JPS63105162A - Production of carpet - Google Patents

Abstract

(57) [Abstract] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention involves dyeing a knitted structure under low tension, passing the knitted structure through at least two squeezing rollers, and dyeing the knitted structure under low tension.
This invention relates to a method for producing carpets of excellent color and shade uniformity by unraveling the R structure and producing the carpets from the unraveled dyed yarns.

W-21 Wool carpet threads were usually dyed in a cold and then wound into spools for weaving into carpets or for tasseling (touch ink). Synthetic yarns, such as nylon, follow the same method as wool, and some yarns are further dyed for use in pattern weaving. However, most synthetic carpet yarns, especially bulky continuous filaments, are undyed when manufactured in carpet form and are either dyed to a uniform tone throughout the carpet or have a pattern of color. If desired, print.

The advantages of dyeing in carpet form are relatively low processing costs per weight of yarn and better uniformity of color than dyeing with yarn. The disadvantages are the large capital investment in dyeing equipment and the difficulty in achieving accurate shade uniformity across the entire width of the carpet, which can add up to 15 feet of floor space. Today, tasseling is the main means of carpet production, in which a large number of threads are fed into an array of sewing machine-type needles closely spaced across the width of the carpet backing fabric, and the needles are moved up and down. Insert the thread into the lined dish towel and form a loop on the other side. Approximately 18oO is used to tuft the thread and feed it to the needle.
The spool racks required to hold packages of yarn up to and including the spools also require a large amount of floor space.

If one yarn or yarns are dyeable to a different degree than the others, visible light or dark streaks will appear along the entire length of the rug after dyeing, making the rug difficult to dye. It is difficult to accept. However, such defects can only be detected after the carpet has been dyed.

Prior patents temporarily combine a large number of yarns into a woven or knitted structure for ease of handling, and then remove temporary weft yarns or remove the knitted structure for later delivery to subsequent operations. We are disclosing how to unknit and separate the yarns. U.S. Pat. No. 4,045,848 to Honda et al. discloses such temporary weft insertion and removal, and U.S. Pat. No. 4,045,848 to Whitley et al. and U.S. Pat. No. 4,327,464 to Hutchison discloses knitting and unknitting. Furthermore, Whitacre and Hutcheson disclose dyeing and printing such temporary structures in multicolored patterns to obtain ``space dyed'' or Berber effect yarns. - No method has hitherto been realized that allows the use of such temporary structures in combination with special dye application methods to achieve excellent color uniformity of impressive shades.

Here: (a) The crimped thread is woven into a multi-ended ribbon-like structure; (b) The ribbon-like structure is first fed into the dye bath under low tension, and then preferably ribbon-like The dye is forced through each thread in the ribbon-like structure at least twice by feeding the structure into at least two squeeze rollers, where the squeeze rollers force the dye into each thread in the ribbon-like structure. pushing through and removing excess dye; (c) fixing the dye by heating the ribbon-like structure, preferably with steam at about 100°C; (d) rinsing the ribbon-like structure. and squeezing; (e) dyeing the ribbon-like structure; (f) unraveling the ribbon-like structure to separate the yarns; and (g) sending the unraveled yarn to a carpet tufting machine where it is finely processed. There has now been found a method for producing carpets with good color and shade uniformity from dyed yarn, comprising the steps of: producing a carpet with good color and shade uniformity.

The crimped yarns are preferably assembled into a ribbon-like structure by warp stockinette knitting or open weaving, characterized by the insertion of weft threads, the weft threads being removed when the ribbon-like structure is unraveled.

It is preferred to continuously add fresh dye to the dyeing machine so that all yarns can be treated with a uniform concentration of dye. By two or more sets of squeezing rollers or by other means such as two or more sets of jets or sprays from one or both sides, or by winding the thread under low tension with one or more fixed wiper bars, contact The dye can be repeatedly forced through the yarn by redispersing the dye onto the yarn and into the system by pulling it under.

by temporary rough weaving with weft yarns that are later retracted, or preferably to minimize the bulk of the assembly and reduce permanent distortion of the yarn into a knitted-dissolved crimped form. Warp stockinette knitting, preferably using a low stitch density, allows the threads to be assembled into a multi-ended ribbon-like structure. In order to avoid such distortion, it is preferable to use threads that have been twisted and fixed in advance. This ribbon-like structure is later unwound to separate the threads.

The open weave or knitting is characterized by the insertion of along-end weft yarns of about 1Cl6 or more, or by warp stockinette knitting forming continuous seams of about 2 cm or more. Such a textured configuration is necessary for complete and uniform penetration of the dye throughout the system and for complete steaming, rinsing and drying. Such penetration is also aided by minimal tension on the assembly during operation, which is also advantageous for optimal crimp and bulk preservation in the yarn.

The yarns mentioned herein may be a single yarn, or they may consist of two or more yarns that are twisted and heat set, or differently dyed, intertwined with air. It may be made of thread that can

When dyeing composite yarns with the method of the present invention, the uniformity of dyeing from yarn to yarn is very good, and the uniformity along the ends is better controlled than in traditional continuous yarn dyeing methods. be able to.

If a thread is present that has a dyeability significantly different from the majority of the threads, the tassel can be detected visually and removed for disposal as it enters the machine.

The dyeing equipment adapted for use in the method of the invention with slight modifications can be used to dye automotive seat belt webs, where the need for uniformity of dyeing in the warp direction is particularly great.

If desired, the yarn may be subjected to other treatments before, during or after dyeing. Such treatments can impart antimicrobial properties or repel stains or stains.

By feeding threads from a ribbon-like array of different colors to specific needles of the machine, stripes or other graphic designs can be formed.

The method of the invention can be used with both short fiber and continuous filament yarns and can be used advantageously with wool and synthetic vA fibers.

The method of the present invention can be carried out continuously from gathering the yarn into a ribbon-like structure to making the carpet, or alternatively, the dyed and dried structure can be stored in cans or tubes and later used. This can also be done on an intermittent basis, such as by supplying the carpet to the carpet manufacturer.

The superior dye uniformity, reduced capital investment, and floor space savings provided by the method of the present invention can benefit carpet factories of any size. Moreover, small carpet factories are especially helped by the increased productivity and reduced yarn inventory made possible by the method of the present invention. A factory located far away from the yarn source, for example in a foreign country, can significantly reduce the time from order to supply.

200 yarns each consisting of two 1700 denier trilobal filament nylon 66 bulky continuous filament yarns of 22 denier/filament, twisted and heat set, were placed on a bobbin shaft. from individual packages to a needle loom to weave in an 8-axis 4x4 configuration with one weft thread inserted for every approximately 1 cm of thread travel. This multi-ended ribbon-like structure is approximately 8 cm wide. The thread travel speed is approximately 10 m/min.

The ribbon was then sent to a Webtex steam dyer to dye Acid Red 361.3y/1:200% and Yellow, 2
g/l and acidic blue 277.0.51/! It is dyed with Ciba-Geigy's Tektalon' dye, which consists of two sets of squeezing rollers that force the dye into each thread. Both squeezing rollers remove excess dye to discard, after which the yarn enters a steamer where live steam brings the temperature of the yarn to about 1
The dye is fixed by increasing the temperature to 00°C. The yarn is then rinsed and wrung in 6 tanks on-line and then dried in a convection dryer at 120° C. for 2.5 minutes. The uniformity of the dye is excellent from edge to edge and meets commercial standards. The weft threads are then pulled out, the threads are separated, and the carpet tufts are sent to the eyelet board of the loom.

Patent Applicant: E.I. DuPont de Nimois & Co., Ltd.

Agent: Patent attorney Heikichi Odajima ・1 4-knee, 1 other person

Claims (1)

[Claims] 1. (a) The crimped yarn is assembled into a multi-ended ribbon-like structure; (b) the ribbon-like structure is first fed into a dyebath under low tension, and then the dye is transferred to the ribbon-like structure; (c) fixing the dye by heating the ribbon-like structure; (d) dyeing the ribbon-like structure by forcing it through each thread at least twice; (d) fixing the dye by heating the ribbon-like structure; (e) drying the ribbon-like structure; (f) unraveling the ribbon-like structure to separate the threads; and (g) sending the unwound threads to a carpet tucking machine. A process for producing a carpet with good color and shade uniformity from dyed yarn, characterized in that it comprises the steps of: producing a carpet with good color and shade uniformity therein. 2. The method according to claim 1, wherein the crimped yarn is assembled into a ribbon-like structure by warp stockinette knitting. 3. The method according to claim 1, wherein the crimped yarns are assembled into a ribbon-like structure by an open weave characterized by the insertion of weft threads, and the weft threads are removed when the ribbon-like structure is unwound. Method. 4. A method according to claim 1, in which the dye is forced through the threads in the ribbon-like structure by two sets of squeezing rollers. 5. further comprising removing excess dye after forcing the dye into the threads within the ribbon-like structure;
The method according to claim 4. 6. The method according to claim 1, wherein the heating for fixing the dye is steaming at about 100°C.