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WO1992002674A1 - Procede et appareil de teinture pour moquette - Google Patents

Procede et appareil de teinture pour moquette Download PDF

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Publication number
WO1992002674A1
WO1992002674A1 PCT/US1991/005469 US9105469W WO9202674A1 WO 1992002674 A1 WO1992002674 A1 WO 1992002674A1 US 9105469 W US9105469 W US 9105469W WO 9202674 A1 WO9202674 A1 WO 9202674A1
Authority
WO
WIPO (PCT)
Prior art keywords
dye
dyeing
carpet
water
dye solution
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1991/005469
Other languages
English (en)
Inventor
Benjamin Franklin Fuller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of WO1992002674A1 publication Critical patent/WO1992002674A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B19/00—Treatment of textile materials by liquids, gases or vapours, not provided for in groups D06B1/00 - D06B17/00
    • D06B19/0005—Fixing of chemicals, e.g. dyestuffs, on textile materials
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B21/00—Successive treatments of textile materials by liquids, gases or vapours

Definitions

  • This invention relates to the dyeing of carpets and, more particularly, to a method and apparatus for dyeing carpets which, through the use of a dye bath which has a much higher boiling point than water, does not require the steaming of the carpet to set or fix the dye to the carpet.
  • the typical carpet dyeing method and apparatus involves the application of a dye to the pile surface of the carpet, fixing the dye onto the carpet pile by steaming and then subjecting the carpet to various other finishing procedures prior to drying the carpet.
  • U.S. Patent No. 4,771,497 discloses a process for the continuous treatment of a textile web material involving the application of a dye to the pile surface of the carpet and then initiating the dye fixation onto the pile surface by steaming.
  • Many of the prior art patents such as the two disclosed above involve such a steam fixation process and are distinguishable from each other by various additional, optional processes added onto this base dyeing technique.
  • Steam fixation has several disadvantages including the need for a tremendous amount of energy required to heat the steam, dilution of the dye as the steam condenses into water and mixes with the dye, and the cost of the equipment, both in material and time, needed to have a steam fixation step in the carpet dyeing process.
  • a further disadvantage is that a carpet dyeing process including a steam fixation step is uneconomical to operate when dyeing small batches of carpet.
  • This invention may be used to dye carpets as well as all types of yarns, fibers, woven fabrics, knits and other fabric type materials made from, for example, nylon, polyester, wool, cotton, rayon and acrylics.
  • This invention continuously dyes carpet without steaming by the use of a high temperature dye bath, fed at a specific temperature and flow rate to an applicator, in which the level and the temperature of the dye are controlled.
  • This invention comprises a novel dye bath applicator which effects the carpet dyeing and fixing step by utilizing a high temperature dye mixture, the temperature of which is higher than the boiling point of water.
  • the apparatus of this invention also generally comprises a preheater which effects the preheating step, a heated mix tank which effects the heating step of the dye and chemicals, a heat exchanger which effects the step of heating the dye prior to the dye entering the applicator, a vacuum extractor which effects the step of recovering the excess dye and returning it to the heat exchanger, and wash boxes with overflows which effect the step of neutralizing the pH of the carpet and washing the carpet before the carpet enters the drying stage.
  • This invention eliminates the need for a steam fixator by preheating the dye to a temperature above the boiling point of water and applying it to a preheated textile web.
  • a unique mixture of chemicals allows the dye to be heated above the boiling point of water in this invention such that the dye is fixed onto the carpet pile during the dyeing step, therefore eliminating the need for a steam fixator after the dye application step.
  • the method and apparatus of the present invention can dye a single strand of carpet yarn or a twelve foot (12*) wide piece of carpet or wider, or any carpet size in-between, in a level configuration. It also is economical to dye small dye lots in the present invention as the dye beck time is reduced significantly compared to the prior art. Furthermore, the preheater used in this invention is heated from the heating system used to heat the dye bath applicator, thus saving significantly on heating costs throughout the system.
  • FIG. 1 is a schematic of the method and apparatus of the present apparatus.
  • FIG. 1 A general schematic of the method and apparatus of the present invention showing the various components necessary to carry out this method is shown in Fig. 1.
  • this invention using a novel dye solution comprising dye, various chemicals as dye assistants and water, utilizes a dye solution which has a much higher boiling point than water.
  • This higher boiling point dye solution is used as a bath to dye carpet.
  • This bath is the main aspect that makes this invention unique from conventional methods of dyeing carpet.
  • carpet is used in this disclosure to cover all fabrics, yarns and textile webs and is not meant to be limited to conventional carpeting as known in the art.
  • carpet is colored by the dye in the higher boiling point bath.
  • the higher boiling point dye bath allows the dye to be fixed to the carpet at that step, thus eliminating the need for a steam fixator.
  • the higher boiling point bath is heated in a novel and unique way as compared to the method for heating conventional dye baths.
  • the bath is heated by electric coils or elements or, alternatively, with an enclosed steam system to a temperature greater than the boiling point of water, a temperature which cannot be obtained in conventional systems.
  • the method of heating also provides a more direct heat source.
  • the presence of a steam fixator causes a dilution of the dye solution. Therefore, the elimination of the steam fixation step also is important to the invention because the dye solution contains a given concentration of dye, chemicals, and water and any dilution of this solution may affect both the coloring of the carpet and the ability of the dye to be heated above the boiling point of water.
  • the carpet is squeezed to remove excess dye, which dye is recycled to the dye bath. Then the carpet enters a cold water bath in which they dyeing process is stopped or fixed. Once the dye is fixed, normal variations in color in the carpet from side to center to side do not occur, as is common in continuous dyeing with a steam fixation step. The carpet is then rinsed in one or more wash boxes with overflow.
  • the dye solution utilized in this invention is stored in a dye vat 26.
  • the dye solution utilized in this invention is a unique mixture of specific dyes, chemicals and water.
  • dye solutions are formed by dissolving dyes in a portion of the water to be used in the dye bath 18.
  • Dyeing assistants and an acid to control the pH of the dye solution then are dissolved in the balance of the water to be used in the dye bath 18.
  • the dissolved dye and the dyeing assistants and acid then are combined and mixed with a quantity of glycol.
  • the glycol increases the boiling point of the dye solution to a temperature above the boiling point of water.
  • This dye solution is heated to a temperature just below the boiling point of the dye solution, which, due to the mixture of components in the dye solution, is higher than the boiling point of water, and is applied to the carpet 10 in the dye bath applicator unit 17, as described more fully below.
  • Useful dyes include, for example, acid dyes, disperse dyes, direct dyes, basic dyes, vats dyes, fiber reactive dyes, and any other dyes that can be applied hot to a substrate.
  • Two examples of representative dye solutions are as follows:
  • Fulgen SDM (Ethoxylated C12-C15 Primary Alcohol and Coconut Condensate) Sulfamic Acid, 15% sol.
  • the selected acid dyes are first dissolved in a portion of the 316.00 g (or 316 ml) of water great enough to allow for the dissolution of the dyes.
  • the dyeing assistants such as benzyl alcohol and Fulgen SDM, and an acid to control pH, such as sulfamic acid, are then added to the dye/water mixture. These then are combined and mixed with the diethylene glycol or other glycol, which previously has been mixed with the remainder of the 316.00 g of water, to form the dye solution.
  • the boiling point of this specific dye solution is approximately 228-230°F. This specific dye solution is particularly useful for nylon tufted carpet or other nylon fabrics.
  • the dye first is dissolved in a portion of the water great enough to allow for the dissolution of the dye.
  • the water for this specific dye should be hot and a dispersing agent, such as the Fulpon GP, generally is needed to assist in complete dissolution.
  • a leveling agent, such as Fulpal ME, and an acid to control the pH, such as sulfamic acid, is then added to the dye/water mixture.
  • This solution is combined and mixed with a glycol, which previously has been mixed with the remainder of the water, to increase the boiling point of the dye solution.
  • the boiling point of this specific dye solution also is approximately 228-230°F. This specific dye solution is particularly useful for polyester carpet or other fabrics.
  • any glycol which allows heat transfer is suitable for the dye solution.
  • the appropriate dying assistants are selected so as to complement the fiber being dyed. That is, certain fibers dye better when certain dyeing assistants are used, as is known in the art.
  • Anionic, nonionic, cationic, wetters, levelers, and retarders are all suitable dyeing assistants which are chosen according to the fiber being dyed.
  • the most suitable acids include formic, sulfamic, citric, acetic and phosphoric, as well as acid generators.
  • the carpet indicated generally by carpet roll 10, first enters a preheater 14 before it enters the dye bath applicator unit 17.
  • the entrance door 12 generally is a spring loaded door, or a door with one way hinges, opening toward the interior chamber 13 of the preheater so as to minimize heat loss from the preheating chamber 13 through the door 12 into the atmosphere.
  • the carpet 10 is supported by roller 16 as the carpet 10 travels through the preheater 14. .
  • the purpose of the preheater 14 is to heat the carpet 10 prior to the carpet 10 entering the dye bath applicator unit 17. Preheating of the carpet 10 keeps the 5 dye bath 18 from cooling down and helps open dye sites on the carpet 10 so that the carpet 10 will be ready to take the dye from the dye bath applicators 19.
  • the preheater 14 and preheating chamber 13 are heated using the same heating system 30 that heats the dye bath applicator unit
  • the heat system 30 may be any conventional heat system, such as electric coils or enclosed steam.
  • the preheater 14 heats the carpet 10 to any selected temperature up to about 220°F.
  • the carpet 10 exits the preheater 14 and enters 5 the dye bath applicator unit 17.
  • the dye bath applicator unit 17 generally comprises dye bath 18, dye applicators 19a, 19b, 19c, dye entrance ports 22, squeeze rollers 32, and exit rollers 34.
  • the dye solution is supplied to the dye bath 0 applicator unit 17 through dye solution entrance ports 22.
  • the dye solution upon leaving dye vat 26, is introduced through feedline 28 to a heat exchanger 20.
  • the heat exchanger 20 which can be any conventional heat exchanger unit, is used to heat the dye solution to a high 5 temperature, generally to any temperature up to about 240°F, prior to the dye solution entering the dye bath 18 and the dye bath applicators 19a, 19b, 19c.
  • a flow meter (not shown) is located between the heat exchanger 20 and the dye bath application unit 17 so as to regulate the 0 flow of the dye solution to the dye bath 18 so as to keep the level of the dye bath 18 constant.
  • the carpet 10 passes through high temperature dye bath applicators 19a, 19b, 19c which apply the dye solution to the carpet 10. 5
  • the dye is further heated to between about 160°F and about 240°F.
  • the carpet 10 and the dye bath applicators 19a, 19b, 19c are submerged within the dye bath 18 facilitating in the even application of the dye to the carpet 10.
  • the carpet 10 is threaded under first applicator roller 19a, over second applicator roller 19b, and over third applicator roller 19c to ensure even and thorough dye application.
  • the carpet 10 is submerged in the dye bath 18 as it passes under, over, and under the applicator rollers, 19a, 19b, 19c, respectively.
  • the carpet 10 leaves the dye bath 18 and passes through squeeze rollers 32 to remove excess dye solution.
  • the squeeze rollers 32 are located above the dye bath 18 such that any excess dye solution squeezed from the carpet 10 falls back into the dye bath 18 in a recycle fashion.
  • the dyed carpet exits the dye bath applicator unit 17 through exit rollers 34 which serve to remove some excess dye solution and to prevent heat loss from the dye bath applicator unit 17.
  • the dyed carpet 10 which may still contain excess dye solution from the dye application process, next passes through a vacuum extractor 36.
  • the vacuum extractor 36 is a conventional unit which further removes excess dye solution from the dyed carpet 10 through a vacuum means. Any excess dye solution removed from the carpet 10 by the vacuum extractor 36 is returned to the heat exchanger 20 through recycle line 38. The excess dye solution, therefore, is recycled back to the dye bath applicator unit 17 for dyeing further carpet.
  • the dyed carpet passes from the vacuum extractor
  • wash box 40 The purpose of wash box
  • the wash box 40 is to wash off excess dye solution and chemicals, and to clean the carpet from any other debris which may have been picked up during the dyeing process.
  • the wash box 40 uses a cold water bath with a neutral pH for the cleaning purpose. A further effect of the cold water bath is to aid in halting the dyeing process and to aid in fixing the dye on the carpet 10 surface.
  • the carpet 10 travels between one or more rollers 44 in the wash box 40 to increase the amount of time the carpet is in the cold water bath.
  • the carpet 10 passes by a spray washer 46 which also acts as the water introduction unit to the wash box 40.
  • the carpet 10 passes through squeeze rollers 48 to remove excess water.
  • Each wash box 40 also is equipped with an overflow 42 to maintain a constant level of water in the wash box 40.
  • the carpet 10 is dried in a conventional manner, using conventional carpet drying apparatus.
  • the above process when applied with the appropriate apparatus will dye nylon, polyester, cotton, wool and other fibers utilizing acid, disperse, direct and basic class dyestuffs.
  • the above process when utilized with the appropriate apparatus also accomplishes currently acceptable fastness and crocking performance levels with no steamer unit or other steam requirement for satisfactory color setting.
  • the process of this invention when utilized with the appropriate apparatus achieves near 100% exhaustion of the dye solution and reduces affluent waste in the dye process by approximately 75% and is applicable to certain existing equipment upon modification of that equipment.
  • the color shade is fully developed and will not continue to build in color department. Further, the water used in the wash box 40 can be recycled with simple plumbing additions (not shown) .
  • the apparatus of the present invention can be retrofitted to most existing carpet dyeing equipment of the continuous range variety.
  • the primary change would be to install the dye bath applicator 17 in line with the existing equipment.
  • the existing steamer can be removed from the existing equipment as it is no longer needed, and the dye bath applicator 17 may be installed in its place.
  • the dye bath applicator 17 may be placed immediately before the existing steamer with the carpet 10 first traveling through the dye bath applicator 17, then through the existing steamer, then to the carpet washing system. If this alternative is utilized, the existing steamer need not be turned on as it is unnecessary.
  • the dye bath applicator 17 may be placed immediately after the existing steamer with similar results.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Coloring (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

Procédé et appareil faisant appel à une nouvelle solution colorante pour teindre une moquette (10). Selon ce procédé, on chauffe la solution colorante jusqu'à une température supérieure à celle du point d'ébullition de l'eau, ce qui permet de fixer la teinture sur la moquette (10) sans avoir recours à une machine à vaporiser et à fixer à chaud.
PCT/US1991/005469 1990-08-01 1991-08-01 Procede et appareil de teinture pour moquette Ceased WO1992002674A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US56116190A 1990-08-01 1990-08-01
US561,161 1990-08-01

Publications (1)

Publication Number Publication Date
WO1992002674A1 true WO1992002674A1 (fr) 1992-02-20

Family

ID=24240880

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1991/005469 Ceased WO1992002674A1 (fr) 1990-08-01 1991-08-01 Procede et appareil de teinture pour moquette

Country Status (4)

Country Link
CN (2) CN1032494C (fr)
AU (1) AU8314091A (fr)
TW (1) TW223133B (fr)
WO (1) WO1992002674A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102885564B (zh) * 2012-09-24 2014-08-27 浙江家园地毯实业有限公司 一种簇绒尼龙染色地毯的加工方法及产品
CN104371368B (zh) * 2014-11-14 2016-06-29 菲诺染料化工(无锡)有限公司 超细还原液状染料及制备方法和在纤维素纤维印花的应用

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB242790A (en) * 1924-11-15 1925-11-19 Joseph Dean Improvements in and relating to dyeing machinery
US2387200A (en) * 1943-12-30 1945-10-16 Uxbridge Worsted Co Inc Method of dyeing woolen and other nitrogenous textile materials
US3418065A (en) * 1965-10-04 1968-12-24 United Piece Dye Works Method for high temperature dyeing
US3707351A (en) * 1970-04-17 1972-12-26 American Cyanamid Co Treatment for improving polypropylene dyeability
US3922738A (en) * 1971-12-13 1975-12-02 Riggs & Lombard Inc Method for treating a running fabric web
US3986831A (en) * 1972-07-18 1976-10-19 Hoechst Aktiengesellschaft Process for the dyeing of knit-fabrics of synthetic fiber materials
US4058517A (en) * 1972-02-29 1977-11-15 Badische Anilin- & Soda-Fabrik Aktiengesellschaft Preparation of a concentrated solution of an anionic azo dye containing a sulfonic acid group
US4082502A (en) * 1973-06-22 1978-04-04 Hoechst Aktiengesellschaft Process for the dyeing of synthetic or natural fibers
GB2063943A (en) * 1979-11-21 1981-06-10 Sando Iron Works Co Continuous processing of fabric materials
GB2125449A (en) * 1982-08-17 1984-03-07 Vita Tex Limited Dyeing shrinkable textile fabrics
US4447924A (en) * 1982-02-18 1984-05-15 Albany International Corp. Moisture control system for controlling the amount of chemical added to a fabric
US4655786A (en) * 1983-11-15 1987-04-07 Ciba-Geigy Corporation Process for dyeing hydrophobic fibre material with disperse dye and surfactant

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB242790A (en) * 1924-11-15 1925-11-19 Joseph Dean Improvements in and relating to dyeing machinery
US2387200A (en) * 1943-12-30 1945-10-16 Uxbridge Worsted Co Inc Method of dyeing woolen and other nitrogenous textile materials
US3418065A (en) * 1965-10-04 1968-12-24 United Piece Dye Works Method for high temperature dyeing
US3707351A (en) * 1970-04-17 1972-12-26 American Cyanamid Co Treatment for improving polypropylene dyeability
US3922738A (en) * 1971-12-13 1975-12-02 Riggs & Lombard Inc Method for treating a running fabric web
US4058517A (en) * 1972-02-29 1977-11-15 Badische Anilin- & Soda-Fabrik Aktiengesellschaft Preparation of a concentrated solution of an anionic azo dye containing a sulfonic acid group
US3986831A (en) * 1972-07-18 1976-10-19 Hoechst Aktiengesellschaft Process for the dyeing of knit-fabrics of synthetic fiber materials
US4082502A (en) * 1973-06-22 1978-04-04 Hoechst Aktiengesellschaft Process for the dyeing of synthetic or natural fibers
GB2063943A (en) * 1979-11-21 1981-06-10 Sando Iron Works Co Continuous processing of fabric materials
US4447924A (en) * 1982-02-18 1984-05-15 Albany International Corp. Moisture control system for controlling the amount of chemical added to a fabric
GB2125449A (en) * 1982-08-17 1984-03-07 Vita Tex Limited Dyeing shrinkable textile fabrics
US4655786A (en) * 1983-11-15 1987-04-07 Ciba-Geigy Corporation Process for dyeing hydrophobic fibre material with disperse dye and surfactant

Also Published As

Publication number Publication date
CN1128279A (zh) 1996-08-07
TW223133B (fr) 1994-05-01
AU8314091A (en) 1992-03-02
CN1032494C (zh) 1996-08-07
CN1058625A (zh) 1992-02-12

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