Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04G—MAKING NETS BY KNOTTING OF FILAMENTARY MATERIAL; MAKING KNOTTED CARPETS OR TAPESTRIES; KNOTTING NOT OTHERWISE PROVIDED FOR
  • D04G3/00—Making knotted carpets or tapestries
• • 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
  • D06B3/00—Passing of textile materials through liquids, gases or vapours to effect treatment, e.g. washing, dyeing, bleaching, sizing, impregnating
  • D06B3/04—Passing of textile materials through liquids, gases or vapours to effect treatment, e.g. washing, dyeing, bleaching, sizing, impregnating of yarns, threads or filaments
• • D—TEXTILES; PAPER
  • D05—SEWING; EMBROIDERING; TUFTING
  • D05C—EMBROIDERING; TUFTING
  • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
  • D05C17/02—Tufted products
  • D05C17/026—Tufted products characterised by the tufted pile surface
• • 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
  • D06B23/00—Component parts, details, or accessories of apparatus or machines, specially adapted for the treating of textile materials, not restricted to a particular kind of apparatus, provided for in groups D06B1/00 - D06B21/00
  • D06B23/04—Carriers or supports for textile materials to be treated

Definitions

• This invention relates to a process for making carpets of greater color and shade uniformity by dyeing a knit structure under low tension, passing the knit structure through at least two squeeze rollers, unravelling the knit structure and making a carpet from the unravelled dyed yarns.
• Wool carpet yarns have traditionally been dyed in hanks then spooled for weaving or tufting into carpets. Synthetic yarns such as nylon followed the same techniques as wool at first, and some yarns are still yarn dyed for use in pattern weaving. However, the great majority of synthetic carpet yarns, particularly bulked continuous filament, are now undyed when made into carpet form, and the entire carpet is dyed to a solid shade or is printed when color patterning is desired.
• the crimped yarns are preferably assembled into the ribbon-like structure by warp knitting or loose weaving characterized by insertion of weft thread, wherein the weft thread is removed when the ribbon-like structure is unravelled.
• Fresh dye is preferably added continuously to the dye applicator so that all yarn is treated with dye of a uniform concentration.
• the dye may be forced repeatedly through the yarns by two or more sets of squeeze rollers or by other means such as two or more sets of jets or sprays from one or both sides or by pulling the yarn under low tension in wrapping contact with one or more stationary wiper bars to redistribute dye on and within the yarns.
• the yarns may be assembled into multi-end ribbon-like structure by temporary loose weaving, employing a weft yarn which is later removed, or by warp knitting, preferably using a low stitch density construction to minimize the bulk of the assembly and to reduce permanent distortion of the yarns into a knit-de-knit crimp form.
• the use of previously twist-set yarns is preferred for avoiding such distortion.
• the ribbon-like structure is later unravelled to separate the yarns.
• Loose weaving or knitting is characterized by along-end weft insertions of about 1 cm or greater or by warp knitting forming continuous stitches of about 2 cm or greater. Such loose construction is necessary for complete and uniform penetration of dye throughout all yarns as well as for thorough steaming, rinsing and drying. Such penetration is also aided by minimum tension on the assembly during the operations, which also is beneficial in preserving optimum crimp and bulk in the yarns.
• a yarn as referred to herein may either be a single yarn or may be two or more single yarns which have been plied and heat set, or may be differentially-dyeable yarns which have been air entangled.
• yarn-to-yarn dye uniformity is excellent, and along-end uniformity can be controlled better than in current continuous yarn dyeing practice.
• any yarns may be detected visually as the yarns enter the tufting machine and may be removed to waste.
• Dyeing equipment which is suitable with minor modifications for use in the present process is used for dyeing automobile seat belt webbing, for which product the along-end dye uniformity requirements are particularly stringent.
• Such treatments may impart anti-microbial activity or may repel soil and stains.
• Yarns from ribbon-like arrays of different color may be fed to particular needles of a tufting machine so as to form stripes or other graphic designs.
• the process of the invention may be used with both staple and continuous filament yarns and is advantageous for wool as well as for synthetic fibers.
• the process may either be continuous from assembling the yarns into a ribbon-like structure to carpet making, or it may be interrupted, as by storing the dyed and dried structure in a can or box and later feeding the structure to carpet making.
• the superior dye uniformity, reduction of investment and floor space savings of the present process can benefit carpet mills of any size.
• small carpet mills are particularly aided by the increase in productivity and the reduction in yarn inventory which the present method makes possible. Mills which are distant from a source of yarn, such as in foreign countries, can appreciably reduce their lead time for ordering supplies.
• Two hundred yarns each consisting of two 1700 denier trilobal filament nylon 66 bulked continuous filament yarns of 22 denier per filament which have been ply twisted and hea t set together are led from individual packages on a creel to a needle loom and woven on an eight shaft four by four construction inserting one weft thread pick approximately every 1 cm of yarn travel.
• the multi-end ribbon-like structure is approximately 8 cm wide.
• the speed of yarn advance is about 10 meters per minute.
• the ribbon is then fed to a webtex pad steam dyer and is dyed with Ciba Geigy "Tectalon" dyes comprising acid red 361, 3 g/liter, 200% and yellow, 2 g/liter and acid blue 277, 0.5 g/liter, in a bath where two sets of squeeze rollers force the dye through each yarn. Both squeeze rollers removes excess dye to waste, after which the yarns enter a steamer which raises the yarn temperature to about 100°C for an exposure time of 4-1/2 minutes with live steam to set the dye.
• the yarns are then rinsed and squeezed in six tanks on line and are then dryed at 120°C for 2-1/2 minutes in a convection dryer.
• the dye uniformity is excellent edge to edge and meets commercial standards end to end.
• the weft is then withdrawn and the yarns are separated to enter the eyelet board of a carpet tufting machine.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Coloring (AREA)
• Knitting Of Fabric (AREA)
• Treatment Of Fiber Materials (AREA)
• Automatic Embroidering For Embroidered Or Tufted Products (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=25439895

Family Applications (1)

Country Status (13)

Cited By (1)

Citations (5)

• 1987
  • 1987-10-09 BR BR8705420A patent/BR8705420A/pt unknown
  • 1987-10-12 JP JP62254804A patent/JPS63105162A/ja active Pending
  • 1987-10-12 PL PL1987268171A patent/PL268171A1/xx unknown
  • 1987-10-13 EP EP87309012A patent/EP0264251A1/en not_active Withdrawn
  • 1987-10-13 FI FI874506A patent/FI874506A/fi not_active Application Discontinuation
  • 1987-10-13 NO NO874261A patent/NO874261L/no unknown
  • 1987-10-13 DK DK535587A patent/DK535587A/da not_active Application Discontinuation
  • 1987-10-13 IL IL84159A patent/IL84159A0/xx unknown
  • 1987-10-13 PT PT85912A patent/PT85912B/pt not_active IP Right Cessation
  • 1987-10-13 KR KR870011310A patent/KR880005304A/ko not_active Application Discontinuation
  • 1987-10-13 HU HU874612A patent/HUT46377A/hu unknown
  • 1987-10-14 AU AU79757/87A patent/AU7975787A/en not_active Abandoned
  • 1987-10-14 DD DD87307934A patent/DD264244A5/de not_active IP Right Cessation

Patent Citations (5)

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