods and apparatuses for dyeing carpet require the steaming of the carpet to set or fix the dye to the carpet after the dye has been 15 applied to the carpet. For e~ample, the typical carpet dyeing method and apparatus involves the application of a dye to the pile surface of the carpet, fixing the dye onto the carpet pile by steaming and then subjecting the carpet to ~arious other finishing procedures prior to drying the 20 carpet.
Once such conventional carpet dyeing process is disclosed in V.S. Patent No. 4,101,270. This paten~
discl~ses a method for dyeing carpet which includes the teps of advancing a continuous textile web through a 2S pre~hrinking station, moistening the te2tile web, dyei~g the textile web using applicator rolls and~or dye ;~ applicators, and then fixing the dye onto the textile web by passage through, for example, a chamber containin~
steam. This basic method generally forms the base for th~
30 other prior art carpet dyeing systems and is well known -in the art.
Likewise, a second e2ample of a carpet dyeing process including a steam fi2ator is disclosed in U.S.
Patent No. 4,771,4g7. This patent discloses a process for 35 the continuous treatment of a te~tile web material W0~3/1622~ PCT/U~92/1~3 ~ 12 9 g~U~ 2 -involving the application of a dye to the pile surface of the carpet and then initiating the dye fi~ation onto the pile surface by steaming. Many of the prior art patents such as the two disclosed above involve such a steam 5 fi~ation process and are distinguishable from each other by various additional, optional processes added onto this base dyeing technique.
The patent issued to Walter, U.S. Patent No.

2,387,200, discloses and claims a method for dyeing 10 material which is carried out in a sealed chamber, namely a closed chamber incorporating compressed air and saturated steam. The ~200 method is carried out at a temperature substantially above 212F and under pressure.
Therefore, the '200 method incorporates by its nature a 15 steam figation step as when the material emerges from the dye bath which is heated substantially above 212F, it encounters co~pressed air and saturated steam under pressure, which is the equivalent of a steam fi~ation step. The apparatus of the present invention is not a 20 closed or sealed chamber, but is open to the atmosphere, and does not use water-based dye baths or steam, thus eliminating the steam fixation step which can cause uneven dyeing and running of the dye. Further, the use of an open chamber and lower overall temperatures, namely 25 typically between 212F and 2~0~F, allows the present invention to be much more economical in terms of energy costs and apparatus material costs.
The method disclosed in the '200 patent also does not comprise a separate, independent material preheatin~
30 step, nor the means for carrying out such a separate, independent material preheating step. The material to be dyed in the '200 method is introduced to the pressure chamber and almost immediately submerged into the dye bath. Although the material to be dyed encounters 35 elevated temperatures upon being introduced to the WO~3/162~4 PCT/US92/1~3 2 12 9 9 ~ S ~ '~

pressure chamber, no specific control or methodology is present to constitute a preheating step or means. In the present invention, a separate, independent preheating step accomplished by a separate, independent preheating means 5 is carried out on the material to be dyed prior to the introduction of the material to be dyed to the main dye bath. The controlled preheating of the material to be dyed to a temperature near or at the tempe~ature of the dye bath helps to reduce the dye application time and the 10 heat loss from th~ dye bath which would occur if the material to be dyed needed to be heated to the temperature of the dye bath during the dyeing process. Such a separate, independent preheating step and means, which may utilize the same heat source as the dye bath, has economic 15 advantages over prior art processes, such as that ;~ disclosed in the '200 patent.
The patent to von der Eltz et al., U.SO Patent No. 3,986,831, discloses and claims a high temperature, high pressure batch process for dyeing materials which 20 incorporates a pressure vessel and high-pressure steam fixation. The '831 apparatus and method operate in an essentially air-free environment. Further, the dye fi~ation dis~losed in the '831 patent occurs at a temperature over about 255F, creating the need for 25 significant energy input. Likewise, the patent to Blount, V.S. Patent No. 3,418,065, discloses and ~laims a high temperature, h_gh pressure batch process which also is carried out in a sealed pressure chamber not open to the atmosphere and which incorporates a steam fixation step 30 On the c -~rary, the present process and apparatus are open to t l'mosphere and do not involve the use of ste~
or steam ~ ition. The present process is a continuou process which is carried out on a continuous-running apparatus. Further, the entire process of the present 35 invention can occur at a temperature of between 212F and WO93/16224 PCT/US92/1~3 212g960 ~ 4 -about 240F, significantl:y reducing the energy costs and the apparatus costs.
The disadvantages of such prior art carpet dyeing methods and apparatuses which incorporate steam fixation 5 components is the necessity for the steam fi~ation step.
Steam fi~ation has several disadvantages including the need for a tremendous amount of energy required to heat the steam, dilution of the dye as the steam condenses into water and mi~es with the dye, and the cost of the lQ equipment, both in material and time, needed to have a steam fixation step in the carpet dyeing process. A
further disadvantage is that a carpet dyeing process including a steam fixation step is uneconomical to operate when dyeing small batches of carpet.
The development of the open-to-the-atmosphere process and apparatus also allows for the dyeing of materials at significantly lower energy costs and with a higher degree of safety. Less energy is necessary as there are no materials to be superheated and no pressure 20 needs to be created. Materials costs are reduced as vessels open to the atmosphere typically do not need the reinforcing required for a pressure vessel. Lastly, pressure operations typically inherently are more dangerous than an equivalent atmospheric operation.
SUMMARY OF THE I~VENTION
In accord with this invention, a more efficient, less costly carpet dyeing method and apparatus is disclosed. This invention may be used to dye carpets as 30 well as all types of yarns, fibers, woven fabrics, kni-ts ~;~ and other fabric type materials made from, for example, nylon, polyester, wool, cotton, rayon and acrylics This inv~ntion continuously dyes carpet without steaming by the use of a high temperature dye bath, fed at a specific 35 temperature and flow rate to an applicator, in which the WO93J16224 PCT~US92/1~M3 ~ 5 ~ 2 1a 9 ~ 6~

level and the temperature of the dye are controlled.
This invention comprises a novel dye bath applicator which effects the carpet dyeing and fixing step by utilizing a high temperature dye mixture, the 5 temperatuxe of which is higher than the boiling point of water. The apparatus of this invention is open to the atmosphere and does not constitute a pressure vessel in the sense disclosed in prior art dyeing apparatuses. By eliminating the need for pressure vessel-type couplings 10 and materials, the apparatus of this invention is both much less costly and safer to operate. The appara~us of this invention also generally comprises a preheater which effects the preheating step, a heated mix tank which effects the heating step of the dye and chemicals, a heat 15 e~change{ which effects the step of heating the dye prior to the dye entering the applicator a vacuum e~tractor which effects the step of recovering the excess dye and returning it to the heat exchanger, and wash boxes with overflows which effect the step of neutralizing the pH of 20 the carpet and washing the carpet before the carpet enters the drying stage.
This invention eliminates the need for a steam f~ator by preheating the dye to a temperature above the boiling point of water and applying it to a preheated 25 te~tile web. A unique mi~ture of chemicals allows the dye ; to be heated above the boiling point of water in this invention such that the dye is fixed onto the carpet pile during the dyeing step, therefore eliminating the need for a steam fixator after the dye application step.
There are numerous advantages to the novel met-hod and apparatus of this invention. Some of these advantage~
include the elimination of any steam necessary in the dye fixation process, the elimination of the need for gum or thickeners, the elimination of the need for defoamers, and 35 the reduction in the amount of pollutants emanating from WO93/16224 PCT/US92/1~3 ~ ~ 6 -the system. Other advantages include ~he elimination of dye or chemical waste, no increase in chemical and dyestuff content, and the need for less water usage in the system, which water can be recycled. Further advantages 5 of this invention include a more uniform dye application to the carpet from the side to the center to the side of the carpet, better carpet definition, a less expensive dye machine, and the need for less dye space for the dye applicator.
Many conventional dye applicators or machines can be converted inexpensively to the method and apparatus of the present invention. Additionally, the method and apparatus of the present invention can dye a single strand of carpet yarn or a twelve foot (12') wide piece of carpet 15 or wider, or any carpet size in-between, in a level configuration. It also is economical to dye small dye ; lots in the present invention as the dye beck time is ~ reduced significantly compared to the prior art.
- Furthermore, the preheater used in this invention is 20 heated from the heating system used to heat the dye bath applicator, thus saving significantly on heating costs throughout the system.
Accordingly, it is an object of the present invention to provide a carpet dyeing method and apparatus~
25 which eliminates the need for a steam fixation apparatus and step.
It is another object of the present invention to provide a carpet dyeing method and apparatus which has lower costs than conventional carpet dyeing methods anc1 30 apparatuses, including lower power costs, lower machine costs, lower materials costs, and lower operating cnsts.
It is a further object of the present invention to provide a carpet dyeing method and apparatus which eliminates the need for gums, thickeners, and defoamers.
It i5 yet another object of the present invention WO93/16224 PCT/US~ 3 to provide a carpet dyeing method and apparatus which has no dye or chemical wastes and has no increase in chemical and dyestuff content.
It is still another object of the present 5 invention to provide a carpet dyeing method and apparatus which gives a more uniform dye application from side to center to side and which gives better carpet definition.
It is a still further object of the present invention to provide a carpet dyeing method and apparatus 10 which utili~es a less expensive dye machine, takes up less floor space for the dye applicator and uses less water and recycles the water which it uses.
It is another object of the present inven~ion to provide a carpet dyeing method and apparatus which can dye 15 a single strand of carpet yarn all the way up to a twelve foot (12'~ wide or wider piece of carpet and which is economical to operate when dyeing small dye lots.
It is yet another object of the present invention to provide a carpet dyeing method and apparatus in which 20 the preheater is heated from the heater unit used to heat the dye bath appli~ator.
It is also an object of the present invention to provide a unique dye solution which can be heated above the boiling point of water and can be figed to a te~tile ~; 25 web without the need for steam fi~ation.
These and other objects of the invention will become apparent to those skilled in the art upon reading the following detailed description of the invention taken in conjunction with the following drawing in which like 30 characters of reference correspond to like parts.

BRIEF DESSRIPTION OF THE DRAWI~G
Fig. 1 is a schematic of the method and apparatus of the present apparatus.

WO93/16224 PCT/US92/1~3 21`~9~1~0 ~ 8 - `

DETAILED DESCRIPTION OF A PR~FERK~D EM~ODIME~T
A general schematic of the method and apparatus of the present invention showing the various components necessary to carry out this method is shown in Fig. l. In 5 general, this invention, using a novel dye solution comprising dye, various chemicals as dye assistants and water, utilizes a dye solution which has a much higher boiling point than water. This higher boiling point dye solution is used as a bath to dye carpet. This bath is l0 the main aspect that makes this invention unique from conventional methods of dyeing carpet. The term carpet is used in this disclosure to cover all fabrics, yarns and textile webs and is not meant to be limited to conventional carpeting as known in the art.
15In this invention, carpet is colored by the dye in the higher boiling point bath. The higber boiling ; point dye bath allows the dye to be fixed to the carpet at that step, thus eliminating the need for a steam fi~ator.
Additionally, the higher boiling point bath is heated in a 20 novel and unique way as compared to the method for heating conventional dye baths. For example, the bath is heated by electric coils or elements or, alternatively, wîth an enclosed steam system to a temperature greater than the bo;ling point of water, a temperature which cannot be ZS obtained in conventional systems. The method of heating ~j:
also provides a more direct heat source.
The presence of a steam fixator causes a dilution of the dye solution. Therefore, the elimination of the steam fixation step also is important to the inventiol-30 because the dye solution contains a given concentration ofdye, chemicals, and water and any dilution of this solution may affect both the coloring of the carpet and the ability of the dye to be heated above the boiling point of water. As the carpet leaves the dye bath, the

3~ carpet is squeezed to remove excess dye, which dye is :::
~::

4 PCT/US92/1~3 9 21~60 ~

recycled to the dye bath. Then the carpet enters a cold water bath in which the dyeing process is stopped or fixed. Once the dye is fixed, normal variations in color in the carpet from side to center to side do not occur, as

5 is common in continuous dyeing with a s.team fixation step. ~he carpet is then rinsed in one or more wash boxes with overflow.
Referring now to Fig. 1, the dye solution utilized in this invention is stored in a dye vat 26. The 10 dye solution utilized in this invention is a unique mixture of specific dyes, chemicals and water. In general, dye solutions are formed by dissolving dyes in a portion of the water to be used in the dye bath 18.
Dyeing assistants and an acid to control the pH of the dye 15 solution then are dissolved in t.he balance of the water to be used in the dye bath 18. ~,he dissolved dye and the ~: dyeing assistants and acid then are combined and mixed .
with a quantity o~ glycol. The glycol increases the . boi~ing point of the dye solution to a temperature above 20 the boiling point of water. This dye solution is heated to a temperature just below the boiling point ~f the dye solution, which, due to the mixture of components in the dye solution, is higher than the boiling point of water~
and is applied to the carpe~ 10 in the dye bath applicator 25 unit 17, as d~scribed more fully below.
Many mi~tures of dye, chemicals and water may be made depending upon the dye desired. Useful dyes include, for example, acid dyes, disperse dyes, direct dyes, basic dyes, vats dyes, fiber reactive dyes, and any other dy!es 30 that can be applied hot to a substrate. Two examples of ~ representative dye solutions are as follows:

:

WO93/16224 PCT/US92/1~3 2129960 f ~.. , 3'~ ~r - lO

E~LE 1 ComPone~t Percent bY W~i~ht Grams/Lite S Dyes (selected acid dyes) XX.X X.XX
Benzyl ~lcohol (747-Alcohol, DEG Glycol, Anonic and Nonic Surfactant) 0.2 2.00 Fulgen SDM (Etho~ylated C12-C15 Primary Alcohol and Coconut Condensate) 0.2 2.00 15 Sulfamic Acid, 15% sol. 1.0 10.00 Water 23.5 31~.00 Subtotal of Dye 2~.0% 330.00 Diethylene Glycol (sp.
gr. 1.12) or other types of Glycol 75.0 670.0Q
25 TOTAL 100.0% 1000.00 As described above, the selected acid dyes are first dissolved in a portion of the 316.00 g ~or 316 ml) of water great enough to allow for the dissolution of the 30 dyes. The dyeing assistants, such as benzyl alcohol and ~ulgen SDM, and an acid to control pH, such as sulfamic acid, are then added to the dye/water mixture. These then ~ , are combined and mi~ed with the diethylene glycol or other glycol, which previously has been mi~ed with the remainder 35 of the 316.00 g of water, to form the dye solution. The boiling point of this specific dye solution is approximately 228-230F. This specific dye solution is particularly useful for nylon tufted carpet or other nylon abrics.

'~

WO93/16224 PCT/US92/1~3 212g960 E~MPLE 2 ComponentsPer~ent by Weiaht Grams/Lite r 5 Dyes XX.X X.X
Fulpon GP (Potassium Salt of Etho~ylated Phosphate Alcohol)(Phosphated DA-43 0.2 ~.0 Water 10.0 130.0 Fulpal ME Anionic Surfactant (P-NP-9) 0 5 5.0 Sulfamic Acid, 15% sol. 0.5 5.0 Water 1~.8 188.0 20 Subtotal of Dye 25.0~ 330.0 Diethylene Glycol or other ~ ~lycol ~5.0 -~70-Q
:: 25 TOTA~ 100.0% 1000.0 As in E~ample 1, the dye first is dissolved in a : portion of the water great enough to allow for the dissolution of the dye. The water for this specific dye ;~ 30 should be hot and a dispersing agent, such as the Fulpon P,~ generally is needed to assist in complete di~solution. A leveling agent, such as Fulpal ME, and an acid to control the pH, such as sulfamic acid, is then added to the dye/water mixture. This solution is combined .
3~ and mixed with a glycol, which pre~iously has been mi~ed with the remainder of the water, to increase the boiling point of the dye solution. The boiling point of this specific dye solution also is approximately 228-230F.
This specific dye solution is particularly useful for 40 polyester carpet or other fabrics.
Any glycol which allsws heat transfer is suitable for the dye solution. The appropriate dying assistants are selected so as to complement the fiber being dyed.

WO93/16224 PCT/US9?/1~3 2 1 2 9 a ~ 12 That is, certain fibers dye better when certain dyeing assistants are used, as is known in the art. Anionic, nonionic, cationic, wetters, levelers, and retarders are all suitable dyeing assistants which are chosen according 5 to the fiber being dyed. Although most any acid is appropriate to add to the dye solution, the most suitable acids include formic, sulfamic, citric, acetic and phosphoric, as well as acid generators.
The carpet, indicated generally by carpet roll 10 10, first enters a preheater 14 before it enters the dye bath applicator unit 17. The preheater 1~, which generally is an extension of the dye bath applicator unit 17, generally comprises an entrance door 12, a preheating chamber 13 and transport rollers 16. The entrance door 12 15 generally is a spring loaded door, or a door with one way hinges, opening toward the interior chamber 13 of the ~ ~ :
prehea~er so as to minimize heat loss from the preheating chamber 13 through the door 12 into the atmosphere. The ; preheater 14, as well as the entire dye bath applicator 20 unit 17, is open to the atmosphere. Door 12, being a ~ spring loaded door, and e~it rollers 34, to keep the -~ carpet 10 travelling through the apparatus, do not create a pressure seal. Additionally, the dye bath applicator , . .
unit 17 is not enclosed in a pressure vessel, as are ~; 25 current carpet dyeing apparatuses. The carpet 10 is supported by roller 16 as the carpet 10 travels through the preheater 14. The purpose of roller 16 is to support and spread the ~arpet 10 as it enters the dye bath applicator unit 17, in order to avoid wrinkles in the 30 carpet 10 and to prevent uneven dyeing.
The purpose of the preheater 14 is to heat the carpet 10 prior to the carpet 10 entering the dye bath applicator unit 17. Preheating of the carpet 10 keeps the dye bath 18 from cooling down and helps open dye sites on ; 35 the carpet 10 so that the carpet 10 will be ready to take WO93/16224 PCT/US92/1~3 '''''''"`' ` 212gaC~

the dye from the dye bath applicatvrs 19. The preheater 14 and preheating chamber 13 are heated using the same heating system 30 that heats the dye bath applicator unit 17. The heat system 30 may be any conventional heat 5 system, such as electric coils or enclosed -steam. The preheater 14 heats the carpet 10 to any selected temperature up to about 220F.
The carpet 10 exits the preheater 14 and enters the dye bath applicator unit 17. The dye bath applicator 10 unit 17 generally comprises dye bath 18, dye applicators l9a, l9b, lgc, dye entrance ports 22, squeeze rollers 32, and exit rollers 34.
The dye solution is supplied to the dye bath applicator unit 17 through dye solution entrance ports 15 22. The dye solution, upon leaving dye vat 26, is introduced through feedline 28 to a heat exchanger 20.
~: : The heat exchanger 20, which can be any conventional heat ~; : e~changer.unit, is used to heat the dye solution to a high temperature, generally to any temperature up to about 0 24gF, prior to the dye solution entering the dye bath 18 : and the dye bath applicators l9a, l9b, l9c. A flow meter (not shown) is located between the heat e~changer 20 and the dye bath application unit 17 so as to regulate the flow of the dye solution to the dye bath 18 so as to keep the level o~ the dye bath 18 constant.
In the dye bath applicator unit 17, the carpet 10 passes through high temperature dye bath applicators l9a, l9b, l9c which apply the dye solution to the carpet 10.
~ .
:~ : In~the dye bath applicator unit 17, the dye is furthel 30 heated to between about 160F and about 240F. The carpet and the dye bath applicators l9a, l9b, l9c are ~: submerged within the dye bath 18 facilitating in the even application of the dye to the carpet 10. The carpet 10 is ~; threaded under first applicator roller l9a, over ~econd :: 35 applicator roller l9b, and over third applicator roller WO93/16224 PCT/USg2/1~3 .
~ 1 2 9 9~ 14 l9c to ensure even and thorough dye application. In the dye bath application unit 17, the carpet 10 is submerged in the dye bath 18 as it passes under, over~ and under the applicator rollers, l9a, l9b, l9c, respectively.
After the dye solution has been applied to the carpet 10, the carpet 10 leaves the dye bath 18 and passes through squeeze rollers 32 to remove excess dye solution.
The squeeze rvllers 32 are located above the dye bath 18 such that any excess dye solution squeezed from the carpet 10 10 falls back into the dye bath 18 in a recycle fashion.
After having the excess dye solution squeezed from the carpet 10 by the squeeze rollers 32, the dyed carpet exits the dye bath applicator unit 17 through exit rollers 34 which serve to remove some excess dye solution and to 1~ prevent heat loss from the dye bath applicator unit 17.
Squeeze rvllers 32 function to remove e~cess dye from the dyed carpet 10 and are located within the extended dye bath applicator unit 17. E~it rollers 34 typical~y are constantly moving rollers which function to keep the 20 carpet 10 moving continuously at a desired rate through the apparatus such that the method can be carried out.
The nature of the rollers 34 and the carpet 10 is such that this type of roller 34 does not squeeze the carpet 10 to such an extent so as to create a pressure seal within 25 the e~tended dye bath applicator unit 17.
As any width of carpet 10 may be dyed in the present apparatus using the present method, and rollers 34 are constant width, there typically will be space between the edges of the carpet 10 and the edges of the rollers 3~
30 such that the dye bath applicator unit 17 is open to the atmosphere via these and other spaces. Thus, pressure build-up within the dye bath applicator unit 17 is prevented.
The dyed carpet 10, which may still contain 35 excess dye solution from the dye application process, next WO93/1~24 PCT/US92/1~3 - 15 - 2129~ t,~

passes through a vacuum extractor 36. The vacuum e~tractor 36 is a conventional unit which further removes excess dye solution from the dyed carpet lO through a vacuum means. Any excess dye solution removed from the 5 carpet lO by the vacuum extractor 36 is returned to the heat e~changer 20 through recycle line 38. The e~cess dye solution, therefore, is recycled back to the dy~ bath applicator unit 17 for dyeing further carpet.
The dyed carpet passes from the vacuum extractor lO 36 to one or more wash boxes 40. The purpose of wash box 40 is to wash off excess dye solution and chemicals, and to clean the carpet f rom any other debris which may have been picked up during the dyeing process. The wash box 40 uses a cold water bath with a neutral pH for the cleaning 15 purpose. A further ef~ect of the cold water bath is to aid in halting the dyeing process and to aid in fi~ing the dye on the carpet lO surface.
In operation, the carpet lO travels between one or more rollers 44 in the wash box 40 to increase the 20 amount of time the carpet is in the cold water bath. Upon leaving the wash box 40, the carpet lO passes by a spray washer 46 which also acts as the water introduction unit to the wash box 40. After ~eing sprayed wi~h cold water by the spray wash 46, the carpet lO passes through squeeze 5 rollers 48 to remove e~cess water. In some applications, it is advantageous to have a plurality of wash boxes 40 which generally are identical with each other. Each wash box 40 also is equipped with an overflow 42 to maintain a ~; constant level of water in the wash bax 40. After leaving 30 the wash bo~ 40, the carpet lO is dried in a convention-a~
manner, using conventional carpet drying apparatus.
The above process when applied with the appriopriate apparatus will dye nylon, polyester, cotton, wool and other fibers utilizing acid, disperse, direct and 35 basic class dyestufs. The above process when utilized WO93/16224 PCT/US92/1~3 2 1 29 ~ ~ 16 -with the appropriate apparatus also accomplishes currently acceptable fastness and crocking performance levels with no steamer unit or other steam requirement for satisfactory color setting. Furthermore, the process of 5 this invention when utilized with the appropriate apparatus achieves near 100% exhaustion of the dye solution and reduces affluent waste in the dye process by approximately 75% and is applicable to certain existing equipment upon modification of that equipment. When the 10 carpet 10 comes out of the dye bath 18, the color shade is fully developed and will not continue to build in color department. Further, the water used in the wash box 40 can be recycled with simple plumbing additions (not shown).
The apparatus of the present invention can be 15 retrofitted to most e~isting carpet dyeing equipment of the continuous range variety. The primary change would be to install the dye bath applicator 17 in line with the existing eguipment. The existing steamer can be removed from the existing equipment as it is no longer needed, and 20 the dye bath applicator 17 may be installed in its place.
:~ Alternatively, the dye bath applicator 17 may be placed ~ immediately before the e~isting steamer with the carpet 10 -~ first traveling through the dye bath applicator 17, then through the existing steamer, then to the carpet washing 25 system. If this alternative is utilized, the existing s~eamer need not be turned on as it is unnecessary.
Likewise, the dye bath applica~or 17 may be placed immediately after the e~isting steamer with similar results.
This invention can be applied to all continuous dye ranges for carpet dyeing and to all forms of yarn dyeing such as, for e~ample, warp, skein and knit-deknit space dyeing~ This invention produces superior side to side color matching on continuous dye ranges and produces 35 improved tuft definition and hand in saxony and velvet cut W093/16224 PCT/U~92/1~3 . ~ ~
` - l7 - 2 1 2 9 g 6 ~ ~

pile constructions. Furthermore, this invention has no practical limitation on speed other than the equipment speed limitations. Carpet dyed by the present process and apparatus displays superior color characteristics when 5 compared to carpets dyed by conventional dy-e becks and continuous ranges.
It will be obvious to those skilled in the art that many variations may be made in the embodiment chosen for the purpose of illustrating the best mode of this lO invention without departing from the scope thereof as defined by the appended claims.

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Claims

I Claim l. An apparatus for dyeing fabric materials in which steam fixation of the dye onto the fabric materials is unnecessary, comprising:
a. a dye bath means containing a dye;
b. a heating means which heats the dye to a temperature higher than 212°F at standard temperature and pressure;
c. a dyeing means for applying the dye to the fabric materials;
d. a removal means for removing excess of the dye from the fabric materials;
e. a recovering means for recovering excess of the dye from the fabric materials; and f. a dyeing process halting means for halting the dyeing process and aiding in fixing the dye on the fabric;
wherein said dye bath means, said dyeing means, said removal means, said recovering means and said dyeing process halting means are open to the atmosphere.
2. An apparatus for dyeing fabric materials in which steam fixation of the dye onto the fabric materials is unnecessary, comprising:
a. a dye bath means containing a dye having a boiling point greater than 212°F;
b. a heating means adjacent to said dye bath means which heats the dye within said dye bath means to a temperature greater than 212°F at standard temperature and pressure;
c. a dyeing means immersed in the dye within said dye bath means for applying the dye to the fabric materials;
d. a removal means for removing excess of the dye from the fabric materials;

e. a recovering means for recovering excess of the dye from the fabric materials;
f. a preheating means to preheat the fabric materials to a temperature of up to about 220°F, wherein said preheating means is located prior to said dye bath means and adjacent to the fabric materials; and 9. a dyeing process halting means for halting the dyeing process and aiding in fixing the dye of the fabric;
wherein said dye bath means, said dyeing means, said removal means, said recovering means, said preheating means and said dyeing process halting means are open to the atmosphere.
3. The dyeing apparatus as described in Claim 1, further comprising a dye mixing means, said mixing means comprising means for heating the dye prior to the dye being introduced to the dye bath means and means for introducing the dye to the dye bath means.
4. The dyeing apparatus as described in Claim 3, further comprising removal means for removing excess dye from the fabric materials, said removal means being located downline from said dyeing means.
5. The dyeing apparatus as described in Claim 4, further comprising washing means for washing the fabric materials, said washing means being located downline from said vacuum means.
6. The dyeing apparatus as described in Claim 5, further comprising vacuum means for recovering excess dye from the fabric materials, said vacuum means being located downline from said removal means.
7. The dyeing apparatus as described in Claim 6, further comprising recycle means for recycling said recovered excess dye to said mixing means.
8. The dyeing apparatus as claimed in Claim 1, wherein said dye is a dye solution comprising dye, dyeing assistants, acid and water said dye being selected from the group consisting of acid dyes; said dyeing assistants being selected from the gorup consisting of alcohols, glycols, glycerols and ionic surfactants, and coconut condensate; and said acid being sulfamic acid.
9. The dyeing apparatus as described in Claim 2, wherein said preheating means is co-extensive with said heating means.
10. The dyeing apparatus as described in Claim 2, wherein said preheating means is separate from said heating means.
11. The dyeing apparatus as described in Claim 2, further comprising a fabric materials preheating zone located prior to said dye bath means, the fabric materials being preheated within said preheating zone by said preheating means.
12. The dyeing apparatus as described in Claim 2, wherein said recovering means is located subsequent to said removal means relative to said dye bath means.
13. The dyeing apparatus as claimed in Claim 2, wherein said dye is a dye solution comprising dye, dyeing assistants, acid and water; said dye being selected from the group consisting of acid dyes; said dyeing assistants being selected from the group consisting of alcohols, glycols, glycerols and ionic surfactants, and coconut condensate; and said acid being sulfamic acid.
14. A method for continuously dyeing fabric materials, which method is carried out under atmospheric conditions, comprising the steps of:
a. providing a dye solution having a boiling point above about 212°F at standard-temperature and pressure;
b. providing a fabric material;
c. heating said dye solution to a temperature above about 212°F at standard -temperature and pressure;
d. applying said heated dye solution to said fabric material; and e. fixing said dye to said fabric material without the need for steam fixation.
15. The dyeing method as described in Claim 14, further comprising the step of preheating said fabric material to a temperature up to about the temperature of said heated dye solution prior to step d.
16. The dyeing method as described in Claim 15, wherein said fabric material is heated to a temperature above the boiling point of water, that being 212°F at standard temperature and pressure.
17. The dyeing method as described in Claim 14, further comprising the step of preheating said dye solution prior to step c.
18. The dyeing method as described in Claim 17, wherein said dye solution is heated to a temperature above the boiling point of water, that being 212°F at standard temperature and pressure.
19. The dyeing method as described in Claim 14, further comprising the step of removing excess dye solution from said fabric material subsequent to step d.
20. The dyeing method as described in Claim 19, further comprising the step of recycling said excess dye solution.
21. The dyeing method as described in Claim 14, further comprising the step of washing said fabric material subsequent to step d.
22. The dyeing method as described in Claim 14, further comprising the step of neutralizing the pH of said dye solution and said fabric material subsequent to step d.
23. The dyeing method as described in Claim 14, further comprising the step of drying said fabric materials subsequent to step d.
24. A dye solution comprising dye, dyeing assistants, acid and water.
25. A dye solution as described in Claim 24, wherein said dye is selected from the group consisting of acid dyes; said dyeing assistants are selected from the group consisting of alcohols, glycols, glycerols, anionic surfactants, ionic surfactants, and coconut condensate;
and said acid being sulfamic acid.