Patent Application
20120198634
The present invention relates to the production of carpet and other textiles. In the carpet and other textile industries, unused, excess, and waste yarn and fiber often results in both financial and environmental costs. Such yarn and fibers are usually pre-dyed in particular colors, severely limiting flexibility in their reuse. The loss is constantly incurred and incrementally becomes very large. Consequently, such fiber and yarns are sold off for a fraction of their cost, used in low grade products, or thrown away. Waste, cationic solution dyed yarn and fibers present particular difficulties of disposal and recycling into saleable, valuable products. Dyeing primarily cationic-dyeable fiber with acid (anionic) dyes is especially challenging as the ionic charge of the dyestuff is the same as the fiber.
Accordingly, a need exists for new uses for waste yarn and fiber generally that help retain the value of the yarn and fiber. A need also exists for floorcoverings and other textiles that are aesthetically pleasing, functionally durable, and environmental.
It is a feature of the present invention to provide aesthetically pleasing, functional, economical, and environmental overdyed carpets and other textiles. It is also a feature of the present invention to provide systems and methods for reclamation of waste yarns at full or partial value. Yet another feature of the present invention is to provide systems and methods for styling in a new medium.
The present invention allows for the overdyeing of a carpet or other textile into one or more colors. Multiple different base carpets can be dyed in a multitude of colors to offer choices from a resulting palette of virtually unlimited color combinations. Making a similar range of choices by predying yarns and setting up individual carpet manufacturing runs would be logistically and financially extraordinarily complicated, time consuming and costly as well as operationally complex.
Another feature of the present invention is to provide a method of preparing an overdyed carpet, or other textile, having a predominant hue throughout the overdyed carpet. The method can include contacting at least one carpet containing a plurality of fibers with a dye bath containing at least one dye; heating the dye bath to a target temperature; adding at least one auxiliary chemical to the dye bath. The plurality of fibers can include predyed and/or undyed fibers, which can differ in hue, saturation, or value, or any combination thereof from each other and/or that of the overdye. The at least one auxiliary chemical can provide stain resistance, color fastness, or bleach resistance, or any combination thereof.
A further feature of the present invention is to provide an overdyed carpet, or other textile, having a predominant hue throughout. The carpet can contain a plurality of predyed fibers overdyed with at least one dye. The carpet can optionally contain at least one auxiliary chemical that provides stain resistance, color fastness, or bleach resistance, or any combination thereof.
Additional features and advantages of the present invention will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practice of the present invention. The objectives and other advantages of the present invention will be realized and attained by means of the elements and combinations particularly pointed out in the description and appended claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide a further explanation of the present invention, as claimed.
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate some of the features of the present invention and together with the description, serve to explain the principles of the present invention.
In accordance with the present invention, a method of making an overdyed carpet, or other textile, having a predominant hue throughout the overdyed carpet, is provided. The method can include contacting at least one starting carpet containing a plurality of fibers with a dye bath(s) containing at least one dye, the dye bath having a pH, such as from about 1.5 to about 6.5; heating the dye bath to a target temperature, such as from about 140° F. to about 240° F.; and adding at least one auxiliary chemical, such as in an amount of less than 25 wt. % (based on the weight of the carpet), to the dye bath after at least one dye has been previously introduced and at least partially exhausted, such as at least 1 wt %, at least 5 wt %, at least 10 wt %, at least 15 wt %, or at least 25 wt % of the at least one dye (based on the total weight of the dye) has been exhausted from the dye bath. The auxiliary chemical(s) can provide stain resistance, color fastness, and/or bleach resistance to the carpet.
Any desired carpet or carpet component can be used as the starting carpet for the overdyeing process. The methods of the present invention are not limited to carpets and can be used to produce any desired overdyed textile. Any textile or combination of textiles is suitable. For example, any desirable fabric is suitable, such as upholstery, panel fabrics, and/or other decorative textiles for indoor or outdoor use. Starting carpets can include loop pile carpets, cut pile carpets, cut and loop carpets, broadloom carpets, and carpet tiles. The starting carpet can be fused, woven, knitted, needle-punched, and/or tufted. The starting carpet can have a primary backing. Additional backing, padding, and/or other layers can be provided before and/or after overdyeing. Carpets lacking a broadloom or a tile backing, and which the marketplace reaction has shown to be undesirable in color can also be employed in accordance with the present invention. Carpets can also include “scraper” floor mat types, for logo, janitorial, safety or other flooring types.
The starting carpet can be provided in any desired size. For example, a carpet with a width of about 6 inches to about 12 feet or more can be used in the methods of the present invention, such as 6 feet to 12 feet and any other conventional carpet width or other dimension. The length can be any length including standard rolls of carpet such as less than, equal to, or more than 100 feet. Carpet tiles of any size and/or shape, rectilinear and/or curvilinear can be used as the starting carpet. For example, carpet tiles 12 inches square, 18 inches square, 24 inches square, 30 inches square, 36 inches square, 48 inches square, and/or 96 inches square can be used.
The dye bath can be prepared in any appropriate matter using any suitable container(s). Open and/or closed containers can be used. Containers can include a bath, vat, beck, or any combination thereof. For example, overdyeing can be performed in 800 mL (Ahiba) containers, sample becks (each beck of a twin beck can hold approximately 35 liters of dye bath), larger sample becks holding approximately 500 L, or a production beck holding approximately 3200 gallons of dye bath and configured with a capacity of 6,000 gallons.
Closed containers can be configured for pressurization. The contents of the dye bath can be prepared inside the container, outside the container, or any combination thereof. For example, the dye bath can be prepared by: adding water to a bath, the water, for instance, having an initial temperature of from about 35° F. to about 120° F.; optionally adding at least one water treatment chemical to the bath; if needed, adding at least one acid to the bath to achieve a pH from about 1.5 to about 6.5; and adding the at least one dye to the bath. The order of addition of the dye bath contents is not important and can be in any sequence or combination. The dye bath can be mixed and/or circulated using any suitable means. Mixing and circulation can be performed when the dye bath is formed as well as subsequently during the dyeing of the carpet. Movement of the carpet through the dye bath can also aid in mixing.
The methods of producing overdyed carpets and the overdyed carpets themselves can contain any number or kind of predyed fibers. Accordingly, a plurality of predyed fibers can be employed. At least a portion of the predyed fibers can differ in hue, saturation, and/or value from a different portion of the predyed fibers. Predyed fibers are fibers that are primarily colored (prior to overdyeing) using any combination of one or more coloring processes and/or one or more coloring components. Predyed fibers can be or include fibers predyed with at least one pigment (e.g., solution dyed), at least one acid (anionic) dye, at least one cationic dye, or any combination thereof. The dye can be associated with the fibers by any means or combination of means. Dye and/or pigment can be associated with fibers through any kind of bonding or as part of a solution—liquid or solid. Dyes (that form the predyed fibers) can include light colors, dark colors, or any combination thereof.
The starting carpets employed in the overdyeing processes and the resulting overdyed carpets of the present invention can contain any combination of different predyed fibers. From about 25 wt % to about 100 wt % of the predyed fibers can contain pigment and from 0 wt % to about 75 wt % of the predyed fibers can contain acid dye based on the total weight of the predyed fibers. From about 1 wt % to about 50 wt %, from about 5 wt % to about 35 wt %, from about 10 wt % to about 20 wt %, of the predyed fibers can contain acid dye based on the total weight of the predyed fibers. The plurality of fibers dyed in the methods of the present invention can include undyed fibers, partially dyed fibers, and/or fully dyed fibers, or any combination thereof. The plurality of fibers can be or contain cationic-dyeable fibers. Cationic fibers are those fibers by their own natural properties or through chemical engineering that have the capability of being dyed using cationic dyes. Such engineering can employ sulfonation to provide negatively charged groups on the fiber that attract positively charged cationic dyes, while also repelling anionic dye and/or stains. One example of a predyed fiber, is a nylon fiber that has been melt extruded with at least one pigment.
Any type of naturally occurring and/or synthetic fibers can be employed in the carpets and methods of the present invention. Any type, length, number, or combination of modified and/or unmodified polymer can be used. The plurality of fibers can be or include polyamide fibers such as nylon. Any type of nylon can be included, for example, nylon-6,6 fibers, nylon-6 fibers, or any combination thereof. Solution (pigment) dyed nylons can be employed. Examples of nylon fibers that can be used are those available from INVISTA S.à r.l. (Wichita, Kans.) including ANTRON® carpets fibers such as LEGACY or LUMENA. The plurality of fibers can be or contain polyester fibers. The fibers can be or include triexta fibers. The plurality of fibers can be or include polyolefin fibers (e.g., polypropylene), polyvinyl fibers, or any combination thereof. Nylon fibers can be dyed using any suitable method, for example as described in U.S. Pat. No. 5,925,149, which is incorporated in its entirety by reference herein.
Fibers of the carpets and methods of the present invention can include one or more yarn. The plurality of fibers can include waste yarn also known as unused yarn or leftover yarn. Waste yarn can include, for example, yarn that is leftover on the spool which has not been tufted during a manufacturing run. From 1 wt % to 100 wt % of the fibers (by weight of fibers) in the starting carpet can be waste fiber/yarn, recycled fiber/yarn, leftover fiber/yarn, and/or fiber/yarn that would be otherwise disposed of. This amount can be from 10 wt % to 100 wt %, 20 wt % to 100 wt %, 30 wt % to 100 wt %, 40 wt % to 100 wt %, 60 wt % to 100 wt %, 75 wt % to 99 wt %, 85 wt % to 99 wt %, 90 wt % to 99 wt %, all wt % based on weight of carpet fibers present. The plurality of fibers can contain predyed yarn. Examples of predyed yarn include space dyed yarn, solution dyed yarn, dyeable yarn, and/or recycled yarn. Waste fiber and yarn augmentation selection processes allow for the selection a wide variety of different yarns. Yarn used in the present invention can either singly or jointly be of the bulked continuous filament types, and/or staple types including pre-processed types, one instance being singed staple or other modified types. Examples of waste yarns that can be used include undyed dye variant types, such as, but not limited to, nylon light dyeable, medium dyeable, deep dyeable, and/or cationic dye type chemistries. Such yarns can be dyed by means of the skein, knit-deknit, short space, and/or long space dye, or any other process, or any combination of processes thereof.
The carpets that are overdyed to produce overdyed carpets can be of any variety and/or from any source. The methods of the present invention can include the step of forming the at least one carpet from fibers prior to placing the at least one carpet in the dye bath. For example, the starting carpet can be a STRING WORKS carpet available from Mannington Mills (Salem, N.J.). STRING WORKS contains a level loop with no patterning except for the blending of color families to produce a “candy stripe” effect, for example, of unused pre-dyed yarns such as those described in U.S. Pat. No. 7,341,772, incorporated by reference in its entirety. Carpets, generally having a “candy stripe” pattern can be used having alternating dark and light fibers including various colored fibers and space dyed fibers. Examples of other carpets that can be used include, but are not limited to, ART CRAFT carpet and MODERN PRIMITIVE carpet also available from Mannington Mills.
Any kind of dye can be employed as the predye(s) or overdye(s) in the carpets and methods of the present invention. The dye(s) can be or include at least one acid (anionic) dye. The acid dye(s) can be or include at least one leveling acid dye, at least one premetalized acid dye, and/or at least one milling acid dye, or any combination thereof. The at least one dye can contain at least one yellow dye, at least one red dye, and/or at least one blue dye, or any combination thereof. The at least one dye can contain at least one yellow acid dye, at least one red acid dye, and/or at least one blue acid dye, or any combination thereof. Any kind of acid dye can be used, for example, one or more acid dyes from the Color Index of acids dyes can be used. The at least one dye can contain at least one Color Index acid yellow dye, at least one Color Index acid red dye, and/or at least one Color Index acid blue dye, or any combination thereof. A combination of dyes such as TECTILON Yellow 3R, TECTILON Red 2B, TECTILON Blue 4R can be employed as the dye(s). TECTILONs are mono-sulfonated acid dyes available from Huntsman International LLC (The Woodlands, Tex.). Any desirable acid dye from the Color Index can be used. Examples include Red 414. Leveling acid dyes available from Dixie Dye & Chemical, Inc. (Lafayette, Ga.) can also be used, dyes available from Dharma Trading Company (San Rafael, Calif.), and/or dyes available from Huntsman. Examples of yellow leveling acid dyes include Color Index numbers 156, 199, or 246, or any combination thereof. Examples of red leveling acid dyes include Color Index numbers 266, 361, or any combination thereof. Examples of blue leveling acid dyes include Color Index numbers 277, 324, or any combination thereof. Any desirable premetalized dye from the Color Index or other source can be used. Examples include C.I. Acid Yellow 151 (Erionyl Golden Yellow M-R-02™), C.I. Acid Red 251 (Lanacron Bordeaux EL™), C.I. Acid Blue 271 (Lanacron Blue N-3GL™), C.I. Acid Black 172 (Erionyl Black AMR™), C.I. Acid Orange 162 (Lanacron Yellow N-3RL™), C.I. Acid Black 244 (Lanacron Black N-RBLN™), and C.I. Acid Red 211 (Lanacron Red N-2GL™). Dyes, other chemicals, and processes, described in Trotman's Dyeing and Chemical Technology of Textile Fibres and Horrocks and Anand's Handbook of Technical Textiles can also be employed, which are incorporated herein by reference in their entirety.
Between the stainblock and dye, and in particular leveling dyes, there can be provided a synergistic effect for enhanced carpet properties such as appearance, color fastness, stain resistance, and/or bleach resistance. The amount of dye can be varied in the overdyeing process of the present invention without significant variation in the final appearance of the carpet. The overdye(s) can differ from the plurality of fibers of a starting carpet, prior to overdyeing, in hue, saturation, value, or any combination thereof. The overdye can be or include at least one dye darker than at least one of the plurality of fibers, at least one dye darker than the darkest of the plurality of fibers, or at least one dye darker than the lightest of the plurality of fibers, or any combination thereof. All dyes, stainblocks, auxiliary chemicals, water treatment chemicals, and any other chemical or component described herein are commercially available. Use of premetalized dyes can allow for use of less stainblock.
The dye bath employed in the methods of the present invention can include any component or combination of components to aid the dyeing process and production of overdyed carpet. The dye bath can contain at least one water treatment chemical. The at least one water treatment chemical can include at least one water softener, at least one wetter, and/or at least one defoamer, or any combination thereof. A water treatment chemical is any chemical that adjusts the properties of the water present in the bath to allow for better overdyeing, stainblock application, or the like, of the carpet. For example, removing mineral ions that could interfere with the dye, helping the dye equilibrate between the dye bath and carpet to allow for consistent application of the dye.
“Sequests” can include water softeners such as chelators that help control or remove unwanted or excess ions from the dye bath. Examples of sequests include RESOCAL (RESO.) (Fibro Chem), MARPLEX CL-3 available from Lenmar Corporation (Huntingdon Valley, Pa.), STARQUEST GSA available from ArrowStar, L.L.C. (Dalton, Ga.), and QUESTALL WSA available from Phoenix Chemical Company, Inc. (Calhoun, Ga.). Sequest can be present in the dye bath in an amount less than 0.01 g/L, in an amount from about 0.01 g/L to about 10 g/L, from about 0.1 g/L to about 7.5 g/L, from about 0.5 g/L to about 5.0 g/L, from about 1.0 g/L to about 3.0 g/L, from about 1.5 g/L to about 2.5 g/L about 1.75 g/L to about 2.25 g/L, or greater than 10 g/L. The water treatment chemical and/or sequests can include anti-chlorine compounds such as sodium thiosulfate for removing chlorine ions from municipal water supplies that could damage dye molecules.
Examples of levelers include anionic surfactants such as alkyldiphenyloxide disulfonate. Examples of such levelers include 2% of a DOWFAX 2A1 based leveler—Supralev AC (Phoenix Chemical) and Fibrossist DG-100 is a leveler available from Fibro Chem, LLC (Dalton, Ga.). Levelers are used to help provide an even and consistent dyeing, and to avoid areas of carpet that have more or less dye than another. Examples of wetters include ULTRAWET LPDS (Phoenix Chemical). LPDS contains an alkoxylated alcohol. Wetters can be surfactant based. Wetters can also be used to prevent dye particle agglomerization and/or to promote absorption of the dye by the carpet fibers. Leveler(s) and/or wetter(s) can be present in the dye bath in an amount of less than 0.01 wt %, from about 0.01 wt % to about 10 wt %, from about 0.1 wt % to about 7.5 wt %, from about 1 wt % to about 5 wt %, from about 1.5 wt % to about 4.5 wt %, from about 2 wt % to about 3 wt %, or greater than 10 wt % based on the weight of the carpet or on the weight of goods (o.w.g.).
Lubricants can also be optionally included. Lubricant(s) can be present in the dye bath in an amount of less than 0.1 wt %, from about 0.1 wt % to about 10 wt %, from about 0.5 wt % to about 7.5 wt %, from about 1 wt % to about 5 wt %, from about 1.5 wt % to about 4.0 wt %, from about 2 wt % to about 3 wt %, or greater than 10 wt % based on the weight of the carpet or on the weight of goods (o.w.g.). Examples of lubricants include STARLUBE (KJL ArrowStar) and HILUBE BK available from HiTech (Greenville, S.C.).
The dye bath can contain one or more acids. The acid can be buffered. Acid, buffered or unbuffered, can be present in the dye bath in an amount less than 0.01 g/L, in an amount from about 0.01 g/L to about 10 g/L, from about 0.1 g/L to about 7.5 g/L, from about 0.5 g/L to about 5.0 g/L, from about 1.0 g/L to about 3.0 g/L, from about 1.5 g/L to about 2.5 g/L about 1.75 g/L to about 2.25 g/L, or greater than 10 g/L, based on the volume of dye bath. For example, the acid can include acetic acid, sulfuric acid, or a combination thereof. The sulfuric acid can be provided by at least one organic sulfate, at least one inorganic sulfate, or any combination thereof. One example of an organic sulfate is urea sulfate such as System SA-8 (Phoenix Chemical). System 484 is an inorganic sulfuric acid blend with corrosion inhibitors available from Phoenix Chemical. Buffer MB-62 is also available from Phoenix Chemical. The dye bath can be used in the absence of a cationic dye. The dye bath can be used in the absence of a cationic auxiliary chemical. The dye can be added before and/or after the addition of acid. One or more acids and/or buffers can be employed to obtain a desired pH. The dye bath can be maintained at a constant pH. For example, the dye bath can be maintained at a desired pH with a deviation of less than 2.0 pH units, less than 1.5, less than 1.0, less than 0.5, less than 0.25, less than 0.1, or less than 0.05 pH units. The dye bath can have a pH of from about 0.5 to about 7.0, from about 1.0 to about 6.75, from about 1.5 to about 6.5, from about 2.0 to about 5.0, from about 3.0 to about 4.0, from about 1.75 to about 3.0, or from 2.0 to 2.5, about 2.25, or any value within the ranges thereof.
Any number of auxiliary chemicals can be used in the present invention. The auxiliary chemical(s) can contain at least one stain blocker, at least one dye fixative, and/or at least one bleach resistant chemical. A single auxiliary chemical or a combination of auxiliary chemicals can provide stain resistance, color fastness, and/or bleach resistance, or any combination thereof. When more than one auxiliary chemical is used, it can be introduced together, or sequentially, or in any order of addition. The auxiliary chemical(s) can be or include substituted acrylic acid in the presence of a sulfonated aromatic aldehyde condensation polymer. Examples of such suitable auxiliary chemicals are PERMSEAL NCL-3, NCL-4, LSR, LSR-2, LSR-3, LSR-4, and NRF-7, available from Phoenix Chemical. Other examples include ARROSHIELD BLXCH, BAYGUARD SBOX, and BAYPROTECT SRP available from ArrowStar. The auxiliary chemical(s) can be or include anionic, cationic, amphoteric, or zwitterion, and/or nonionic, or any combination thereof. The auxiliary chemical can be used in any suitable amount. The auxiliary chemical can be added to the dye bath in an amount of less than 0.1 wt %, from about 0.1 wt % to about 40 wt %, from about 0.25 wt % to about 35 wt %, from about 0.5 wt % to about 25 wt %, from about 1.0 wt % to about 25 wt %, from about 3 wt % to about 20 wt %, from about 5 wt % to about 18 wt %, from about 6 wt % to about 15 wt %, from about 8 wt % to about 10 wt %, or from about 13 wt % to about 40 wt %, or greater than about 35 wt % based on the weight of the carpet overdyed (or on the weight of goods, o.w.g).
The auxiliary chemical can be added to the dye bath at any suitable time, and/or in any suitable order relative to the addition of other components of the dye bath. The auxiliary chemical can be added to the dye bath when a certain amount of the dye has been exhausted, and/or when the dye bath has reached a particular temperature, or any combination thereof. The auxiliary chemical can be added after less than 1 wt %, at least 5 wt %, at least 10 wt %, at least 25 wt %, at least 30 wt %, at least 35 wt %, at least 40 wt %, at least 45 wt %, at least 50 wt %, at least 55 wt %, at least 60 wt % at least 65 wt %, at least 70 wt %, at least 75 wt %, at least 80 wt %, at least 85 wt %, at least 90 wt %, at least 95 wt %, or at least 99 wt % of the dyes (in the dye bath) (based on the total weight of the dye(s)) has been exhausted from the dye bath. The auxiliary chemical can be added all at once, or fed continuously over time, or added as batches. Exhaustion of dye can be measured using any suitable means. For example, spectrophotometrical comparison of a sample relative to a standard. One or more samples can be taken at one or stages of the overdyeing process. For example, a sample can be taken after addition of the dye(s) to the bath, at particular temperature(s), before or after the addition of the auxiliary chemical(s), and/or before the dye bath is drained.
The dye bath can be heated by any means, using direct or indirect heat. Examples of heating sources include heat exchangers, heating elements, or steam, or any combination thereof. Water used in or added to the dye bath can be of any suitable temperature. The initial temperature of the dye bath can be of any suitable temperature as well. For example, the dye bath can begin at a temperature of less than about 32° F., from about 32° F. to about 212° F., from about 35° F. to about 210° F., from about 40° F. to about 205° F., from about 50° F. to about 200° F., from about 60° F. to about 195° F., from about 70° F. to about 190° F., from about 80° F. to about 185° F., from about 90° F. to about 180° F., from about 100° F. to about 175° F., from about 110° F. to about 170° F., from about 120° F. to about 165° F., from about 125° F. to about 160° F., from about 130° F. to about 155° F., from about 140° F. to about 150° F., greater than 212° F., or any temperature value there between.
The dye bath can be heated or cooled at any desired rate. The rate can be varied, increased, decreased, or held constant, or a combination thereof during one or more stages of the dyeing process. The heating and/or cooling rate can be at a rate of from about 0.05° F./min. to about 25° F./min., from about 1.0° F./min. to about 10° F./min., from about 1.5° F./min. to about 5.0° F./min, from about 2.0° F./min. to about 4.5° F./min., from about 3.0° F./min. to about 4.0° F./min., about 2.5° F./min., less than about 0.05° F./min., or greater than about 25° F./min., or any rate value there between. The heating can continue to a target temperature, to at least one intermediate temperature, or a peak temperature, or any combination thereof. The temperature can be maintained for any desired time after reaching a target temperature, to at least one intermediate temperature, or a peak temperature, or any combination thereof. Cooling can be employed after reaching a target temperature, at least one intermediate temperature, or a peak temperature, or any combination thereof.
The auxiliary chemical(s) can be added before, at, and/or after the target temperature is reached. The target temperature, at least one intermediate temperature, and/or peak temperature can be less than about 100° F., from about 120° F. to about 260° F., from about 120° F. to about 240° F., from about 140° F. to about 220° F., from about 150° F. to about 212° F., from about 160° F. to about 205° F., from about 175° F. to about 200° F., from about 180° F. to about 195° F., from about 185° F. to about 190° F., about 140° F., about 150° F., about 155° F., about 160° F., about 165° F., about 170° F., about 175° F., about 180° F., about 185° F., about 190° F., about 195° F., about 200° F., about 202° F., about 205° F., about 210° F., about boiling, about 212° F., about 230° F., about 250° F., or greater than about 260° F., or any temperature value there between. The target temperature can correspond to the glass transition temperature of one or more fibers in the carpet. For example, the target temperature can correspond to the glass transition temperature of the fiber with the lowest glass transition temperature, the fiber with the highest glass transition temperature, a fiber having a moderate glass transition temperature, or an average of the glass transition temperatures of the fibers present. The target temperature can correspond to the temperature at which the auxiliary chemical is initially added. The target temperature can correspond to the temperature at which a sufficient amount of dye has been taken up by the carpet from the dye bath that termination of the dye bath and/or addition of an auxiliary chemical, such as a stainblocker, would not significantly or deleteriously affect the overdyeing process and final appearance of the overdyed carpet.
The temperature of the dye bath can be further increased following the addition of the auxiliary chemical(s). A further increase in temperature can help open up the fiber matrix to expose additional sites for binding of dye and/or auxiliary chemical(s). A further increase in temperature can allow for better leveling, that is, allow for a more even overdyeing of the carpet. The temperature of the dye bath can be further increased to a peak temperature of from about 175° F. to about 250° F., of about 180° F., from about 185° to about 230° F., from about 195° F. to about 215° F., to about 205° F., to about a boil, to less than about 175° F., or to greater than about 250° F., or any temperature value therein. The target temperature can be a temperature of from about 140° F. to about 212° F. and the temperature of the dye bath can be held at the target temperature with a deviation of less than 5° F. from about 5 seconds to about 1 hour. The target temperature can be a temperature of from about 170° F. to about 205° F. and the temperature of the dye bath can be held at the target temperature with a deviation of less than 5° F. from about 5 minutes to about 45 minutes. The target temperature can be a temperature of from about 180° F. to about boiling, and the temperature of the dye bath can be held at that temperature range from an hour or less. The carpet that has been overdyed can be removed from the dye bath at any time and/or can remain until the auxiliary chemical is exhausted from the dye bath, such as at least 10 wt %, at least 25 wt %, at least 50 wt %, at least 75 wt %, at least 95 wt %, or at least 99 wt % of the auxiliary chemical (by total weight of auxiliary chemical) is exhausted from the dye bath.
The contents of the dye bath can be drained, for example, after the addition of the at least one auxiliary chemical and/or after the dye bath has been allowed to cool. For example, the dye bath can be allowed to cool from a higher target temperature, intermediate temperature, or peak temperature to a temperature above 200° F., from about 40° F. to about 200° F., from about 80° F. to about 190° F., from about 100° F. to about 180° F., from about 120° F. to about 170° F., from about 140° F. to about 160° F., less than about 40° F., or any temperature there between. Cooling can take place at any desired rate or for any desired time. For example, cooling can occur for several seconds, less than 5 hours, from about 5 minutes to about 2 hours, from about 10 minutes to about 1 hour, from or about 20 minutes to about 30 minutes, or for any duration there between. Cooling can be allowed to progress passively and/or may be aided by any active cooling process.
The at least one carpet after being removed from the dye bath can be rinsed with water, alone or in combination with any other suitable components. Rinsing can be performed, for example, after application of the overdye to carpet and/or addition of the at least one auxiliary chemical. Rinsing typically occurs with water, and is generally done at a pH of 5 or above. Drying of the overdyed carpet can take place in the bath container after draining and rinsing and/or after removal from the container. Subsequent drying can be performed in a range or oven. Drying can occur at ambient temperature and/or at a higher or lower temperature. Drying can occur at a temperature of from about 32° F. to about 320° F., from about 50° F. to about 300° F., from about 75° F. to about 250° F., or from about 125° F. to about 200° F. Tenting can be used while drying the carpet to help prevent wrinkling or other undesirable distortions to the carpet. For example, a pin tenter can be employed. The overdyed carpet can be finished using any desirable process or materials, such as applying a secondary backing(s). For example, a backing layer(s), padding layer(s), reinforcement layer(s), foam layer(s), and/or other layer can be applied into the overdyed carpet to make a finished overdyed carpet. Examples of suitable backing materials can include urethane, latex, vinyl, and various hot melt applications.
Any number of overdyed carpets can be produced using the methods of the present invention. A single carpet or multiple carpets can be produced separately or part of a common batch dyeing process. The method can include a batch process, a continuous process, or any combination thereof. The method can include a skein process, a knit-deknit process, a warp process, a short space process, a long space process, a solid space process, or any combination thereof. The present invention can employ yarn dyeing, piece (whole carpet) dyeing, continuous dyeing, printing or other processes. The products and methods of the present invention impart significant added value such as good lightfastness, wet bleed and dry crock fastness, as well as fastness to bleach oxidative stains including bleach solution.
The present invention includes one or more overdyed carpets produced by the method of the present invention, as well as carpet tile and other carpet products. The methods of the present invention are not limited to carpets and can be used to produce any desired overdyed textile. The overdyed carpet can be processed into any desired size. For example, a carpet with a width of about 6 inches to about 12 feet or more can be produced, such as 6 feet to 12 feet, 4 meters, and any other conventional carpet width or other dimension. The length can be any length including standard rolls of carpet such as less than, equal to, or more than 100 feet. The method can include finishing and/or cutting the overdyed carpet into a plurality of carpet tiles. Carpet tiles can also be made in any size and/or shape, rectilinear and/or curvilinear. For example, carpet tiles 12 inches square, 18 inches square, 24 inches square, 30 inches square, 36 inches square, 48 inches square, and/or 96 inches square can be provided. “Scraper” floor mat types, for logo, janitorial, safety or other flooring types can be produced.
The overdyed carpet (or other textile) of the present invention can have a predominant hue throughout the carpet. A predominant hue is a hue with which the observer most readily identifies the overall appearance of the carpet. Hue can be determined according to any color system, for example, the Munsell color system, CIELAB, and/or CIECAM02. One or more hues can be present. The carpet can have a plurality of predyed fibers overdyed with at least one dye, wherein from about 25 wt % to about 100 wt % of the dye present in the carpet is pigment and from 0 wt % to about 75 wt % of the dye present in the carpet is acid dye based on the total weight of dye in the carpet. The carpet can optionally contain at least one auxiliary chemical that provides stain resistance, color fastness, and/or bleach resistance. The auxiliary chemical(s) can be present in the carpet in an amount of from about 0.5 wt % to about 30 wt %, from about 1.0 wt % to about 25 wt %, from about 3 wt % to about 20 wt %, from about 5 wt % to about 18 wt %, from about 6 wt % to about 15 wt %, from about 8 wt % to about 10 wt %, or from about 13 wt % to about 20 wt % based the weight of the carpet (e.g., carpet fibers) in the absence of the at least one auxiliary chemical and overdye; i.e., prior to overdyeing.
The present invention allows for the overdyeing of a carpet into many different colors by separate overdyeing of different starting colors (base carpets) so a range of many different carpet colors can be effected, for example, twenty, offered for customer choice. For example, five different base carpets can be dyed in these twenty colors to offer a choice from a wider palette of 100.
Any desirable method can be employed to test the properties of overdyed carpets of the present invention and their preparation. For example, test methods from the American Association of Textile Chemists and Colorists (AATCC) (Research Triangle Park, N.C.) can be employed. Percent overdye amounts can be based on weight percentages of “o.w.g” or “on weight of goods,” for example, the carpet sample to which the overdye was applied. For lightfastness, AATCC Test Method 177 can be employed. Lightfastness can be performed using AATCC test number 177 at 60 standard fade units (SFU), 80 SFU, and/or 100 SFU. Lightfastness and bleed tests can be ranked on a scale from 1 to 5 with 1 indicating poor results and 5 indicating excellent results. Ratings can be based on AATCC Grey Scale for change with 5.0 indicating no change. The wet bleed values can be water-based or TIDE-based (TIDE dissolved in water) using the TIDE powder, available from Proctor & Gamble (Cincinnati, Ohio) (2 g/L) in solution at pH 9 using AATCC test number 107.
The present invention includes the following aspects/embodiments/features in any order and/or in any combination:
The present invention can include any combination of these various features or embodiments above and/or below as set forth in sentences and/or paragraphs. Any combination of disclosed features herein is considered part of the present invention and no limitation is intended with respect to combinable features.
The following examples are given to illustrate the present invention. It should be understood, however, that the present invention is not to be limited to the specific conditions or details set forth in these examples.
Various overdyed carpets were made following the present invention, except where indicated. For purposes of the example, percent overdye amounts are based on weight percentages of “o.w.g” or “on weight of goods,” in this case, the carpet sample to which the overdye was applied. For lightfastness, the following examples employ AATCC Test Method 177. Carpets samples used for overdyeing, unless otherwise indicated, were STRING WORKS™ carpet available from Mannington Mills (Salem, N.J.). STRING WORKS contains a level loop with no patterning except for the blending of color families to produce a “candy stripe” effect, for example, of unused pre-dyed yarns such as those described in U.S. Pat. No. 7,341,772, incorporated by reference in its entirety. Overdyeing was performed in 800 mL (Ahiba) containers or in becks. Each beck of a twin beck held approximately 35 L of dye bath. Larger sample becks held approximately 500 L. The largest beck used (for sample 39) held approximately 3200 gallons of dye bath, with a maximum capacity of 6,000 gallons. The following leveling acid dyes were used for overdyeing unless otherwise indicated: Color Index (C.I.) Acid Yellow 246 (Yellow 3R), C.I. Acid Red 361 (Red 2B), and C.I. Acid Blue 277 (Blue 4R). The red leveling acid dye was Dixicid Red 2B available from Dixie Dye & Chemical, Inc., or was TECTILON brand dye from Huntsman.
Lightfastness was performed using AATCC test number 177 at 60 standard fade units (SFU), 80 SFU, and/or 100 SFU. Lightfastness and bleed tests were all ranked on a scale from 1 to 5 with 1 indicating poor results and 5 indicating excellent results. Ratings are based on AATCC Gray Scale For Evaluating Change in Color with 5.0 indicating no change. The wet bleed values are described as WB and TIDE using the TIDE powder, available from Proctor & Gamble (Cincinnati, Ohio) (2 g/L) in solution at pH 9 using AATCC test number 107. “Stainblock” or “S/B” in the examples refers to one or more auxiliary chemicals that provide stain resistance, bleach resistance, and/or color fixative properties. Further, preparation of overdye carpet samples is described in the tables below, along with the results of the overdyeing.
Table 1 sets forth various runs for making an overdyed carpet. Table 1 sets forth the percent (based on OWG) of the yellow dye, red dye, and blue/black dye amounts used to make the overdyed carpet. Further, the particular dye used is also set forth. Table 1 also sets forth the amount of sequestering agent, as well as the type of sequestering agent used. Further, the name/amount of wetting agent/leveler are also indicated. Also, the amount of acid/buffer and the name are provided, as well as the starting pH of the dye solution. Also, the amount and type of auxiliary chemical, which typically was a stainblocker, is also provided in Table 1.
The following additional comments are noted with regard to Table 1 and the subsequent results set forth in Tables 2-6. Sample 5 did not contain any auxiliary chemical (e.g., no stainblocker), and if one compares Sample 5 with Samples 6, 7, 8, and 9, it is noted that the amount of dye and type of dye, the amount of sequestering agent and type of sequestering agent, the omission of a wetter/leveler, and the amount of acid/buffer was nearly the same or the same. The samples did use different amounts of auxiliary chemical/stainblocker. From the results set forth in Table 4, one can see that when no auxiliary chemical/stainblocker was present, the wet bleed was very low and considered unacceptable, whereas when the auxiliary chemical/stainblocker was present, the wet bleed properties were greatly improved and, in most instances, was considered excellent. Further, the lightfastness was considered acceptable or good in each of the samples. Thus, the present invention shows that the presence of an auxiliary chemical, such as a stainblocker, provides an acceptable balance of wet bleed properties in combination with lightfastness properties, which would not be achievable when a stainblocker is not used in the process.
Similarly, Samples 31-38 also provide examples which compare the presence of overdyed carpet where stainblocker was present, compared to when stainblocker was not present. For instance, Sample 31 (with stainblocker) can be compared with Sample 32 (without stainblocker), wherein all other amounts and processes were kept the same. As can be seen, the bleach resistance without the stainblocker was significantly lower. Further, the wet bleed was considered unacceptable for Sample 32. Similar results can be found comparing Sample 33 to Sample 34, and comparing Sample 35 to Sample 36, and comparing Sample 37 to Sample 38. In each instance, similar results can be seen, wherein when a stainblocker was not present as part of the process, the wet bleed properties were unacceptable and the bleach resistance properties were considered unacceptable or significantly lower than when the stainblocker was present as part of the present invention.
Table 2 sets forth the results for Sample 1 for lightfastness and wet bleed using water in one test and Tide powder in another test. As can be seen in Table 2, the results for Sample 1 were quite acceptable with regard to these lightfastness and wet bleed values. Table 3 provides similar results for Samples 2 and 3 and further provides results regarding resistance to acetic acid.
Overdyeing was performed on carpet samples to produce various dark hues. All sample carpets were STRING WORKS. Sample 1 resulted in a dark brown overdyed carpet. Lightfastness was performed at 60, 80, and 100 SFU. The overdye used was a mixture of either leveling acid dyes or premetalized acid dyes. Either AC or DG100 levelers were employed. Stainblock was generally added when the dye bath was at 180° F.
The dE test is a comparison of dye bath from a particular sample compared to a standard sample (in all of these examples the standard was nearly clear and had the following: 0.175% N3RL, 0.299% EL, 0.147% NRBLN, 39 g GSA, 75 g 0.484 Acid/Buffer, pH=2.06, and 4% NCL4 Stainblocker). A higher number indicates a higher amount of dye remaining in the bath. dE looks at color difference based on an L factor (white to black), an A factor (red to green), and a B factor (yellow to blue). The delta E (dE) of the spent dye bath shows a definite loss in dye exhaustion as the amount of acid decreases. Excess residual dye in the spent dye bath (at the end of the cool down step) is not desirable for economic and environmental reasons.
The bleach resist procedure was carried out as follows. Overdyed carpet samples are exposed to bleach (fresh CLOROX bleach defined as 6% sodium hypochlorite) for 24 hours and then rinsed thoroughly with cold water. After extract, and neutralization was performed for 30 minutes with 50 cc of 10% sodium metabisulfite. After a second extract and thorough rinsing with cold water, the samples are left to air dry overnight, and then ratings are made. The rating scale is from 10 to 1 with 10 being no change (perfect bleach resistance). Ratings 10 through 1 correspond to dL values (measurement of reflectance as compared to the original color), wherein the L value is a spectrophotometer representation of the lightness to darkness of the sample—similar to a gray scale with white=100 and black=0. The control with no bleach has an L value of 39.08 and is a medium gray color. Ratings correspond to dL values as follows: 10 (0), 9 (1.52), 8 (2.76), 7 (3.38), 6 (5.14), 5 (8.0), 4 (12.23), 3 (15.34), 2 (16.78), and 1 (20.41).
Sample 39 was a mill trial using 12 ft wide (broadloom) carpet (normal width) and it was 386 ft long. The predyed carpet was an aqua green pigment dyed portion with multicolored space dyed yarn (which contained some beige & light rust colors). The carpet included the following yarns available from INVISTA: DU12 produced from LUMENA L432, L472, L770; PCZ45 produced from LEGACY P1528(797A), an undyed fiber; and KA69 produced from LUMENA L117, L623, and L635. The color of the overdye was a burgundy, so the resulting overdyed carpet was a reddish dark brown color with a visible pattern with lighter brown remaining (reddish brown highlights). Both wet bleed tests (water and TIDE) yield results of 5.0, and the Xenon 60 SFU result was 4.00. dE (relative to the standard) after adding the dye to the dye bath and before heating was 23.6 and dE after overdyeing was 4.94 corresponding to a dye exhaustion of about 80%. These results demonstrate excellent performance for an overdyed carpet prepared using the methods of the present invention.
Applicants specifically incorporate the entire contents of all cited references in this disclosure. Further, when an amount, concentration, or other value or parameter is given as either a range, preferred range, or a list of upper preferable values and lower preferable values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the invention be limited to the specific values recited when defining a range.
Other embodiments of the present invention will be apparent to those skilled in the art from consideration of the present specification and practice of the present invention disclosed herein. It is intended that the present specification and examples be considered as exemplary only with a true scope and spirit of the invention being indicated by the following claims and equivalents thereof.
This application claims the benefit under 35 U.S.C. §119(e) of prior U.S. Provisional Patent Application No. 61/439,614, filed Feb. 4, 2011, and U.S. Provisional Patent Application No. 61/481,773, filed May 3, 2011, which are incorporated in their entirety by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 61439614 | Feb 2011 | US | |
| 61481773 | May 2011 | US |
