DE60110404T2 - MULTI-COLORED FLOORING - Google Patents

Description

AREA OF INVENTION

The The invention relates to a multicolor floor covering and more particularly a multi-colored carpet made from a combined yarn which has at least 3 components of synthetic yarns.

BACKGROUND THE INVENTION

To the wishes Designers and consumers want multi-colored floor coverings, such as For example, opposite carpets monochromatic rugs over additional Diversity and flexibility the aesthetic Features of carpets feature. One of the conventional methods of producing a multicolor Carpet is that it is made from yarn, which are themselves combinations of yarn components that have different Färbbarkeiten feature, and then the carpet using a mixture of dyes, such as acidic and cationic dyes is dyed. For example, nylon yarns can be made with strongly acidic, slightly acidic ones and cationic dyeability by combining them with high air pressure to produce a mixed yarn twisted or swirled. The combined yarn can be tufted or woven to create a carpet and the carpet afterwards in a dyebath colored which contains acidic and cationic dyes. In this example Since two of the three yarn components are acid-dyeable, they are combined in the combined Yarn always included two yarn components that are in the same Colored family are over bright and deep shades of the same color features. Therefore it is impossible, to dye this combined yarn in such a way that it's all three has different colors, i. the flexibility of coloring the carpet is limited.

One another method of producing multicolored carpets is to acidic and cationic dyeable Nylon yarns with a polyethylene terephthalate (abbreviated PET or alternatively 2GT). PET is opposite acidic and cationic dyes inert and can only with Disperse dyes are dyed. PET (unmodified) is for dyeing on a continuous dyeing machine or a plant used for carpet dyeing on a continuous basis is not suitable because the dye run or the uniformity of the dye are low. Dyeing on a continuous dyeing plant is to dye from carpet the most economical method. A bad color gradient occurs when the fiber has low dyeability with respect to dyeing speed and has dye exhaustion resulting in low dye uniformity and lead to mottling. PET leaves with disperse dyes in conjunction with a carrier to dye. A carrier is an organic chemical substance that for swelling or opening the polymer structure of the PET fiber is used, so that the fiber in an acceptable way with a continuous dyeing process dyed at high speed can be. Carriers, however, are expensive and toxic. One using this combination of yarns can when using acidic, cationic and disperse dyes and carrier is dyed, lead to a multi-colored effect, wherein Each color of one yarn component is different from the other. However, these carpets have a low impact resistance and durability against felting, reflecting the weak recovery of the PET component of the Garns is due. Because the impact resistance is unacceptable and costly and toxic carrier is the one prepared in this way multicolored carpet no desirable option.

The following disclosures may be relevant to the various aspects of the present invention and are briefly summarized as follows:
U.S. Patent 5,160,347 to Kay et al. discloses carrier-dyeable polyester yarns dyed by space-dyeing by spraying them with aqueous dispersions of disperse dyes without thickener or carrier, followed by a short steaming process and autoclaving to develop the dyes, or by a process in which the yarn is knit into stockings or tubes which are subjected to roller-printing process with disperse dye thickener and carrier dissolved in water of various colors, followed by steaming, scrubbing, drying and desmutting. The yarns so produced by the space-dyeing process are then tufted into a face bridge together with undyed yarns of "carrier-free" polyester fibers and / or nylon fibers and dyed with a cationic, acid or disperse dye according to the dye receptivity of the undyed yarns overstaining of the space-dyeing dyed yarns to form a multicolor colored area bridge is avoided.

The U.S. Patent No. 5,354,342 to Jenkins discloses stain resistant multicolor cationically dyeable Carpet fibers that are space-dyeing with an acid dye colored or are dyed with a metallized dye, heat-set and subsequently together with uncoloured, cationically dyeable Nylon fibers are tufted into a carpet. The carpet will be then with an acid dye or pre-metalated acid dye pre-dyed, to selectively only the previously undyed cationic dyeable Nylon fibers without staining or discoloring the adjacent ones previously colored To dye fibers resulting in a multi-colored, stain-resistant carpet.

The U.S. Patent 5,199,958 to Jenkins et al. discloses a multicolored, stain resistant Nylon carpet, cationic by tufting by space-dyeing colorable Carpet nylon is made with an acidic or pre-metallized Dye dyed, mixed and tufted with an acid dyeable nylon, and the with an acid dye is over-dyed, to selectively acidify the acid Dye fibers, however not the already dyed in space-dyeing yarns.

The U.S. Patent 3,652,198 to Farber et al. discloses a method for dyeing Fibers, textile fabrics or other shaped articles made from blends of either poly (α-olefins) or polyesters and various thermoplastic, nitrogen containing basic polymers are produced, to a multicolor Template.

The aim becomes a system for dyeing a multi-component carpet, wherein each component is of three-component Yarns can be dyed with another dye without that a carrier is used, the resulting carpet being a high impact resistance and high resistance to felting Has.

SUMMARY THE INVENTION

Summarized It can be said that according to one of the aspects of the present invention a multicolored floor covering granted comprising combined yarns, each of the combined yarns at least one acid-dyeable Multifilament nylon yarn, at least one cationic dyeable multifilament nylon yarn and at least one multifilament poly (trimethylene terephthalate) yarn, the floor covering with at least three different colors in a carrier-free Bath dyed This is a combination of acid dye, cationic dye and disperse dye.

According to another aspect of the present invention, there is provided a method of producing a multicolor floor covering comprising the steps of:
Combining at least one acid-dyeable nylon multifilament yarn, at least one cationically dyeable nylon multifilament yarn, and at least one poly (trimethylene terephthalate) multifilament yarn to form a combined yarn; Producing a floor covering using the combined yarn and dyeing the floor covering with at least three different colors in a carrier-free dyebath using acidic dyes, cationic dyes and non-carrier disperse dyes.

SHORT DESCRIPTION THE DRAWINGS

Other Features of the present invention will become apparent from the following Description and with reference to the drawing obviously where are:

1 a schematic representation of an embodiment of the present invention of a combined yarn having three yarn components, which are twisted together.

Although the present invention in conjunction with a preferred embodiment it is understood that they are not on this embodiment limited is. Much more should it all alternatives, modifications and equivalents which are considered to be within the scope of the invention can be by the attached claims is fixed.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides multi-colored floor coverings with versatility, such as bridges and carpets. In one embodiment of the present invention, the combined yarn comprises at least two polyamide yarns and at least one poly (trimethylene terephthalate) (ie PTT) yarn for at least three different colors for the floor covering. The two polyamide yarns usable in one embodiment of the present invention include any known bulk continuous filament (ie BCF) or yarn of any type of nylon 6 or nylon 6,6 polymer. These yarns are commonly used in carpet making. The denier or denier of these yarns typically ranges between about 500 and about 2,800. In one embodiment of the present invention, at least one of the polyamide yarns is dyeable with acid dyes. The dyeability of these yarns can vary from a light to medium to deep color. In addition, at least one other of the polyamide yarns usable in the invention is dyeable with cationic dyes. Third, at least one poly (trimethylene terephthalate) yarn useful in the invention is any bulked continuous filament yarn. The denier of this yarn is also in the range between about 500 and about 2,800.

The Polyamide and PTT multifilament yarns of one embodiment of the present invention Invention are either by air entanglement or by Verzwirnung combined together. There are several methods in the field air entanglement (for example, those described in US Pat. No. 3,978,558) and twisting (as disclosed, for example, in U.S. Patent Nos. 3,368,336 described) are well known. In the present invention Any of the known methods are used. Combining the yarns with the help of the air entanglement leads to a yarn with colors, which are usually mixed and covered. Combining the Yarns by twisting leads to a yarn that over a stronger one Color separation features. Typically, there are three yarns, each with 500 to 2,800 deniers (1 denier = 0.9 dtex) combined with one of the two methods.

Reference will now be made to the drawings, in which the description has the object of describing a preferred embodiment of the invention without limiting it. For clarity, the figure is not to scale. 1 illustrates a twisted combined yarn 10 wherein the yarn 1 an acid-dyeable polyamide yarn is yarn 2 is a cationic dyeable polyamide yarn and yarn 3 is a poly (trimethylene terephthalate) yarn. In addition, yarns can be incorporated into the combined yarn to give the resulting carpet a desired aesthetic characteristic.

The multicolor carpet according to an embodiment of the present invention is produced by tufting or weaving in a conventional manner and preferably by tufting. A typical carpet construction according to the present invention is about 0.04 to about 0.27 g / cm ² (12 to about 80 ounces per square yard) having a pile height of 0.3175 to 2.54 cm (1 / 8 "to 1"). The multicolor carpet preferably has loop pile, although it may also have cut pile. Schlingenflor provides a better look with different colors in the carpet.

The carpet is dyed with a combination of acid, cationic and disperse dyes in a bath, ie carrier-free. By "carrier-free" is meant that no carrier is present in the dyeing process. Each yarn (yarns 1 . 2 and 3 in 1 ) is receptive to dyeing for various dyes. For example, yarn is 1 acid dyeable and its color is determined by the acid dye and disperse dye; yarn 2 is cationically dyeable and is more receptive to the cationic dye and disperse dye; and fixing the color of yarn 3 takes place by only the carrier-free disperse dye. This provides at least three different colors for an aesthetically pleasing appearance of a multicolored carpet.

Of the Carpet can be dyed using conventional dyeing processes, such as a process associated with continuous staining devices is applied, such as a commercially available dyeing plant from the Kuster Corporation. In continuous dyeing the dyes first sprayed on the carpet. The dyes are used in amounts ranging from about 0.01% to about 2% but preferably between about 0.01% and about 1% of the fiber weight applied. Subsequently For example, the carpet is steamed for about 2 to about 5 minutes Temperatures typically from about 210 ° to about 212 ° F. Subsequently the carpet is rinsed and dried. Although a process in a continuous dyeing plant is preferred is, the present invention is also on a batch process applicable (such as the "Beck dyeing").

Of the colored Carpet of the present invention has excellent pile height retention. The carpet of the invention has a pile height retention of at least 85%, and preferably at least 90%, if he does the drum test subjected to Vetterman.

TEST METHODS

DRUM TEST TO VETTERMAN

The Carpet samples are cut to 26.67 cm x 26.67 cm (10.5 "x 10.5") size and in a room at constant temperature (70 ° F) and humidity (65% relative humidity) for Conditioned for 24 hours. Subsequently, the samples in the Vetterman drum given and held with a retaining ring. The Samples are subjected to a 5,000 cycle cycling test (Standard ASTM D5417-93). The samples tested are then placed in a room at constant temperature (70 ° F) and humidity (65% relative humidity) Humidity) for Conditioned for 24 hours. The pile heights of the samples tested become then measured by inserting a dipstick into the pile of a rug and the pile height read in inches. (The thickness of the back and the latex layer are excluded.)

The pile height retention is calculated as follows: Pile height retention = (pile height after 5,000 cycles / pile height before test) × 100%

A embodiment The present invention is illustrated by the following example illustrates:

EXAMPLE

It a combined yarn was produced by placing on a vortex machine from Belmont (available at Belmont Textile Machinery Company, Belmont, NC) the following yarn components were swirled: an acid-dyeable Nylon BCF yarn with 2,400 denier, a cationic dyeable Nylon BCF yarn with 2,400 denier and four poly (trimethylene terephthalate) BCF yarns with 1,100 denier. A comparative control yarn was produced by: the same yarns were swirled and four poly (ethylene terephthalate) -BCF yarns with 1,100 denier for the four poly (trimethylene terephthalate) yarns were replaced.

The yarns for the example and control yarns were tufted into 907.2 g (32 oz.) Loop pile carpets on a 5/32 inch (1 inch = 25.4 mm) calibering / tufting machine. Subsequently, the carpets were dyed on a continuous Kuster dyer (available from Zima Corporation, Spartanburg, South Carolina). The dyes were sprayed onto the carpet prior to steaming for dye fixation. The following dye formulations and conditions were used:

The dye liquid was applied with a wet pick-up of 450 to 500%. The pH of the dye liquid was set to 6 to 6.5. The residence time in the vapor was 3,8 min.

The resulting carpets contained three attractive color patterns. The carpets were subjected to the drum test according to Vetterman with 5,000 cycles. The samples were placed in a room for 24 hours at 70 ° F and 65% relative humidity conditioned. Before and after each test, the pile height of each carpet was measured. The relative recovery of each carpet was calculated from pile height measurements using the aforementioned formula.

Claims (12)

Multi-colored floor covering, comprising combined Yarns, each of the combined yarns being at least one acid dyeable yarn Multifilament nylon yarn, at least one cationic dyeable Multifilament nylon yarn and at least one multifilament poly (trimethylene terephthalate) yarn, the floor covering with at least 3 different colors in a carrier-free bath colored This is a combination of acid dye, cationic dye and disperse dye. Multi-colored floor covering according to claim 1, having a pile height retention of at least 85%, when subjected to the drum test after Vetterman. Multi-colored floor covering according to claim 2, having a pile height retention of at least 90%, when subjected to the drum test after Vetterman. Multi-colored floor covering according to claim 1, wherein the combined yarns are twisted be united. Multi-colored floor covering according to claim 1, wherein the combined yarns by swirling with high air pressure. Multi-colored floor covering according to claim 1, wherein each yarn of the combined yarns with at least one of three different colors is colored and in color different from two of the other multifilament yarns of the combined yarn. Multi-colored floor covering according to claim 1, comprising a carpet. Method for producing a multicolored floor covering, comprising the steps: a. Combine at least one acid-dyeable Nylon multifilament yarn, at least one cationic dyeable Nylon multifilament yarn and at least one poly (trimethylene terephthalate) multifilament yarn producing a combined yarn; b. Making a flooring using the combined yarn; and c. Dyeing the flooring with at least three different colors in a carrier-free Dye bath using acidic dyes, cationic Dyes and disperse dyes. The method of claim 8, wherein the step of combining a twisting or swirling with high air pressure includes. The method of claim 8, wherein each of the Multifilament yarns of combined yarn with one of the three colored different colors is and is in the color of two of the other multifilament yarns of the combined yarn. The method of claim 8, wherein the manufacturing step includes tufting or weaving. The method of claim 8, wherein the multicolor flooring includes a rug.