US3922736A

US3922736A - Machine and method for space dyeing

Info

Publication number: US3922736A
Application number: US412294A
Authority: US
Inventors: Emery M Mand; Joyce C Amley; Executrix By Loretta Amley
Original assignee: Mand Carpet Mills
Current assignee: Mand Carpet Mills
Priority date: 1971-11-22
Filing date: 1973-11-02
Publication date: 1975-12-02
Anticipated expiration: 1992-12-02

Abstract

A machine for dyeing each of a plurality of strands of yarn with a plurality of colors in a random color pattern. Yarn taken from a creel is passed through a guide ring, a mixer board, and a traversing chain and then is delivered to a plurality of printing rollers. The mixer board and the traversing chain, moving in unison, cause the plurality of strands of yarn to be twisted and retwisted relative to its axis in opposite directions. This insures that the entry location of each individual strand into the dye printer, and therefore its location as it traverses the printer, is constantly varied to produce a truly random color pattern on each strand.

Description

[ Dec. 2, 1975 United States Patent Mand et al.

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.lliilullriillll MACHINE AND METHOD FOR SPACE DYEING [73] Assignee: Mand Carpet Mills, Los Angeles, 3 21 7 0 Calif.

Primary ExaminerDonald E. Watkins Attorney, Agent, or FirmGeorge F. Smyth [22] Filed: Nov. 2, 1973 21 Appl. NO.I 412,294

[57] ABSTRACT A machine for dyeing each of a plurality of strands of Related US. Application Data Continuation of Ser. No. 200,738, Nov. 22, 197i, abandoned.

yarn with a plurality of colors in a random color pattern. Yarn taken from a creel is passed through a guide ring, a mixer board, and a traversing chain and [52] US. Cl. 8/149; 8/l5l.2; 68/202;

then is delivered to a plurality of printing rollers, The mixer board and the traversing chain, moving in unison, cause the plurality of strands of yarn to be twisted and retwisted relative to its axis in opposite directions. This insures that the entry location of each individual strand into the dye printer, and therefore its location 0 ,i 9 m4 M 1 P121 3 5 0 5 D N A/ m 8 461 M Em M "'2 "W6 W WW m 6 o e ur "m7 5 20 0 d Ld mm 11] 18 55 .ll

Referen Cit d as it traverses the printer, is constantly varied to pro- UNITED STATES PATENTS duce a truly random color pattern on each strand.

37 Claims, 6 Drawing Figures U.S. Patent Dec. 2, 1975 Sheet 10f3 3,922,736

VENT EMERY M. M D

INVENTORS EMERY M. MAND JOYCE C. AMLEY 7 fl dl md A TTORNEVS U.S. Patent Dec. 2, 1975 Sheet 2 of3 I \I In",

/ olJ US. Patent Dec. 2, 1975 Sheet 3 of3 3,922,736

INVENTO EMERY M. MA JOYCE C. AMLEY A TT'ORNEVS MACHINE AND METHOD FOR SPACE DYEING This is a continuation application of my application Ser. No. 200,738 filed Nov. 22, 1971 and now abandoned.

BACKGROUND OF THE INVENTION This invention relates to a method and apparatus for dyeing a large number of strands of material in such a way that each strand is provided with a random pattern of several colors. Such strands may be used, for example in carpeting.

After the strands are dyed, they are passed through a steamer in order to set the colors, are washed to remove the excess dye, are dried to remove all moisture, and finally, are wound onto individual strand-receiving spools.

The strands to be dyed may be of any natural or manmade material and of any thickness and consistency so long as they are strong enough to be drawn through the dyeing machine without breaking. Although a variety of uses of such dyed strands have been developed over the years, it has been found extremely practical to use the materials to produce carpeting.

Originally, carpets and other items with multicolored pile utilized a plurality of spools of fiber, each having a single color. In the case of natural fibers, the material was vat-dyed and, in the case of man-made fibers, the material was either vat-dyed or color was added to the chemicals before the fiber was formed. No matter how the fibers were dyed, however, careful selection in the order of use of the spools was required when manufacturing the carpets and/or extra weaving steps were required to ensure that desired color variation effects were achieved across the carpet surface.

An improvement over that original method has been found to be to dye each strand with a plurality of colors along its length. The effect achieved is very good when the color pattern along the length of each strand is varied, and is best when the variation is random with respect to the length of each color and the order in which one color succeeds another along the strand. Although the effect produced is very effective and attractive in a low pile carpet, an exceptionally pleasing effect is achieved when the strands are used to produce shag carpeting.

Although almost any number of colors can be used for dyeing such strands, it has been found that the most commercially acceptable carpeting utilizes no more than three distinct colors in the tufts of the pile. However, unless the three colors are dyed into the individual strands in a truly random pattern, the finished carpeting in which the strands are used will appear to have a chevron-type color scheme which is unacceptable in most cases since such carpeting appears to alter the shape of the room, clashes with furniture and other decorative effects, and is usually unpleasant to the eye of the viewer. In other words, in order to insure that the colors are randomly dispersed throughout the surface of the carpeting so that the carpet does not appear to have a patterned appearance, the individual strands must be passed through the dye machine in such a way that the printing of the colors thereon is not accomplished in an apparent cyclic pattern.

In dyeing a plurality of strands, it has been proposed to pass the strands between a plurality of several pairs of rollers, the number of pairs corresponding to the number of colors to be printed onto the strands. One

of each pair of rollers is provided with an engraved dyeapplying section which extends about the periphery of the roller along a predetermined part of the length thereof. For example, if the strands are to be dyed so as to have three different colors, approximately onethird of one of the rollers in each pair is engraved with a dye-applying section. The three dye-applying sections are so located that the three engraved sections, considered together, extend across the full width of the printer through which the strands pass. In other words, the first engraved section might be positioned at the right side of the machine, the second at the center of the machine, and the third at the left side of the machine. Thus, every strand which passes through the machine contacts at least one of the engraved sections.

In some machines, the width of the dye-applying section in each successive pair of rollers is less than onethird the width of the machine and structure is provided which alters the time of contact between each strand and each dye-applying section.

In any event, both of the described types of machines require that all of the strands to be dyed be moved laterally back and forth across the width of the machine as they are drawn longitudinally through it. Thus, each strand will contact each of the dye-applying sections for a length of time determined by the lateral velocity of the strands relative to the machine. To accomplish this, some machines have been devised which will cause a plurality of parallel strands to move both longitudinally and laterally through the dye section. For example, a laterally oscillating comb has been provided through which the parallel strands must pass prior to entering the dyeing section. Movement of the comb causes the strands to move laterally back and forth across the machine as they are drawn through it; therefore, each strand will contact each of the engraved dyeapplying sections for a length of time dependent upon the width of the section and the speed of movement of the comb.

Unfortunately, these machines have not produced an optimum result since, for any given strand, the machine timing is such that the applied colors appear to be absolutely cyclically applied to the strand. In other words, each strand might have consecutive six inch sections of the first color, the second, the third, the second, the first, and so on, as it is moved back and forth across the printer. This might not be totally unacceptable, if every strand passed through the machine could be dyed with exactly the same length color sections since the carpeting might then be able to be manufactured without a discernible pattern, regardless of which strand is used at which location in the carpet. Otherwise, a laborious and expensive cataloging and positioning of strands in the carpet must be employed.

However, the strands in the prior art machines are not all printed so as to be identical since the lateral movement of the parallel strands through the machine causes those strands which are closest, for example, to the engraved dye-applying section of the third color to have more of the third color printed thereon than the strands on the opposite side of the machine. Obviously, this is also true for those strands which are adjacent the engraved dye-applying section for the first color which will be printed with more of the first color than with the third. Those strands at the center of the machine will receive more dye from the second color than from either the first or the third. As a result, random use of the finished spools will either cause a pattern to show up in the finished carpeting or else will cause undesirable streaks of each of the three colors at various locations throughout the surface of the carpet.

Thus, unless such patterns or streaks are desired, some means must be provided to dye each strand passing through the machine with a substantially identical but random color pattern along its length so that a finished carpet will have no discernible pattern, streaks, or chevron effect.

SUMMARY OF THE INVENTION The present invention relates to a method and machine which causes dyes to be applied to a large plurality of individual strands in a manner such that every strand has substantially the same randomly recurring color pattern along its length.

More specifically, the invention relates to a space dyeing machine through which a plurality of strands are passed. Every strand is initially passed through a basic color dye by a first set of rollers at a first dye station so that the natural color of the strand is no longer visible. The strands then pass between a second set of rollers at a second dye station, one of which has a plurality of raised printing surfaces thereon across its width. Only certain strands will contact those printing surfaces at any given instant and the remaining strands will pass between the second set of rollers without being dyed thereby.

A third color can be imparted to the strands by a third pair of rollers similar to the second set. One of the third set of rollers is provided with raised printing surfaces which are so located, relative to the printing surfaces of the second set, that those strands contacting the printing surfaces of the second set will not contact the printing surfaces of the third set.

On the other hand, only some of the strands which pass through the second set without contacting the printing surfaces will contact the surfaces of the third set. Thus, at any given longitudinal section across the plurality of strands will have only the first, basic dye color, some will be dyed to the color applied at the second dye station, and some will be dyed to the color applied at the third dye station. Of course, if additional colors are desired, additional dye stations could be added and the sizes and numbers of the printing surfaces adjusted accordingly.

The invention further relates to a method and machine which causes the strands to be moved through the dye section so that every strand has substantially the same recurring color pattern for each of the three colors. The machine accomplishes this by drawing each strand from the creel in such a manner that it continuously traverses the printer in a lateral direction relative thereto and also relative to the axis of the plurality of strands. This may be accomplished, for example, by forming the plurality of strands into an essentially tubular configuration with each strand extending along the length of the tube. The strands are then passed through a twister which flattens the tubular configuration into a substantially oblong tubular shape. This latter shape is passed through the printer in a flattened form such that the upper and lower walls of the tube actually form two adjacent perpendicular sheets.

Although the specific configuration of the plurality of strands, as it is brought into the printer, is not critical, an understanding of the invention will be enhanced by a discussion thereof in the configurations as described above.

In any event, considering the plurality of strands entering the printer as a flattened tube, this tube is rotated about its axis first in one direction and then in the other by the twister so that the entire plurality of strands may be considered to be twisted clockwise, counterclockwise, and back again in an oscillating fashion.

As a result, the lateral location at which each strand enters the printer is constantly changing and, therefore, the lateral location of each strand passing any given point in the printer is also constantly changing without reference to the location of any other strand. No strand or strands can be considered to be closest to the printing surface of the rollers at the second or third dye stations and every strand will contact one or more printing surfaces at each of the second and third dye stations at one time or another, for essentially equal lengths of time. In other words, rather than having the plurality of strands move laterally and longitudinally through the machine, the plurality of strands is moved longitudinally through the machine at the same time each strand is individually being moved laterally. Thus, each strand moves laterally through the machine individually, but the plurality of strands moves longitudinally as it is continuously twisted and retwisted about its axis.

In order to accomplish the twisting and retwisting of the body of strands as it passes through the dyeing section, a mixer board and a traversing chain are provided which oscillate in unison. Each strand passes through a particular location in each of those elements and movements of the strands through the dyeing section is thereby controlled. Although the mixer board may be formed in any desired configuration, it has been found convenient for it to be formed in the shape of a circular disk having passages all about the edge thereof through which the strands pass. The traversing chain, as seen from the strandent ry end of the machine may be formed in substantially the oblong tubular shape desired for the configuration of the plurality of strands before they enter into the machine. Thus, the strands form a cylindrical configuration as they pass through the mixer and that configuration becomes elongated into an oblong tube as it passes through the traversing chain. Upon leaving the traversing chain, the tube is flattened completely so that its upper and lower surfaces enter into contact and twist across one another as they pass through the dyeing machine.

All of the strands are dyed at the first dye station so as to eliminate all of the original color of the fibers. The structure used to guide the strands through the first station is located so that the strands enter the second dye station from a slightly elevated plane, thereby forcing them against the upper roller at the second station.

Each ofthe upper rollers at the second and third dye stations may be provided with a plurality of raised dye application surfaces formed at different positions along the axes of the rollers. For the sake of convenience, the dye application surfaces will hereinafter be referred to as printing surfaces. The location of the printing surfaces is critical only insofar as it is desired to prevent any strand from contacting printing surfaces in both the second and third stations. The printing surfaces force the strands in contact therewith against the dye carrying surface of an opposed roller at each station, thereby imparting due to those strands.

At the opposite end of the machine from the twisting apparatus, an unraveler is mounted in a slightly elevated position relative to the color imparting rollers. The elevation insures that the strands are forced against the upper roller at the third station. Although the unraveler may be of any desired configuration or structure, in the preferred embodiment it is envisioned as comprising a pair of opposed rollers having intermeshing longitudinal ridges thereon which terminate in similarly intermeshing helixes at the ends of the rollers. At opposite ends of the rollers the helixes are formed extending in opposite directions. The unraveler rollers cooperate with one another to draw the strands from the machine in such a manner that the body of strands remain twisted while in the machine but becomes untwisted as it passes from the unraveler. The individual strands may then be conveniently passed through the remainder of the operation, i.e., steaming, washing, drying, and being wound upon individual spools, without interfering with one another or becoming entangled.

With this invention, each individual strand is provided with a random color pattern which is substantially identical to the random color pattern of every other strand. As a result, when a carpet or other device utilizing the strands are to be manufactured, the operator can select any spool without having to determine whether or not its color pattern will create a pattern or streaking in the finished article. The completed product thus assumes the most commercially acceptable appearance without requiring exceptional time or skill by the operator producing the carpet.

Many further advantages, objects, modes, and embodimenrs of this invention will readily be understood by those skilled in the art by perusal of the following Detailed Description, taken together with the accompanying drawings, which describes what is presently considered to be a preferred embodiment of the best mode contemplated for utilizing the novel principles set forth in the claims. It will be realized, however, that the description and the accompanying illustrations are merely illustrative of the principles of the invention and only one of many specific structures or embodiments which may be utilized in the employment of those principles. Therefore, the illustration and description are not to be considered to be restrictive of the invention defined in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side perspective illustration of a space dyeing machine formed in accordance with the present invention;

FIG. 2 is a rear perspective illustration of one embodiment of a device for twisting the body of strands entering the machine of FIG. 1, as seen along a line IIII therein;

FIG. 3 is a partial view of apparatus for alternately reversing the direction of twist imparted to the body of strands, as seen along a line IIIIII of FIG. 2;

FIG. 4 is a partial view of a traversing element utilized to form a body of strands into an oblong or flattened tubular configuration and twist the tube in opposite directions about its axis as the strands pass through the dyeing structure;

FIG. 5 comprises a sectional side view of two pairs of dyeing rollers, illustrating the manner of passage of the strands therethrough; and

FIG. 6 comprises a partial perspective illustration of an unraveler utilized to draw the body of strands from the dyeing machine in a manner such that the body becomes unraveled only after leaving the machine.

DETAILED DESCRIPTION As shown at the upper left corner of FIG. 1, a large plurality of strands 11 is delivered to a locater 13. The strands may be delivered to the locater by any suitable means from a creel (not shown) in which is mounted a number of spools of material equal to at least the number of strands to be dyed. If desired, each strand can be delivered to the locater 13 through a plastic tube 15 so that the machine operator can trace the location of the strand as it passes to the locater and can direct the strand to it by suitable means such as compressed air.

The locater may be of any desired size and shape and merely serves as a fixed point of reference for each strand as it enters the machine.

The locater 13 may be fixed in position upon a support 17 which, in turn, may be mounted on any suitable base member 19. In use, the operator can position each strand within a tube 15, force compressed air through the tube, and draw the strand through a specific aperture at the end of the tube in the locater. As a result, the operator is required to spend a minimum amount of time in bringing individual strands to the locater.

As each strand comes through the locater, it is brought to a mixer 21 having a plurality of apertures equal in number to the apertures in the locater 13. Each of the strands is passed through a specific passage in the mixer 21, and is then passed through corresponding passages in a traversing element 23 which will be described later.

As is clearly illustrated in the figure, as the body of strands moves from the mixer 21 to the traversing element 23, it is directed into a substantially flattened or elongated tubular configuration. Although this configuration is not necessarily critical and other configurations could be used, it has been found that the flattened tubular configuration is particularly suitable for twisting the body of strands about its axis as it passes through the dyeing machine.

Thus, by structure to be described later, the mixer 21 and the traversing element 23 oscillate about their common axis and form a twisting device 25 which serves to twist the body of strands first in one direction and then in the opposite direction as they pass through the dyeing machine. As a result, each strand is passed through the machine in such a way that the specific point of entry of the strand into the machine is constantly being changed relative both to the machine and to the axis of the plurality of strands. As will be explained below, this allows each individual strand to come into contact with each of the dye colors for essentially the same length of time as does every other strand.

It will be realized by those skilled in the art that this twisting and retwisting could be accomplished by a variety of structures, many of which will not appear to resemble that illustrated and described here but will nevertheless produce the inventive result achieved by this twisting which allows every strand to be in contact with each dye for a specific period of time, relative to its length, regardless of the position of the strand as it passes through the locater 13'.

Referring now to FIGS. 2-4, an exemplary drive system has been illustrated showing a variety of elements which may be utilized to oscillate the twister 25. In the illustrated embodiment, a motor 27, operatively connected to a shaft 29, drives a gear 31 which is in contact with a pinion 33 on a second shaft 35. A cog belt pulley 37 mounted on the shaft 35 may be used to drive a corresponding cog belt pulley 39 on a third shaft 41. The shaft 41 may have mounted thereon a gear 43 and a-cog belt pulley 45 which drive corresponding gears 47 and 49, respectively, on a fourth-shaft 51. A pair of electrically operated clutches 53 and 55 may be mounted on the shaft 51 to control the direction of the output end of the shaft shown on the rear end of the support 17 at 57.

The clutch 53 may cooperate with the gear 47 and the clutch 55 may cooperate with the cog belt pulley 49 to control the direction of rotation of the shaft; For example, assuming that shaft 29 and gear 31 are rotating in the clockwise direction, as seen in FIG. 2, gear 33, shaft 35, and cog belt pulley 37 will rotate in the counterclockwise direction. As a result, gear 39, shaft 41, gear 43, and cog belt gear 45 will rotate in a counterclockwise direction since they are driven by a cog belt operatively connected to the gear 37. Since the gear 43 is rotating in the clockwise direction, gear 47 will rotate in the counterclockwise direction. Therefore, when clutch 53 is engaged, the output end 57 of shaft 51 will rotate in a clockwise direction. On the other hand, since gear 45 is rotating in the counterclockwise direction, acting through a cog belt it will drive pulley 49 in the counterclockwise direction. clutch 55 is actuated, the output end 57 of shaftSlwill be driven in the counterclockwise direction. In other words, the direction of rotation of the output end 57 of shaft 51 will vary depending upon the actuation of the clutches 53 and 55. 1

At the output end 57 of the shaft 51, a gear or pulley 67 drives a chain or belt 69 which turns a corresponding gear or belt 71 mounted adjacent the upper end of the support 17 on a shaft 73 which is rotatable in the support. Mixer 21 is mounted on the shaft 73 and,-as shown in FIG. 4, a gear 75 is also mounted on the shaft to cooperate with upper and lower elements of at least one of the chains 77 of the traversing element 23. If desired, the shaft 73 can extend far enough to include a second gear 79 which also drives the second chain 81. However, the second chain 81 may also be driven by sprockets mounted upon shafts which are operatively fixed to sprockets at the opposite ends of the chains 77.

In summary, any suitable drive system, whether or not identical to that described above, which can oscillate the twister may be utilized without affecting the scope of the invention. With respect to the abovedescribed system, however, it is seen that the motor 27,

acting through the clutches 53 and 55 will cause the Therefore, when shaft 73 to rotate first in one direction and then in the the microswitch 87 which controls the actuation of clutches 53 and 55. For example, if the clutch 53 is actuated, thereby'causing the twister 25 to rotate clockwise, the actuator 85 shown at the right in FIGS. 2 and 3 will contact the lever 87, operating the microswitch 65. In turn, this will deactivate the clutch 53 and activate the clutch 55 causing the mixer to rotate in the opposite direction until the switch lever 87 is contacted bythe actuating lever 85 on the left of the mixer.

By providing the oscillating linkage 61 to operate the lever 63 upon which switch 65 is mounted a more random oscillation of the mixer can be produced since the location at which the operating levers'85 contact the switch lever 87 will vary from one cycle to the next, thereby producing changes in the color pattern provided along the length of each strand. In certain instances, however, it may be desired to produce certain strand-dyeing effects with certain colors in which a more set pattern is used for dyeing each strand. In such a case, the linkage 6lmay be disconnected and the lever 63 fixed in a single position.

Reference to FIGS. 2 and 3 will also clearly reveal that the strands may be brought to the dyeing section of the machine through passages in the mixer 21, locater 13, and traversing element 23 which are located so as to form two or more concentric tubes, thereby increasing the capacity of the machine. Referring again now to FIG. 4, it is seen that each of the traversing chains 77 and 81 is provided with a plurality of individually mounted guide elements 91, each having suitable passages therethrough for guiding the strands into the dyeing machine. Although a single chain, such as 77 or 81 could be utilized in the traversing element 23, it has been foundthat the use of two chains results in better control of the movement of the strands without creating stresses therein which would tend to cause them to break. Further, the use of the two chains allows the flattened tubular configuration to be more precisely delivered to the dyeing section of the machine.

Summarizing the features of the above-described structure, mechanicaland/or electrical components are provided to twist a body of strands about its axis, first in one direction and then in the opposite direction. If desired, structure may also be provided to cause the timing of the oscillation of the twister to vary so that the operation of the twister is not truly cyclic. In other words, rotation of the twister in one direction will not necessarily be equal to the amount of rotation in the opposite direction, orveven in the first direction when itagain revolves in that direction. Of course, when it is desired that the amount of twist in one direction be identical to the amount of twist in the opposite direction, the linkage 61 can be disconnected and the lever 63 fixed against movement.

Referring again to FIG. 1, it is seen that asthe body of strands leave the traversing element 23, the tubular configuration becomes flattened by drawing the strands under a first roller 101 and over a second roller 103 mounted at opposite ends in

frames

105 and 107. Leaving the roller 103, the body of twisted strands enters the first dye station by passing under a first dye roller 109 which draws the strands through a dye trough 111 into which a first coloring dye is passed from a reservoir 1 13. The strands are then drawn betweenthe lower dye roller 109 and an'upper, .dye. roller 1'15 and over about the upper dye roller.

The roller 115 is journaled in bearings mounted on bars 119 and 121 in the

frames

105 and 107, respectively. The bars 119 and 121 are pivoted as at 123 and the opposite ends of the bars may be adjusted relative to the

frames

105 and 107 by suitable bolt means 125 which thread into the frames. As a result, the force applied on the strands between the rollers 109 and 115 can be varied to alter the amount of dye retained by the strands as they leave first dye station 100.

As the body of strands leave the first dye station, they enter the second dye station 130 and pass between a set of dye rollers comprising an upper roller 131 and a lower roller 133. The lower roller 133 revolves in a dye trough 135 which receives dye from a second color reservoir 137. The upper roller 131 may be provided with a plurality of raised printing surfaces, two of which have been illustrated at 139 and 141. The remainder of the roller 131 has a smaller peripheral diameter than that of the printing surfaces so that only the printing surfaces contact the peripheral surface of the lower roller 133. As a result, only those strands which are in contact with the printing surfaces 139 and 141 come into contact with the lower roller 133 and receive dye which has been accepted by the periphery of that roller from the dye pan 133.

As will be seen by a close review of FIG. 1, since the body of strands is forced up and over the roller 115, they are biased upwardly against the roller 131. Therefore, any strands which are not in contact with the dyeapplying surfaces 139 and 141 will be in contact with the smaller diameter surfaces of the roller 131 and will not receive any dye from the lower dye roller 133. It will also be noted that the roller 131 may be moved toward and away from the roller 133 in the same manner that the distance between rollers 115 and roller 109 can be adjusted.

At a third dye station 150, a third set of

dye rollers

151 and 153, which are similar to the

rollers

131 and 133, cooperate in the same manner to apply dye, from a third color reservoir 155 and a dye pan 159, to any strandspassing beneath dye applying surfaces on the roller 151 such as those illustrated at 157, 159, and 161.

With structures such as this, three different dye colors may be applied to each strand as the body of strands passes through the machine. It will be realized, of course, that more colors could be applied to the strands by adding additional dye stations and adjusting the locations of the dye-applying surfaces on the rollers. It will also be realized that, if desired, the locations of

rollers

131 and 133, and also 151 and 153, could be reversed so that the rollers having the dye-applying applying surfaces could be rotated through the dye pans and the strands could be biased upwardly against the rollers having constant diameters. However, in some instances this relationship would be unsatisfactory since the dye might tend to travel along the length of the constant diameter roller and begin to color strands at locations not scheduled for coloring.

In order to more clearly illustrate the passage of the strands through the second and third dye stations, there is shown in FIG. 5, the

dye stations

130 and 150. At any given cross section of the body of strands, some of the strands leaving the first dye station 100 will be forced against the roller 133 at dye station 130 by the dyeapplying surface 141 and those strands will be dyed in accordance with the color material in the pan 135.

However, at the same cross section, other strands will ride against the smaller diameter surface on the roller 131 and will not receive any color from the roller 133. As the selected cross section of the body of strands then travels to dye station 150, between the

roller

151 and 153, some of the strands will accept dye from the roller 153 as a result of being pressed against that roller by the dye-applying surface 159. On the other hand, other strands will be biased against the smaller diameter surfaces of the roller 151 and will not be dyed by that color.

More precisely, at a selected cross section, some strands will receive color from the pan 135, some will receive color from the pan 159, and some will not be dyed at either of those dye stations. Movement of the latter through the dye stations will be such as to bias them against the smaller diameter surfaces of both

rollers

131 and 151. Those strands will therefore receive dye only from the first station since they are forced through the pan 111 by the roller 109. Of course, since the point of entry of each strand is constantly changing, the strands which pass the second and third dye stations as described above are also constantly changing.

As the strands leave the third dye station, they are passed through an unraveler which may, if desired, comprise a pair of

rollers

171 and 173 as shown in FIGS. 1 and 6. The unraveler rollers are mounted in the frames and 107 in such a way that the plane of their intersection is slightly elevated above the plane of intersection of the

rollers

151 and 153, thereby aiding in biasing the strands against the reduced diameter sections of the roller 151.

The unraveler rollers each include a plurality of Iongitudinal ridges 175 on their peripheries. The ridges are curved adjacent each end to form helical ridges or fins 177 which prevent the outer strands from moving toward the center of the machine. The ridges or fins on each roller intermesh with the ridges on the other roller so that the strands are positively gripped between the rollers as they pass from dye station 150. This structure, especially the helical end sections 177 causes a spreading of the strands to take place, thereby prevent ing the twisting and retwisting of the strands from causing the body of strands to combine into a tight, ropelike structure. Therefore, as the strands are drawn from the machine, they are maintained in a substantially parallel relationship for a sufficient distance to allow them to pass through a comb (not shown) for delivery to the steamer in controlled groups which are not twisted or tangled.

The

rollers

171 and 173 serve to pull the strands out of the third dye station for delivery to the next operation. If the

rollers

171 and 173 had a solid or continuous, circumference, the strands would have to be compressed in a nipping action between the rollers in order to be pulled. This compression would squeeze some of the dyes out of the strands, smearing the dyes in an undesirable manner. However, since the rollers have the longitudinal ridges or fins as described above, the cooperating fins, which effectively mesh with one another but never touch, will prevent the strands from being compressed between roller surfaces. Consequently, the dyes on the strands will not be smeared and the resultant products will not be spoiled.

The individual rollers in the machine may be provided with a turning force as necessary by means of a suitable drive mechanism 181, thereby regulating the velocity of the strands through the dyeing section so that the optimum results are achieved.

In summary, the invention provides a space dyeing machine which twists and retwists a large body of strands so that the position of each strand as it passes through the dyeing section of the machine is constantly varied. The strands are not moved laterally through the machine in a body, but instead are constantly moved laterally relative to their axes as well as to the machine, thereby providing better control of the finished product in ensuring identical strand-dyeing. The strands are moved past dye rollers in such a way that they come into contact with specific portions of those rollers, some of which provide dye coloring to the strands and some of which do not. These combinations of features allow each individual strand to be dyed in such a way that a truly random pattern of color is produced on each strand, but every strand which passes through the machine has substantially the identical random color pattern. As a result, products in which the strands are employed are provided with a substantially uniform coloration which does not have any pattern, stripes, or chevron effect across its surface. The resultant strands may be used to produce a much more beautiful carpet which is very relaxing and pleasant to view, compared to those produced by prior art methods.

Thus the applicants have described one embodiment ofa method and machine employing new and improved concepts developed in the space dyeing art. These concepts yield a true advancement in that art since products manufactured from the space dyed strands are far more beautiful and commercially acceptable. Many modifications, alterations, and distinct embodiments of these concepts will now become apparent to those skilled in the art without exceeding the scope of the invention as described in the following claims, wherefore:

What is claimed as the invention is: 1. A machine for dyeing each of a plurality of strands of yarn with a random coloration along the length thereof comprising means for arranging said plurality of strands in substantially a single plane defining a center line axis,

means for moving said plurality of strands longitudinally through the single plane,

means forconstantly varying the position of each strand of said plurality of strands relative to the axis of the plurality thereof and the point of entry of each strand of said plurality into the machine, and

means for applying a dye only to the strands of said plurality which traverse a predetermined location relative to the lateral and longitudinal limits of the plane.

2. The machine of claim 1 wherein said dye applying means comprises a source of dye, a first roller which rotates through said source of dye, a second roller parallel and adjacent to said first roller having a first, relatively small diameter peripheral section extending along a predetermined portion thereof and separated from said first roller and a second, relatively large diameter peripheral section extending along a predetermined portion thereof and closely adjacent to said first roller, and

means for directing said plurality of strands between said first and second rollers. 3. The machine of claim 1 wherein said lateral movement means includes means for forming said plurality of said strands into an oblong tubular configuration, means for flattening the tubular configuration so that the opposed elongated surfaces" thereof are placed into abutment, and means for rotating the flattened tubular configuration about its axis. 4. A machine for dyeing each of a plurality of strands of yarn with a plurality of colors in random coloration along the length thereof comprising means for constantly varying the position of each strand of said plurality of strands relative to the axis of the plurality thereof and the point of entry of each strand of said plurality into the machine, and

means for applying a coloring material to every strand passing a predetermined position relative to the longitudinal and lateral dimensions of the machine and for preventing the application of the coloring material to any other strand which is at the same longitudinal position but at a different lateral position.

5. The machine of claim 4 wherein said means for constantly varying the strand position comprises means for aligning every strand of said plurality relative to every other strand thereof and for aligning said plurality of strands about a common axis, and

means for twisting said plurality of strands about its common axis.

6. The machine of claim 5 wherein said means for twisting said plurality of strands about its common axis comprises oscillatable means for twisting said plurality in alternating clockwise and counterclockwise directions.

7. The machine of claim 6 wherein said twisting means further includes means for causing said oscillatable means to change from clockwise to counterclockwise and back again at varying time intervals.

8. The machine of claim 4 wherein said color material applying means comprises a source of color material, a first roller which rotates through said source and thereby becomes coated with the color material, a second roller having at least one raised surface thereon at a predetermined location along the axial dimension thereof, said first and second rollers being so located relative to one another that said raised surface is in close contact with said first roller,

and means for biasing said plurality of strands against said second roller across the length thereof.

9. The machine of claim 4 including means for unraveling the plurality of strands after the coloring material has been applied thereto.

10. The machine of claim 9 wherein said unraveling means comprises a pair of adjacent rollers having intermeshing ridges extending along the lengths thereof and ending in complementary helixes at the ends thereof. 11. A space dyeing machine comprising means for arranging a plurality of strands in substantially parallel relationship about a common axis, means for oscillatably twisting the plurality of strands about the common axis in opposite directions of rotation including means for constantly varying the point of entry of each strand of the plurality as it enters the dyeapplying section of the machine, a first dye station comprising means for dyeing all of the strands of said plurality a first color, a second dye station comprising means for dyeing selected strands of said plurality a second color, and a third dye station comprising means for dyeing selected strands of said plurality a third color. 12. The machine of claim 11 including means for unraveling said plurality of strands as the dyed portions thereof are removed from the machine. 13. A space dyeing machine comprising means for presenting a plurality of strands to a dyeing apparatus including means for constantly varying the point of entry into the dyeing apparatus of each strand of said plurality, while simultaneously varying the location of each strand of said plurality relative to approximately fifty percent of the strands of said plurality at the point of entry into the dyeing apparatus, and a dye apparatus for selectively applying dye to strands of said plurality in such a manner as to apply dye to every strand of said plurality at intervals along the lengths thereof. 14. A method of space dyeing strands of fiber comprising the steps of arranging a plurality of strands about an axis, alternately twisting the plurality of strands about the axis, first in one direction and then in the opposite direction, then passing the thus alternately twisted plurality of strands through a dyeing apparatus, and applying dye to each strand at intervals, along the length thereof in said dyeing apparatus. 15. The method of claim 14 wherein said step of twisting the plurality of strands includes the step of constantly varying the point of entry of each strand into the dyeing apparatus. 16. The method of claim 14 wherein said step of applying dye to each strand includes the steps of moving said plurality of strands between a first roller having a constant diameter throughout the length thereof and a second, cooperating roller having a plurality of different diameters throughout the length thereof, and biasing the plurality of strands toward the second roller. 17. The method of claim 14 including the penultimate step of applying dye to every strand of the plurality throughout the entire length thereof. 18. The method of claim 14 including the step of applying a second dye to each strand at distinct intervals along the length thereof in said dyeing apparatus. 19. The method of claim 14 including the step of unraveling the plurality of strands after they pass from the dyeing apparatus. 20. A method of space dyeing comprising the steps of constantly varying (a) the point of entry of each strand pulled through a dyeing apparatus and (b) the location of each strand relative to every other strand in a plurality of strands pulled through the apparatus, providing each strand with a first color throughout the length thereof, providing each strand with a second color at random intervals along the length thereof, and providing each strand with a third color at random intervals along the length thereof, the latter two steps so accomplished as to result in finished strands each having three distinct colors at random intervals along the length thereof. 21. Apparatus for space dyeing a plurality of strands of fibers comprising means for locating and arranging the strands of the plurality in a predetermined configuration about a common axis, means for altering the configuration of the plurality of strands into a flattened tubular configuration, means for oscillatably twisting the plurality of strands about their common axis, and means for applying dye to each of the strands of the plurality at random intervals extending along the lengths thereof. 22. The apparatus of claim 21 wherein said dye-applying means comprises means for dyeing each strand to a first color throughout the entire length thereof and means for dyeing each strand to a second color throughout random intervals along the length thereof such that the intervals along the strands of the plurality of strands are not coextensive with one another. 23. A machine for dyeing each of a plurality of strands of yarn comprising means for directing a plurality of strands of yarn in the machine toward a color application apparatus, means downstream from said directing means for applying a coloring material to strands of yarn as they pass a predetermined position relative to said machine, and means downstream from said color application means for drawing the plurality of strands out of said machine including means for preventing smearing of the coloring material on the strands and for preventing entanglement of said strands as they pass out of said machine comprising a pair of adjacent rollers having intermeshing fins extending along the lengths thereof and ending in complementary helixes near the ends thereof. 24. A machine for dyeing each of a plurality of strands of yarn comprising i means for directing a plurality of strands of yarn into the machine and toward a color application apparatus,

means in said machine for applying a color to at least some of said plurality of strands of yarn, and means downstream from said color application means for drawing the plurality of strands past said color application means including means for spreading the strands to prevent entanglement of the strands with one another comprising a pair of adjacent rollers having intermeshing fins extending along the lengths thereof and ending in complementary helixes near at least one longitudinal end of each of said rollers.

25. Apparatus for pulling a plurality of substantially parallel strands arranged in a common plane while maintaining the strands in the substantially parallel relationship comprising a pair of rollers mounted with the axes thereofin parallel, spaced relationship each having a plurality of fins extending substantially parallel to the axis of the roller and substantially equally spaced about the periphery thereof, each fin having a portion, adjacent at least one longitudinal end thereof, extending in a helix relative to the axis of said roller, and

means for driving said rollers so that said fins on each roller intermesh and do not contact the fins of the opposed roller throughout the area across which the strands are passed.

26. The apparatus of claim 25 wherein said fins have helix portions at both ends of said rollers.

27. The apparatus of claim 26 wherein said helix portions at the ends of each of said fins extend in opposite directions, relative to the axis of said roller.

28. A machine for dyeing each of a plurality of strands of yarn into a random coloration along the length thereof comprising means for arranging said plurality of strands in substantially a single plane defining a center line axis, means for moving said plurality of strands longitudinally through the single plane,

means for moving each of said strands in said plurality laterally across the single plane relative to the center line axis of the plane including means for forming said plurality of said strands into an oblong tubular configuration,

means for flattening the tubular configuration so that the opposed elongated surfaces thereof are placed into abutment, and

means for rotating the flattened tubular configuration about its axis, and

29. A method of space dyeing strands of fiber comprising the steps of arranging a plurality of strands about an axis,

twisting the plurality of strands about the axis in a first and second direction, thereby constantly varying the point of entry of each strand into the dyeing apparatus,

passing the twisted plurality of strands through a dyeing apparatus, and applying dye to each strand at intervals along the length thereof in said dyeing apparatus. 30. A method of dyeing strands of fiber comprising the steps of arranging a plurality of strands about an axis,

twisting the plurality of strands about the axis in a first direction and a second direction,

passing the twisted plurality of strands through a dyeing apparatus, and

applying dye to each strand at intervals along the length thereof in said dyeing apparatus by moving said plurality of strands between a first roller having a constant diameter throughout the length thereof and a second, cooperating roller having a plurality of different diameters throughout the length thereof, and

biasing the plurality of strands toward the second roller.

31. The machine of claim 4 including means for pulling the plurality of strands of dyed yarn through the machine without smearing the dye thereon comprising a pair of adjacent rollers having intermeshing fins extending along the lengths thereof and ending in complementary helixes near at least one longitudinal end of each of said rollers. 32. The machine of claim 12 wherein said unraveling means comprises a pair of adjacent rollers having intermeshing fins extending along the lengths thereof and ending in complementary helixes near at least one longitudinal end of each of said rollers.

33. The machine of claim 32 wherein said helix portions at the ends of said fins extend in opposite directions, relative to the axes of said rollers.

34. The machine of claim 1 including means for pulling the plurality of dyed strands of yarn through the machine while maintaining the strands in a substantially parallel relationship comprising a pair of rollers mounted with the axes thereof in parallel, spaced relationship each having a plurality of fins extending substantially parallel to the axis of the roller and substantially equally spaced about the periphery thereof, each fin having a portion, adjacent at least one longitudinal end thereof, extending in a helix relative to the axis of said roller, and means for driving said rollers so that said fins on each roller intermesh and do not contact the fins of the opposed roller throughout the area across which the strands are passed.

35. The machine of claim 34 wherein said fins have helix portions at both ends of said rollers.

36. The machine of claim 35 wherein said helix portions at the ends of each of said fins extend in opposite directions, relative to the axis of said rollers.

37. The method of claim 14 including causing said twisting step to be accomplished randomly.

Claims

1. A MACHINE FOR DYEING EACH OF A PLURALITY OF STRANDS OF YARN WITH A RANDOM COLORATION ALONG THE LENGTH THEREOF OCMPRISING MEANS FOR ARRANGING SAID PLURALITY OF STRANDS IN SUBSTANTIALLY A SINGLE PLANE DEFINING A CENTER LINE AXIS, MEANS FOR MOVING SAID PLURALITY OF STRANDS LONGITUDINALLY THROUGH THE SINGLE PLANE, MEANS FOR CONSTANTLY VARYING THE POSITION OF EACH STRAND OF SAID PLURALITY OF STRANDS RELATIVE TO THE AXIS OF THE PLURALITY THEREOF AND THE POINT OF ENTRY OF EACH STRAND OF SAID PLURALITY INTO THE MACHINE, AND

2. The machine of claim 1 wherein said dye applying means comprises a source of dye, a first roller which rotates through said source of dye, a second roller parallel and adjacent to said first roller having a first, relatively small diameter peripheral section extending along a predetermined portion thereof and separated from said first roller and a second, relatively large diameter peripheral section extending along a predetermined portion thereof and closely adjacent to said first roller, and means for directing said plurality of strands between said first and second rollers.

3. The machine of claim 1 wherein said lateral movement means includes means for forming said plurality of said strands into an oblong tubular configuration, means for flattening the tubular configuration so that the opposed elongated ''''surfaces'''' thereof are placed into abutment, and means for rotating the flattened tubular configuration about its axis.

4. A machine for dyeing each of a plurality of strands of yarn with a plurality of colors in random coloration along the length thereof comprising means for constantly varying the position of each strand of said plurality of strands relative to the axis of the plurality thereof and the point of entry of each strand of said plurality into the machine, and means for applying a coloring material to every strand passing a predetermined position relative to the longitudinal and lateral dimensions of the machine and for preventing the application of the coloring material to any other strand which is at the same longitudinal position but at a different lateral position.

5. The machine of claim 4 wherein said means for constantly varying the strand position comprises means for aligning every strand of said plurality relative to every other strand thereof and for aligning said plurality of strands about a common axis, and means for twisting said plurality of strands about its common axis.

8. The machine of claim 4 wherein said color material applying means comprises a source of color material, a first roller which rotates through said source and thereby becomes coated with the color material, a second roller having at least one raised surface thereon at a predetermined location along the axial dimension thereof, said first and second rollers being so located relative to one another that said raised surface is in close contact with said first roller, and means for biasing said plurality of strands against said second roller across the length thereof.

10. The machine of claim 9 wherein said unraveling means comprises a pair of adjacent rollers having intermeshing ridges extending along the lengths thereof and ending in complementary helixes at the ends thereof.

11. A space dyeing machine comprising means for arranging a plurality of strands in substantially parallel relationship about a common axis, means for oscillatably twisting the plurality of strands about the common axis in opposite directions of rotation including means for constantly varying the point of entry of each strand of the plurality as it enters the dye-applying section of the machine, a first dye station comprising means for dyeing all of the strands of said plurality a first color, a second dye station comprising means for dyeing selected strands of said plurality a second color, and a third dye station comprising means for dyeing selected strands of said plurality a third color.

12. The machine of claim 11 including means for unraveling said plurality of strands as the dyed portions thereof are removed from the machine.

13. A space dyeing machine comprising means for presenting a plurality of strands to a dyeing apparatus including means for constantly varying the point of entry into the dyeing apparatus of each strand of said plurality, while simultaneously varying the location of each strand of said plurality relative to approximately fifty percent of the strands of said plurality at the point of entry into the dyeing apparatus, and a dye apparatus for selectively applying dye to strands of said plurality in such a manner as to apply dye to every strand of said plurality at intervals along the lengths thereof.

14. A method of space dyeing strands of fiber comprising the steps of arranging a plurality of strands about an axis, alternately twisting the plurality of strands about the axis, first in one direction and then in the opposite direction, then passing the thus alternately twisted plurality of strands through a dyeing apparatus, and applying dye to each strand at intervals, along the length thereof in said dyeing apparatus.

15. The method of claim 14 wherein said step of twisting the plurality of strands includes the step of constantly varying the point of entry of each strand into the dyeing apparatus.

16. The method of claim 14 wherein said step of applying dye to each strand includes the steps of moving said plurality of strands between a first roller having a constant diameter throughout the length thereof and a second, cooperating roller having a plurality of different diameters throughout the length thereof, and biasing the plurality of strands toward the second roller.

17. The method of claim 14 including the penultimate step of applying dye to every strand of the plurality throughout the entire length thereof.

18. The method of claim 14 including the step of applying a second dye to each strand at distinct intervals along the length thereof in said dyeing apparatus.

19. The method of claim 14 including the step of unraveling the plurality of strands after they pass from the dyeing apparatus.

20. A method of space dyeing comprising the steps of constantly varying (a) the point of entry of each strand pulled through a dyeing apparatus and (b) the location of each strand relative to every other strand in a plurality of strands pulled through the apparatus, providing each strand with a first color throughout the length thereof, providing each strand with a second color at random intervals along the length thereof, and providing each strand with a third color at random intervals along the length thereof, the latter two steps so accomplished as to result in finished strands each having three distinct colors at random intervals along the length thereof.

21. Apparatus for space dyeing a plurality of strands of fibers comprising means for locating and arranging the strands of the plurality in a predetermined configuration about a common axis, means for altering the configuration of the plurality of strands into a flattened tubular configuration, means for oscillatably twisting the plurality of strands about their common axis, and means for applying dye to each of the strands of the plurality at random intervals extending along the lengths thereof.

22. The apparatus of claim 21 wherein said dye-applying means comprises means for dyeing each strand to a first color throughout the entire length thereof and means for dyeing each strand to a second color throughout random intervals along the length thereof such that the intervals along the strands of the plurality of strands are not coextensive with one another.

23. A machine for dyeing each of a plurality of strands of yarn comprising means for directing a plurality of strands of yarn in the machine toward a color application apparatus, means downstream from said directing means for applying a coloring material to strands of yarn as they pass a predetermined position relative to said machine, and means downstream from said color application means for drawing the plurality of strands out of said machine including means for preventing smearing of the coloring material on the strands and for preventing entanglement of said strands as they pass out of said machine comprising a pair of adjacent rollers having intermeshing fins extending along the lengths thereof and ending in complementary helixes near the ends thereof.

24. A machine for dyeing each of a plurality of strands of yarn Comprising means for directing a plurality of strands of yarn into the machine and toward a color application apparatus, means in said machine for applying a color to at least some of said plurality of strands of yarn, and means downstream from said color application means for drawing the plurality of strands past said color application means including means for spreading the strands to prevent entanglement of the strands with one another comprising a pair of adjacent rollers having intermeshing fins extending along the lengths thereof and ending in complementary helixes near at least one longitudinal end of each of said rollers.

25. Apparatus for pulling a plurality of substantially parallel strands arranged in a common plane while maintaining the strands in the substantially parallel relationship comprising a pair of rollers mounted with the axes thereof in parallel, spaced relationship each having a plurality of fins extending substantially parallel to the axis of the roller and substantially equally spaced about the periphery thereof, each fin having a portion, adjacent at least one longitudinal end thereof, extending in a helix relative to the axis of said roller, and means for driving said rollers so that said fins on each roller intermesh and do not contact the fins of the opposed roller throughout the area across which the strands are passed.

28. A machine for dyeing each of a plurality of strands of yarn into a random coloration along the length thereof comprising means for arranging said plurality of strands in substantially a single plane defining a center line axis, means for moving said plurality of strands longitudinally through the single plane, means for moving each of said strands in said plurality laterally across the single plane relative to the center line axis of the plane including means for forming said plurality of said strands into an oblong tubular configuration, means for flattening the tubular configuration so that the opposed elongated surfaces thereof are placed into abutment, and means for rotating the flattened tubular configuration about its axis, and means for applying a dye only to the strands of said plurality which traverse a predetermined location relative to the lateral and longitudinal limits of the plane.

29. A method of space dyeing strands of fiber comprising the steps of arranging a plurality of strands about an axis, twisting the plurality of strands about the axis in a first and second direction, thereby constantly varying the point of entry of each strand into the dyeing apparatus, passing the twisted plurality of strands through a dyeing apparatus, and applying dye to each strand at intervals along the length thereof in said dyeing apparatus.

30. A method of dyeing strands of fiber comprising the steps of arranging a plurality of strands about an axis, twisting the plurality of strands about the axis in a first direction and a second direction, passing the twisted plurality of strands through a dyeing apparatus, and applying dye to each strand at intervals along the length thereof in said dyeing apparatus by moving said plurality of strands between a first roller having a constant diameter throughout the length thereof and a second, cooperating roller having a plurality of different diameters throughout the length thereof, and biasing the plurality of strands toward the second roller.

31. The machine of claim 4 including means for pulling the plurality of strands of dyed yarn through the machine without smearing the dye thereon comprising a pair of adjacent rollers having intermeshing fins extending aLong the lengths thereof and ending in complementary helixes near at least one longitudinal end of each of said rollers.

32. The machine of claim 12 wherein said unraveling means comprises a pair of adjacent rollers having intermeshing fins extending along the lengths thereof and ending in complementary helixes near at least one longitudinal end of each of said rollers.