US3600732A - Beam-dyeing method for pile fabrics containing acrylic fiber pile - Google Patents

Beam-dyeing method for pile fabrics containing acrylic fiber pile Download PDF

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Publication number
US3600732A
US3600732A US14921A US3600732DA US3600732A US 3600732 A US3600732 A US 3600732A US 14921 A US14921 A US 14921A US 3600732D A US3600732D A US 3600732DA US 3600732 A US3600732 A US 3600732A
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United States
Prior art keywords
pile
dyeing
fabric
winding
dye liquor
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Expired - Lifetime
Application number
US14921A
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English (en)
Inventor
Genichi Hayashi
Tomoji Okubo
Koshin Miyamoto
Masatake Masuda
Syozo Shigita
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Wyeth Holdings LLC
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American Cyanamid Co
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Publication date
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Publication of US3600732A publication Critical patent/US3600732A/en
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    • 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
    • D06B5/00—Forcing liquids, gases or vapours through textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing impregnating
    • D06B5/12—Forcing liquids, gases or vapours through textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing impregnating through materials of definite length
    • D06B5/22—Forcing liquids, gases or vapours through textile materials to effect treatment, e.g. washing, dyeing, bleaching, sizing impregnating through materials of definite length through fabrics

Definitions

  • the present invention discloses a beam-dyeing process for pile fabrics having a pile of acrylic fibers involving use of a perforated plate of triangular cross section to eliminate winding irregularities and maintenance of specific winding density and volume rate of flow of dye liquor during dyeing.
  • Acrylic fibers are highly desirable for use as pile stock in such fabrics as carpets because of superior properties of bulkiness and dyeability.
  • Youngs modulus of acrylic fiber stock is lower in hot water than other types of fiber stock.
  • the pile fabric is spirally wound on a cylindrical beam bored with a number of dye liquor jet holes and the pile fabric in fixed position is dyed in the machine. Accordingly, since there is no withdrawal of pile fabric from the dye liquor during the dyeing procedure, tensile stresses due to withdrawal do not act on the pile fabric and defects inherent in the winch-dyeing machine are substantially eliminated.
  • beam-dyeing of pile fabrics containing acrylic fibers as pile stock the effects of such dyeing on the pile are greatly different from those observed employing other types of fiber stocks and little is known both as to the nature of the effects and the causes and means for elimination thereof.
  • a beam-dyeing procedure for pile fabrics having a pile of acrylic fibers characterized in that a perforated plate of substantially triangular cross section having substantially the same end thickness as the thickness of the pile fabric abuts against the dyeing beam having wrapping cloth therebetween and the pile fabric winding end is in contact with the perforated plate end, the pile fabric being wound around said beam while maintaining the weight per unit volume of pile-winding layers in the range of 0.15 to 0.05 grams per cubic centimeter and while maintaining the volume rate of flow of liquor per unit weight of pile fabric during dyeing in the range of 4 to 0.3 liters per second per kilogram.
  • FIGS. 1 and 2 illustrate the perforated plate used in the process of the present invention and winding of a beam employing said perforated plate.
  • FIG. I is a perspective view of the perforated plate showing the substantially triangular cross section thereof.
  • FIG. 2 is a cutaway sectional view showing a condition in which a pile fabric is wound on a beam.
  • the dyeing beam 3 of a beam-dyeing machine is a cylindrical body made of a metal, usually stainless steel, having rust resistant and corrosion resistant properties with respect to dye liquors and is supplied with dye liquor from a supply source, not shown, which dye liquor flows through a number of dye liquor flow holes 4 arranged in suitably spaced rows bored in the lateral surface of said cylindrical body, said dye liquor thus being supplied to a pile fabric 1 spirally wound on the dyeing beam 3 with the pile surface facing out.
  • the dye liquor is circulated through the beam-dyeing machine to an exhaust hole (not shown) to the supply source and again through the beam holes.
  • the direction of flow of the dye liquor has been indicated as from inside the dyeing beam 3 out through the flow holes and through the fabric winding to the exhaust hole.
  • the flow of dye liquor can be reversed, if desired, so as to enter the exhaust hole, then flow through the fabric winding to the flow holes to the inside of the dyeing beam and recirculated thence to the supply source.
  • Wrapping cloth 2 is a fabriclike body interposed between the dyeing beam 3 and the first layer of the wound pile fabric in order to prevent direct contact between the pile fabric I and the dyeing beam 3.
  • the wrapping cloth is wound around the peripheral surface of the dyeing beam 3 while maintaining a substantially constant thickness prior to the winding of the pile fabric 1.
  • a second wrapping cloth 2' surrounds the outer peripheral surface of the pile fabric 1 spirally wound on the dyeing beam 3, and a clamping pressure is exerted on the wrapping cloth 2' by circular rings 6 fitted on the ends of the dyeing beam.
  • the clamping pressure can be set at a predetermined value without changing the winding density of the pile fabric on the dyeing beam.
  • Pile fabrics can have an appreciable thickness compared to other fabric types. This thickness presents a particular difficulty with respect to winding such fabric around a dyeing beam. This difficulty arises from crossing over the winding end of the fabric of the various layers of pile fabric wound around the beam. Because of the initial crossover the pile near the winding end of the fabric is flattened considerably and interferes with passage of dye liquor therethrough. Since the initial crossover tends to produce an uneven hump in the winding, subsequent crossovers are affected by this hump with the appearance of flattened pile therein and nonlevel dyeing due to the interference with flow of dye liquor therethrough.
  • the perforated plate has a cross-sectional shape that is substantially triangular, with sides diverging slightly from straight lines in order to conform to the curvature of the beam, thus forming a concave side for positioning against the beam and a convex side for positioning the winding so as to eliminate the uneven hump.
  • the end, or base, of the triangular section is of a thickness which substantially corresponds to the thickness of the pile fabric.
  • the length of the perforated plate corresponds to the width of the pile fabric.
  • the sides of the triangular section of the perforated plate are of a length sufficient to prevent formation of the hump and may vary considerably depending upon the thickness of the pile fabric. Since the perforated plate is to eliminate the uneven hump formed when a pile fabric containing acrylic pile fibers is wound on a beam, it is-apparent that any length of sides of the triangular cross section of the perforated plate capable of achieving this result is suitable and may be employed.
  • the perforated plate is bored with a suitable number of holes corresponding in positioning to the pattern of the boring of the beam so that when the plate is positioned on the beam, holes in the plate will be in register with holes in the beam.
  • the perforated plate may be madefrom a variety of suitable materials but it is desirable to employ materials superior in resistance to contamination by dye liquid as in the case of the dye beam, and such materials as teak coated with Teflon or other coating resin and plastic materials which are heat and chemical resistant, such as melamine plastics may be employed. If desired, a fabric, not shown, may be interposed between the perforated plate 5 and the pile fabric 1.
  • the wrapping cloth 2 is wrapped around the dyeing beam 3, the perforated plate 5, with or without wrapping cloth interposed, is arranged to have the end or base of its triangular cross section contact the winding end of the pile fabric while its holes are in register with holes in the beam.
  • the pile fabric is then wound about the beam while maintaining a predetermined winding density.
  • the wrapping cloth 2 is positioned in such a manner as to surround the pile fabric while maintaining the winding density employed.
  • the sides'of the wrapping cloth 2' which extend beyond the width of the pile fabric are drawn to the lateral sur face of the dyeing beam and passed between the circular rings 6 and the dyeing beam.
  • the clamping pressure exerted bythe clamping rings 6 on the wrapping cloth 2' is then adjusted to maintain the winding density of the pile fabric 1 at substantially constant value.
  • the pile fabric contains acrylic pile fibers it is necessary that the wind ing density expressed as weight of pile fabric per unit volume be in the range of 0.15 to 0.05 grams per cubic centimeter. If the winding density is below that range specified, color differences between inner and outer layers of pile fabric after dyeing will be so great as to detract from the commercial value of the pile ,fabric from the viewpoint of level dyeing, although difficulties as to flattening of the pile and damage to the external appearance of the piles will not be encountered because of the low clamping pressure on the pile fabric.
  • the acrylic fibers whose Youngs modulus in hot water is inherently low, would readily lose stiffness with the result that the piles, which were upright in the weaving and finishing steps, will become flattened and contact each other so as to produce fluff or pills. Also, the bulky nature of the pile fabric will be lost and the hand and feel will be spoiled.
  • the volume rate of flow of dye liquor per unit weight of pile fabric be controlled within specific limits.
  • the volume rate of flow of dye liquor must be maintained in the range of from 4 to 0.3 liters per second per kilogram of fabric, preferably in the range of from 2 to 0.3 liters per second per kilogram of fabric. If the volume rate of flow of dye liquor is in excess of the range specified, local flattening of the piles will occur in the innermost and outermost layers of pile fabric on the dyeing beam. If the volume rate of flow of dye liquor is below the range specified, nonuniform dyeing and formation of air spaces will occur in the pile fabric.
  • an acrylic fiber as that term is employed in the present specification, is meant a fiber consisting of a major portion of acrylonitrile, particularly one consisting of at least 70 percent acrylonitrile and the balance of one or more monomers copolymerizable with acrylonitrile, as is well known in the fibers field.
  • the acrylic fibers useful in the invention include composite fibers obtained by cospinningtwo or more acrylonitrile polymers varying in thermal shrinkage, as are well known.
  • the pile fabrics contain pile of at least 50 percent by weight thereof of acrylic fibers and may be mix-spun pile fibers having additionally a content of natural or other synthetic fibers within the limits specified.
  • This fiber is of 10 denier and has staple lengths varying between 89 millimeters and 127 millimeters.
  • fiber B monocomponent fiber having as polymer component that designated as l in fiber A. This fiber is of 10 denier and has staple lengths of l 14 millimeters.
  • fiber C monocomponent fiber having as polymer component that designated as l in fiber A.
  • This fiber is of 15 denier and has staple lengths varying between 89 millimeters and 127 millimeters.
  • the yarn was incorporated into the base fabric so as to form 8 stitches per 25 millimeters, with the height of the cut piles adjusted to about 10 millimeters.
  • a dye liquor having the following composition was prepared for use in dyeing the above-described pile fabric using a beamdyeing machine:
  • the pile fabrics wound on the dyeing beams were immersed in the dye liquor at 60 C. which was then heated for 30 minutes to reach a temperature of 90 C., this temperature being maintained for minutes. Heating was then carried out for ID minutes to reach a temperature of 98 C. and this temperature was maintained for 60 minutes. The temperature was then lowered to 60 C. over a period of 40 minutes, thus completing the dyeing.
  • the dyed pile fabrics were measured for bulkiness by mea- A second set of similar samples of the dyed pile fabrics were separately immersed in 'y-butyrolactone at 60 C. to dissolve the acrylic fiber and the solutions were then allowed to cool to room temperature. The solution containing dissolved dyed fibers was measured for absorbancy by use of a colorimeter. In table ll are shown the various color comparisons expressed as -log T as well as the external appearance of the dyedfabrics based on a visual-sensual evaluation taking into account the pile configuration, bulky feel and hand of the fabrics.
  • Innermost layer s grams/cm 9.92 9. 7a 9. as 8.20 1. 95 7.61 7. 29 5. 25 5.15 Central layer 10. 83 10. 61 10. 54 10. 9. 63 9. 21 8. 88 6. 19 6. 16 outermost layer d0 11. 15 10. 90 10. 85 10. 73 10. 60 10. 10. 21 6. 20 6. 17

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Textile Engineering (AREA)
  • Woven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Coloring (AREA)
US14921A 1969-03-05 1970-02-27 Beam-dyeing method for pile fabrics containing acrylic fiber pile Expired - Lifetime US3600732A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP44017122A JPS4913953B1 (enrdf_load_stackoverflow) 1969-03-05 1969-03-05

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US3600732A true US3600732A (en) 1971-08-24

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US14921A Expired - Lifetime US3600732A (en) 1969-03-05 1970-02-27 Beam-dyeing method for pile fabrics containing acrylic fiber pile

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US (1) US3600732A (enrdf_load_stackoverflow)
JP (1) JPS4913953B1 (enrdf_load_stackoverflow)
BE (1) BE746811A (enrdf_load_stackoverflow)
DE (1) DE2010224A1 (enrdf_load_stackoverflow)
FR (1) FR2034668A1 (enrdf_load_stackoverflow)
LU (1) LU60458A1 (enrdf_load_stackoverflow)
NL (1) NL7002584A (enrdf_load_stackoverflow)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10064655B4 (de) 2000-12-22 2012-01-26 TRüTZSCHLER GMBH & CO. KG Vorrichtung zur Regelung der mindestens einer Karde zuzuführenden Faserflockenmenge

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3309720A (en) * 1963-11-27 1967-03-21 Du Pont Process for treating nonwoven pile fabrics

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3309720A (en) * 1963-11-27 1967-03-21 Du Pont Process for treating nonwoven pile fabrics

Also Published As

Publication number Publication date
NL7002584A (enrdf_load_stackoverflow) 1970-09-08
JPS4913953B1 (enrdf_load_stackoverflow) 1974-04-04
DE2010224A1 (enrdf_load_stackoverflow) 1970-10-22
BE746811A (fr) 1970-09-04
LU60458A1 (enrdf_load_stackoverflow) 1970-07-09
FR2034668A1 (enrdf_load_stackoverflow) 1970-12-11

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