EP1274895A1 - Multicolor flooring article - Google Patents
Multicolor flooring articleInfo
- Publication number
- EP1274895A1 EP1274895A1 EP01913056A EP01913056A EP1274895A1 EP 1274895 A1 EP1274895 A1 EP 1274895A1 EP 01913056 A EP01913056 A EP 01913056A EP 01913056 A EP01913056 A EP 01913056A EP 1274895 A1 EP1274895 A1 EP 1274895A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- yarn
- combined
- yarns
- multicolor
- flooring article
- 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.)
- Granted
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
- D06B11/0056—Treatment of selected parts of textile materials, e.g. partial dyeing of fabrics
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns
- D02G3/346—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns with coloured effects, i.e. by differential dyeing process
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/44—Yarns or threads characterised by the purpose for which they are designed
- D02G3/445—Yarns or threads for use in floor fabrics
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P1/00—General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
- D06P1/0096—Multicolour dyeing
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/82—Textiles which contain different kinds of fibres
- D06P3/8204—Textiles which contain different kinds of fibres fibres of different chemical nature
- D06P3/8214—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of fibres containing ester and amide groups
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/02—Synthetic macromolecular fibres
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/02—Synthetic macromolecular fibres
- D06N2201/0263—Polyamide fibres
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2209/00—Properties of the materials
- D06N2209/08—Properties of the materials having optical properties
- D06N2209/0807—Coloured
- D06N2209/0823—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/02—Material containing basic nitrogen
- D06P3/04—Material containing basic nitrogen containing amide groups
- D06P3/24—Polyamides; Polyurethanes
- D06P3/241—Polyamides; Polyurethanes using acid dyes
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/02—Material containing basic nitrogen
- D06P3/04—Material containing basic nitrogen containing amide groups
- D06P3/24—Polyamides; Polyurethanes
- D06P3/242—Polyamides; Polyurethanes using basic dyes
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/34—Material containing ester groups
- D06P3/52—Polyesters
- D06P3/54—Polyesters using dispersed dyestuffs
Definitions
- the invention relates to a multicolor flooring article, and more particularly a multicolor carpet made from a combined yarn comprising at least three component synthetic yarns.
- Multicolor flooring articles such as carpets
- One conventional method of making a multicolor carpet is to make it from yarns which are themselves combinations of component yarns having different dyeabilities and then to dye the carpet using a mixture of dyes such as acid and cationic.
- dyes such as acid and cationic.
- nylon yarns with deep acid, light acid and cationic dyeabilities may be combined by twisting them together or commingling them with high pressure air forming a combined yarn.
- the combined yarn may be tufted or woven to form a carpet, and the carpet may then be dyed in a dye bath containing acid and cationic dyestuffs.
- the combined yarn will always include two component yarns dyed in the same color family, having light and deep shades of the same color.
- this combined yarn it is not possible to dye this combined yarn in such a way that it has three entirely different colors, i.e. the color styling flexibility of the carpet is limited.
- PET polyethylene terephthalate
- 2GT polyethylene terephthalate
- PET is inert to acid and cationic dyes and can only be dyed with disperse dyes.
- PET (unmodified) is not suitable for dyeing on a continuous dye line, or equipment designed to dye carpet on a continuous basis, because the dye leveling or uniformity of the dye is poor.
- Dyeing on a continuous dye line is the most economical method for dyeing carpet. Poor dye leveling occurs when the the fiber has low dyeability in terms of dye rate and dye exhaust that results in poor dye uniformity and splotchiness .
- PET can be dyed with disperse dyes in conjunction with a carrier.
- a carrier is an organic chemical used to swell or open the polymer structure of the PET fiber so that the fiber may be dyed acceptably in a high speed continuous dyeing process.
- carriers are costly and toxic.
- a carpet using this combination of yarns when dyed with acid, cationic and disperse dyestuffs and carrier can result in a multicolor effect in which each color of a yarn component is different from the other.
- these carpets have poor resistance to crushing and matting, due to the poor resiliency of the PET yarn component.
- the multicolor carpet made in this manner is not a desirable option because the crushing resistance is unacceptable and requires a costly and toxic carrier.
- U.S. Pat. No. 5, 160, 347 to Kay et al discloses carrier dyeable polyester yarns that are space dyed by spraying with water dispersions of disperse dyes without thickeners or carriers followed by a short steaming process and autoclaving to develop the dyes or by a process of knitting the yarn into socks or tubes which are roller printed with disperse dyestuff, thickener and carrier dissolved in water in various colors followed by steaming, washing, drying and deknitting.
- space dyed yarns are then tufted into area rugs along with undyed yarns of "carrierless" polyester fibers and/or nylon fibers and dyed with a cationic, acid or disperse dye appropriate to the dye receptivity of the undyed yarns while avoiding overdyeing of the space dyed yarns to produce a multicolor piece dyed area rug.
- U.S. Pat. No. 5, 354, 342 to Jenkins discloses stain-resistant, multicolored cationic dyeable carpet fibers space dyed with an acid dye or premetalized acid dye, heatset, then tufted together with undyed cationic dyeable nylon fibers into a carpet .
- U.S. Pat. No. 3, 652,198 to Farber et al discloses a process for dyeing fibers, fabrics or other shaped articles made from blends of either poly (alpha- olefins) or polyesters and various thermoplastic nitrogen-containing basic polymers to a multicolor pattern.
- a multicolor flooring article comprising combined yarns, each combined yarn comprising at least an acid dyeable nylon multifilament yarn, at least a cationically dyeable nylon multifilament yarn and at least a poly (trimethylene terephthalate) multifilament yarn wherein the flooring article is dyed at least three different colors in a carrier free dye bath containing a combination of acid dye, cationic dye and disperse dye.
- a process for making a multicolor flooring article comprising the steps of: combining at least an acid dyeable nylon multifilament yarn, at least a cationically dyeable nylon multifilament yarn and at least a poly (trimethylene terephthalate) multifilament yarn forming a combined yarn; making a flooring article using the combined yarn; and dyeing the flooring article at least three different colors in a carrier free dye bath using acid dyes, cationic dyes and carrier-free disperse dyes.
- Figure 1 is a schematic illustration of an embodiment of the present invention of a combined yarn comprising three component yarns twisted together.
- the present invention provides versatility in multicolored flooring articles such as rugs and carpets.
- the combined yarn comprises at least two polyamide yarns and at least one poly (trimethylene terephthalate) (i.e. PTT) yarn for at least three distinct colors for the flooring article.
- the two polyamide yarns useful for an embodiment of the present invention include any known bulked continuous filament (i.e. BCF) or yarn of either type nylon 6 or nylon 6,6 polymer. Such yarns are commonly used in carpet manufacturing.
- the linear density, or denier, of these yarns typically range between about 500 and about 2800.
- at least one of the polyamide yarns is dyeable by acid dyestuffs.
- the dyeability of these yarns can vary from light, to medium to deep in color. Additionally, at least another of the polyamide yarns useful for the invention is dyeable by cationic dyestuffs. Thirdly, at least one poly (trimethylene terephthalate) yarn useful for the invention is any known bulked continuous filament yarn. The denier of this yarn also ranges between about 500 and about 2800.
- the polyamide and PTT multifilament yarns, of an embodiment of the present invention are combined by either air entangling or cable twisting together.
- air entangling for example, those described in US Patent 3,978,558 herein incorporated by reference
- cable twisting for example, the one described in US Patent 3, 368,336 herein incorporated by reference
- Any of the known methods may be applied in the present invention.
- Combining the yarns by air entangling results in a yarn having colors that are blended and generally muted.
- Combining the yarns by cable twisting results in a yarn having more color separation.
- three yarns of 500 to 2800 denier each are combined by either method.
- Figure 1 illustrates a cable twisted combined yarn 10 where yarn 1 is an acid dyeable polyamide yarn, yarn 2 is a cationically dyeable polyamide yarn and yarn 3 is a poly (trimethylene terephthalate) yarn. Additional yarns may also be included in the combined yarn to give a desired aesthetic in the resulting carpet.
- the multicolor carpet according to an embodiment of the present invention is made by tufting or weaving in a conventional manner, preferably by tufting.
- a typical carpet construction of the present invention is about 12 to about 80 oz . weight per square yard with 1/8" to 1" pile height.
- the multicolor carpet is preferably loop pile, although it may also be cut pile. Loop pile provides a better view of the different colors in the carpet .
- the carpet is dyed with a combination of acid, cationic and disperse dyes in a bath that is carrier-free.
- carrier-free is meant that no carrier is present in the dyeing process.
- yarn 1 being acid dyeable, has its color determined by the acid dye and disperse dye; yarn 2 being cationically dyeable, is more receptive to the cationic dye and disperse dye; and yarn 3's color determination is determined by the carrier free disperse dye only.
- yarn 1 being acid dyeable, has its color determined by the acid dye and disperse dye; yarn 2 being cationically dyeable, is more receptive to the cationic dye and disperse dye; and yarn 3's color determination is determined by the carrier free disperse dye only.
- the carpet may be dyed using a conventional dyeing process, such as that used with continuous range dyers such as a commercially available dyeing unit from Kuster Corporation.
- continuous range dyeing first the dyestuffs are sprayed onto the carpet. The dyes are applied in amounts ranging from about 0.01% to about 2%, but preferably between about 0.01% to about 1%, of the weight of the fiber. The carpet is then steamed for about 2 to about 5 minutes at temperatures typically about 210 to about 212 degrees F. The carpet is then rinsed and dried. While the continuous dye line process is preferred, the present invention is applicable to a batch process (such as Beck dyeing) .
- the dyed carpet of the present invention has excellent pile height retention.
- the carpet of the present invention has a pile height retention of at least 85% and preferably at least 90%, when subjected to the Vetterman Drum Test . Test Method
- test carpet samples are cut into 10.5" x 10.5" size and conditioned in a constant temperature (70 F) and humidity (65% RH) room for 24 hours.
- the samples are then placed into a Vetterman drum and secured by a retaining ring.
- the samples are subjected to a 5,000 cycles test (ASTM D5417-93) .
- the tested samples are then conditioned in a constant temperature (70 F) and humidity (65% RH) room for 24 hours.
- the pile heights of tested samples are then measured by inserting a ruler into the pile of a carpet and then reading the height of the pile in inches. (The thickness of the backing and latex coating are excluded.)
- the pile height retention is calculated as follows
- a combined yarn was formed by commingling on a Belmont intermingling machine (available from Belmont Textile Machinery Company, Belmont, NC) the following component yarns: one 2400 denier acid dyeable nylon BCF yarn, one 2400 cationically dyeable nylon BCF yarn and four 1100 denier poly (trimethylene terephthalate) BCF yarns.
- a control combined yarn was formed by commingling the same yarns, substituting four 1100 denier poly (ethylene terephthalate) BCF yarns for the four poly (trimethylene terephthalate) yarns.
- the example and control yarns were tufted into 32 ounce loop pile carpets on a 5/32 inch gauge tufting machine.
- the carpets were then dyed on a continuous Kuster range dyer (available from the Zima Corporation, Spartanburg, South Carolina) .
- the dyestuffs were sprayed onto the carpet before steaming for dye fixation.
- the following dye formulations and conditions were used:
- the dye liquor was applied at 450 to 500% wet pick up.
- the pH of the dye liquor was adjusted to 6-6.5
- the dwell time in the steam was 3.8 minutes.
- the resulting carpets included attractive three color aesthetics.
- the carpets were subjected to the Vetterman Drum Test for 5,000 cycles.
- the samples were conditioned in a 70 degree F, 65% relative humidity room for 24 hours.
- the pile height was measured for each carpet before and after the test .
- the percent recovery of each carpet was calculated from the pile height measurements using the above formula.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Carpets (AREA)
- Coloring (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
Abstract
Description
Claims
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US53544200A | 2000-03-24 | 2000-03-24 | |
US535442 | 2000-03-24 | ||
PCT/US2001/006097 WO2001073189A1 (en) | 2000-03-24 | 2001-02-26 | Multicolor flooring article |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1274895A1 true EP1274895A1 (en) | 2003-01-15 |
EP1274895B1 EP1274895B1 (en) | 2005-04-27 |
Family
ID=24134244
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP01913056A Expired - Lifetime EP1274895B1 (en) | 2000-03-24 | 2001-02-26 | Multicolor flooring article |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP1274895B1 (en) |
CA (1) | CA2397979C (en) |
DE (1) | DE60110404T2 (en) |
WO (1) | WO2001073189A1 (en) |
Families Citing this family (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2008109758A1 (en) * | 2007-03-06 | 2008-09-12 | Futuris Automotive Interiors (Us). Inc. | Tufted pet fiber for automotive carpet applications |
US7674302B1 (en) * | 2007-05-16 | 2010-03-09 | Product Concepts Residential, L.L.C. | Method of creating old art dyeing effect with acid and cationic dyed carpet |
WO2009002285A1 (en) * | 2007-06-28 | 2008-12-31 | Flokser Tekstil Sanayi Ticaret A.S. | Process of patterned flock application of fabric woven by synthetic yarn |
US20090136704A1 (en) * | 2007-11-27 | 2009-05-28 | Invista North America S. A R. I. | Dual acid/cationic dyeable polyamide polymer fibers and yarns, methods of making the same, and textile articles including dual acid/cationic dyeable polyamide polymer fibers |
CN102618987A (en) * | 2012-03-28 | 2012-08-01 | 常州灵达特种纤维有限公司 | Nylon 6 bulked continuous filament three-color carpet yarn and manufacturing method |
AU2015243916B2 (en) * | 2014-04-10 | 2020-01-30 | Invista Textiles (U.K.) Limited | Multicolor carpet and method of making same |
DE102018124482A1 (en) * | 2018-10-04 | 2020-04-09 | Grand Textile Co., Ltd. | Process for dyeing patterns on a fabric |
US20210324548A1 (en) * | 2020-04-17 | 2021-10-21 | Universal Fibers, Inc. | Sharp color effect yarn |
WO2022119770A2 (en) * | 2020-12-02 | 2022-06-09 | Aladdin Manufacturing Corporation | Multicolor polyester fabric and methods of manufacturing same |
WO2022132965A1 (en) * | 2020-12-18 | 2022-06-23 | Aladdin Manufacturing Corporation | Multicolored tufted textiles and methods of making the same |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3101522A (en) * | 1960-12-01 | 1963-08-27 | Hercules Powder Co Ltd | Three-ply tweed yarn |
US3439999A (en) * | 1964-09-28 | 1969-04-22 | Uniroyal Inc | Cross-dyed carpets |
US5199958A (en) * | 1990-05-04 | 1993-04-06 | Burlington Industries Inc. | Stain resistant multicolor textured cut pile carpet: cationic-dyeable nylon yarn dyed with anionic dyes and anionic-dyeable nylon yarn |
US5160347A (en) * | 1990-10-05 | 1992-11-03 | Burlington Industries, Inc. | Multicolored piece-dyed rugs |
-
2001
- 2001-02-26 EP EP01913056A patent/EP1274895B1/en not_active Expired - Lifetime
- 2001-02-26 WO PCT/US2001/006097 patent/WO2001073189A1/en active IP Right Grant
- 2001-02-26 DE DE60110404T patent/DE60110404T2/en not_active Expired - Lifetime
- 2001-02-26 CA CA002397979A patent/CA2397979C/en not_active Expired - Fee Related
Non-Patent Citations (1)
Title |
---|
See references of WO0173189A1 * |
Also Published As
Publication number | Publication date |
---|---|
WO2001073189A1 (en) | 2001-10-04 |
CA2397979A1 (en) | 2001-10-04 |
DE60110404T2 (en) | 2006-03-09 |
CA2397979C (en) | 2009-10-13 |
EP1274895B1 (en) | 2005-04-27 |
DE60110404D1 (en) | 2005-06-02 |
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