U.S. patent application number 10/281568 was filed with the patent office on 2003-03-20 for sculptured pile fabric having improved aesthetic characteristics.
Invention is credited to Child, Mary T., Magee, Ronald, Teaster, Frank W..
Application Number | 20030051298 10/281568 |
Document ID | / |
Family ID | 23920210 |
Filed Date | 2003-03-20 |
United States Patent
Application |
20030051298 |
Kind Code |
A1 |
Child, Mary T. ; et
al. |
March 20, 2003 |
Sculptured pile fabric having improved aesthetic
characteristics
Abstract
The present invention provides a sculptured pile fabric having
both a printed pattern and a sculpted surface of various pile,
heights. The fabric of the present invention has improved aesthetic
qualities as compared with sculptured products of the prior art.
This improved sculptured fabric is the result of a chemical
sculpting method, in which the height of the pile surface is
selectively reduced in a pattern configuration, and that is
followed by an overall "dilute" dyeing process. This "dilute"
dyeing process is similar to that used to "tea stain" textile
products, wherein an overall hue is imparted to a textile by the
use of a relatively dilute (low concentration) dyestuff. The
resulting sculptured product has an appearance that emphasizes the
sculptured areas, making the sculptured areas appear to have
greater depth, especially when viewed at a distance.
Inventors: |
Child, Mary T.; (LaGrange,
GA) ; Teaster, Frank W.; (LaGrange, GA) ;
Magee, Ronald; (LaGrange, GA) |
Correspondence
Address: |
Milliken & Company
P. O. Box 1926
Spartanburg
SC
29304
US
|
Family ID: |
23920210 |
Appl. No.: |
10/281568 |
Filed: |
October 28, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10281568 |
Oct 28, 2002 |
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09483480 |
Jan 14, 2000 |
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6494925 |
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Current U.S.
Class: |
8/494 ;
8/529 |
Current CPC
Class: |
D04H 11/00 20130101;
D06Q 1/02 20130101; D03D 27/00 20130101; D05C 17/02 20130101; D06P
1/0036 20130101; D06P 5/001 20130101 |
Class at
Publication: |
8/494 ;
8/529 |
International
Class: |
D06P 001/00; D06P
003/82 |
Claims
What is claimed is:
1. A process for visually enhancing a sculptured textile substrate
having a dyed pile surface, said surface being comprised of a first
pile area having a first pile height and pile yarns carrying a
first dye at a first concentration and a second pile area,
contiguous to said first pile area, said second pile area having a
second pile height, wherein said first pile height is higher than
said second pile height, and said first pile areas are visually
distinct from said second pile areas, said process comprising the
steps of: (a) uniformly applying and fixing a second dye, in dilute
form, onto said first pile area and said second pile area, said
second dilute dye having a concentration lower than that of said
first dye and wherein said second pile area preferentially accepts
more of said second dye than said first pile area; (b) washing said
textile substrate; and (c) drying said textile substrate.
2. The process of claim 1 wherein said second dilute dye is of the
type selected from the group consisting of acid dyes, acid
premetallized dyes, acid milling dyes, dispersed dyes, direct dyes,
and reactive dyes.
3. The process of claim 1 wherein said second dilute dye is of the
same type as said first dye.
4. The process of claim 1 wherein said second dilute dye is applied
at a temperature in the range of 140.degree. F. to about
160.degree. F.
5. The process of claim 1 wherein said second dilute dye is applied
at ambient temperature and is fixed by heating said textile
substrate to a temperature in the range of about 180.degree. F. to
about 250.degree. F.
6. The process of claim 1 wherein said drying is accomplished by
heating said textile substrate to a temperature in the range of
about 220.degree. F. to about 310.degree. F.
7. The process of claim 6 wherein said drying is accomplished by
heating said textile substrate to a temperature in the range of
about 230.degree. F. to 260.degree. F.
8. The process of claim 6 wherein an effective drying time for
heating said textile substrate is in the range of about three to
about fifteen minutes.
9. A textile substrate having a patterned surface, said surface
being comprised of a pile formed of dyed pile yarns and being
arranged in a pattern comprising first pile areas and second pile
areas, said first and said second areas being contiguous, said
first pile areas being comprised of a plurality of dyed yarns
having a first pile height, said dyed yarns in said first pile
areas carrying a first dye at a first concentration and a second
dye at a second concentration, and said second pile areas being
comprised of a plurality of dyed yarns having a second pile height,
said yarns in said second pile areas carrying said second dye at a
third concentration, wherein said first pile areas have a higher
pile than said second pile areas, and wherein said third
concentration of said second dye is greater than said second
concentration of said second dye.
10. The substrate of claim 1 wherein said first concentration of
said first dye in said first pile areas is higher than said third
concentration of said second dye in said second pile areas.
11. The substrate of claim 1 wherein the concentration of said
first dye in said first pile areas is lower in those portions of
said first pile areas that are immediately adjacent to said second
pile areas than in those portions of said first pile areas that are
further removed from said immediately adjacent areas.
12. The substrate of claim 1 wherein the concentration of said
second dye in said first pile areas is higher in those portions of
said first pile areas that are immediately adjacent to said second
pile areas than in those portions of said first pile areas that are
further removed from said immediately adjacent areas.
13. The substrate of claim 1 wherein the concentration of said
first dye in said first pile areas is lower in those portions of
said first pile areas that are immediately adjacent to said second
pile areas than in those portions of said first pile areas that are
further removed from said immediately adjacent areas, and wherein,
in said immediately adjacent areas, the concentration of said
second dye in said first pile areas is higher than in those
portions of said first pile areas that are further removed from
said immediately adjacent areas.
14. The substrate of claim 1 wherein at least some of said pile
yarns in said first pile area carry a third dye.
15. The substrate of claim 1 wherein at least some of said pile
yarns in said first pile areas and at least some of said pile yarns
in said second pile areas carry a third dye.
16. A textile substrate having a patterned surface, said surface
being comprised of a pile formed of pile yarns and being arranged
in a pattern comprising first pile areas and second pile areas,
said first and said second areas being contiguous, said first pile
areas being comprised of a plurality of dyed yarns having a first
pile height and said second pile areas being comprised of a
plurality of dyed yarns having a second pile height, said first
pile height being greater than said second pile height, said dyed
yarns in said second pile areas carrying a dye at a first
concentration, and said dyed yarns in said first pile areas
carrying said dye at a second concentration in regions directly
adjacent to said second pile areas and carrying said dye at a third
concentration in regions of said first pile areas further removed
from said directly adjacent areas, wherein said first concentration
of said dye is greater than said second concentration, and said
second concentration of said dye is greater than said third
concentration.
Description
TECHNICAL FIELD
[0001] The present invention relates to sculptured textile
substrates, and specifically pile fabrics, and to a process for
producing such fabrics. More particularly, the present invention
relates to a sculpturing process wherein the tensile strength of
the fibers comprising the areas of the fabric to be sculptured is
reduced so that the pile may be more easily removed in those
selected areas by mechanical means. The process further includes a
color wash or dye treatment that may be applied to the fabric to
enhance the visual impact of the sculptured areas and, where
necessary, eliminate any undesired bleached effect often seen in
areas adjacent to the sculptured areas as a result of the
sculpturing process.
BACKGROUND
[0002] In the production of pile fabrics, it is often desirable to
provide a sculptured effect on the surface thereof in order to
enhance the decorative appeal. Several techniques have been used to
create such a sculptured surface, although none of these techniques
has been completely satisfactory.
[0003] One of the early attempts to achieve such a sculptured
effect was by means of a heated embossing roll or plate which has
been engraved or otherwise treated to create a desired design in
raised relief on the surface of the pile fabric. When using a
heated embossing roll, depth is created by the partial or complete
melting of the embossed areas. However, fibers may lose their
individual integrity and become bonded together, thereby often
making the feel or hand of the embossed areas harsh and
undesirable.
[0004] More recent embossing techniques have not been completely
successful in overcoming these problems.
[0005] Other sculpturing methods that utilize chemical means to
shrink the fibers are known. Those processes that employ a chemical
shrinking agent to create the embossed areas have been generally
unsatisfactory because the embossed areas tend to have a harsh and
undesirable hand.
[0006] An alternative method of creating a sculptured fabric uses
chemicals to dissolve, completely or partially, those fibers that
come into contact with the chemical solution. Use of solvents to
dissolve fibers in selected areas has been largely unsuccessful
since the solvent may destroy the entire pile length in the areas
to be embossed, thereby exposing the backing of the fabric, which
may not be desired. Even if total dissolution of the pile is
avoided, fiber integrity may be compromised and a harsh,
undesirable hand may be the inevitable result.
[0007] A satisfactory sculpturing process is disclosed in U.S. Pat.
No. 4,846,845 to McBride et al., which is herein incorporated, in
its entirety, by reference. The process involves the selective
carving of a pile fabric with a chemical fiber-degrading agent that
may be incorporated as part of the fabric dyeing process. The pile
fabric is then finished by heating, neutralizing the degrading
agent, washing, and drying. Finally, the degraded fibers are
removed by mechanical means to provide a sculptured pile fabric.
Because the fiber-degrading agent is known to attack the dye
components in areas adjacent to the sculptured portions as well as
the areas to which it is directly applied, the resulting sculptured
fabric made by this prior art process frequently has bleached "halo
areas" immediately adjacent to the sculptured regions. When viewed
from a distance, these halo areas can be more apparent than the
textured portion of the sculptured fabric, thereby degrading the
overall appearance of the patterned area. A method to make these
halo areas visually less prominent, or eliminate them entirely, has
heretofore been unknown.
[0008] The present invention provides such a method, which
comprises applying a dilute dye solution over the entire substrate
surface, thereby coloring both the sculptured portions and the
non-sculptured portions, but to a different degree. The sculptured
areas tend to be more receptive to this application of dilute dye
than the non-sculptured areas. Somewhat surprisingly, the
non-sculptured areas immediately adjacent to the sculptured areas
tend to have an intermediate affinity for the dilute dye, i.e., the
relative concentration of dye is greatest in the sculptured areas,
least in the central regions of non-sculptured areas, and
intermediate in those non-sculptured "boundary areas" immediately
adjacent to the sculptured areas. The result of this overall dyeing
step is a dramatic reduction in the visual prominence of any
"halos" surrounding the sculptured areas. Additionally, this step
has the unexpected effect of giving the appearance of a greater
depth of sculpturing to the finished sculptured pile fabric. For
these reasons, the present invention represents a useful
advancement over the prior art. It should be noted that, as used
herein, the term "fabric" is used in a broad sense, and is intended
to include carpets and rugs, in addition to upholstery fabrics and
the like.
SUMMARY
[0009] The present invention provides a sculptured pile fabric
having both a printed pattern and a sculptured surface of various
pile heights. The fabric of the present invention has improved
aesthetic qualities as compared with sculptured products of the
prior art. This improved sculptured fabric is the result of a
chemical sculpting method, in which the height of the pile surface
is selectively reduced in a pattern configuration, that is followed
by an overall dyeing process involving the application of a dilute
dye solution. This "dilute" dyeing process is similar to that used
to "tea stain" textile products, wherein an overall shade is
imparted to a textile by the use of a relatively dilute (low
concentration) dyestuff. The resulting sculptured product has an
appearance that emphasizes the sculptured areas, making the
sculptured areas appear to have greater depth, especially when
viewed at a distance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic representation of the location and
relative concentration of two dyes along a boundary between a first
pile area and a second pile area on a fabric dyed in accordance
with the teachings herein;
[0011] FIG. 2 is a schematic representation of the location and
relative concentration of a single dye along a boundary between a
first pile area and a second pile area on a fabric dyed in
accordance with the teachings herein; and
[0012] FIG. 3 is a schematic representation of the location and
relative concentration of three dyes along a boundary between a
first pile area and a second pile area on a fabric dyed in
accordance with the teachings herein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] This invention provides a process for sculpturing pile
fabrics (which, optionally, may already be dyed or patterned),
which, for previously unsculptured fabrics, comprises:
[0014] (a) selectively contacting the pile surface of a pile fabric
corresponding to a pattern with a fiber degrading composition, said
composition comprising a fiber degrading agent in a concentration
sufficient to reduce the tensile strength of the fibers of the
pile, and optionally selectively applying a first dye in pattern
form and in registry with the fiber degrading agent;
[0015] (b) heating the pile fabric to temperatures above about
180.degree. F., but below about 250.degree. F. (preferably, using
atmospheric steam), sufficiently to degrade the selected fibers of
the pile and to provide fixation of the dyes;
[0016] (c) washing the pile fabric to remove any residual
components of the fiber degrading composition from the pile
fabric;
[0017] (d) mechanically removing the degraded pile fibers;
[0018] (e) neutralizing the fiber degrading composition with an
acid-neutralizing solution containing, as a component, a
composition selected from the group consisting of a hydroxide,
carbonate, or phosphate of Group I and II metals;
[0019] (f) washing the pile fabric to remove any residual
components of the acid-neutralizing composition from the pile
fabric;
[0020] (g) applying and fixing a low concentration dye to the
overall surface of the sculptured pile fabric;
[0021] (h) washing the sculptured, dyed pile fabric of step (g) and
mechanically removing any remaining thickeners or excess dye
chemicals; and
[0022] (i) drying the pile fabric by any appropriate means.
[0023] This process, beginning with step (g), can also be used on
any pile substrates that have been previously sculptured by
chemical or other means.
[0024] Turning now to the drawings, FIG. 1 is a representation of
the relative locations and concentrations of two dyes along the
boundary of a first pile area 10 and a second pile area 20. First
pile area 10 has a pile height higher than the pile height of
second pile area 20. The boundary area 15 shall be understood to
mean the area that is part of first pile area 10 and that is
immediately adjacent to second pile area 20. A first dye is
indicated by forward slanting lines, and a second dye (which in
this example may be a dilute dye) is indicated by backward slanting
lines, as shown in FIG. 1. In addition, a substantially uniform,
relatively high concentration of the first dye is present in first
pile area 10, except in areas directly adjacent to second pile area
20, i.e., boundary area 15. Boundary area 15 has a relatively low
concentration of the first dye and a relatively low concentration
of the second dye. A substantially uniform, relatively high
concentration of the second dye (relative to the concentration of
the second dye in boundary area 15), which may be in dilute form,
is present in second pile area 20.
[0025] FIG. 2 is a representation of the relative locations and
concentrations of a single dye along the boundary of a first pile
area 10 and a second pile area 20, as would occur if the dilute dye
application disclosed herein would be applied to a sculptured, but
undyed, substrate. In this example, the first dye may be a dilute
dye and is indicated by backward slanting lines. First pile area 10
has a substantially uniform, relatively low concentration of the
first dye. Boundary area 15 has a concentration of the first dye
that is intermediate between the concentration found in first pile
area 10 and second pile area 20. Second pile area 20 has a
substantially uniform, relatively high concentration of the second
dye (relative to the concentration of the second dye in boundary
area 15).
[0026] FIG. 3 is intended to show the effect of the present
invention on a textile substrate that has been uniformly dyed prior
to being patterned and sculptured. This representation shows the
relative locations and concentrations of a first dye (represented
by forward slanting lines), a second dye (represented by backward
slanting lines), and a third dye (represented by vertical broken
lines). First pile area 10 has a substantially uniform, relatively
high concentration of the first dye, except at boundary region 15
wherein the concentration of first dye is reduced as a result of
the effects of the migration of the sculpturing agent applied to
second pile area 20. First pile area 10 has a relatively low
concentration of the second dye (relative to second pile area 20)
in boundary area 15 and has an even lower concentration of the
second dye in areas outside boundary area 15. A similar situation
exists in first pile area 10 with respect to the relative
concentration of the third dye. Boundary area 15, as indicated, has
intermediate concentrations of the first dye, the second dye, and
the third dye, as a result of the migration of the sculpturing
agent applied to second pile area 20, as discussed above. Second
pile area 20 has a substantially uniform, relatively high
concentration (relative to boundary area 15) of the second dye and
a concentration of the third dye that is lower than that found in
first pile area 10 or boundary area 15, reflecting the propensity
of the sculpturing chemical to degrade any dye to which it comes
into contact.
[0027] The textile substrates that may be processed according to
the present invention include virtually all pile fabrics, and
especially those used in floor coverings (carpets and rugs),
upholstery, and other interior furnishing applications. Such
fabrics may or may not have been dyed prior to the sculpturing step
or the overall dyeing step. Examples of fibers that comprise the
pile fabrics include synthetic fibers prepared from polyamides such
as nylons that are well known to those skilled in the art, natural
fibers such as wool, and blends of the foregoing examples. The
preferred pile fabrics employed in the process of the invention
include nylon and nylon-wool blends. The term "synthetic fibers,"
as employed herein, is intended to include any long chain polymeric
amide that has recurring groups as an integral part of the main
polymer chain and that is capable of being formed into a filament
in which the structural elements are oriented in the direction of
the axis of that chain.
[0028] Polyamide resins coming within the scope of the present
invention are formed generally by reaction of the dicarboxylic acid
with a diamine or by the self-condensation of an aminocarboxylic
acid. Illustrative of these polyamide resins are nylon 6,6
(prepared by the condensation of hexamethylenediamine and adipic
acid); nylon 6 (prepared by the self-condensation of epsilonamino
caproic acid or caprolactum); as well as a variety of polymers
prepared from polymerized dibasic acids and polyamine compounds.
The preferred fibers are nylon 6, nylon 6,6, and wool blends with
either of these two nylons.
[0029] The fiber degrading composition of the process is applied to
the pile fabrics in order to produce the desired sculptured effect.
The fiber degrading composition contains a fiber degrading agent as
the primary active component of the composition. For purposes of
discussion herein, the term "fiber degrading composition" may be
defined as any active chemical compound or composition, which, when
applied to the pile fabric, causes that portion of the pile to
which it has been applied to become brittle or to realize
substantial reduction in strength without actually dissolving the
fiber. As a result, the degraded portion of the pile can be removed
at a later stage in the process by conventional mechanical means.
The composition should be capable of being substantially removed
from the pile or at least neutralized in subsequent sculpturing
steps. It should also be capable of increasing the affinity of the
fibers in the sculptured areas for dye applied following the
sculpturing step.
[0030] The fiber degrading agent should be present in the fiber
degrading composition in a concentration sufficient to reduce the
strength of the fibers so that the fibers may be removed by
mechanical means after the application of heat. The concentration
of the sculpturing agent should not be so high as to cause the
complete destruction of the fiber integrity prior to the subsequent
removal thereof by mechanical means. It has been found that the
fiber degrading agent, which is preferably one or more of the
isomers of toluene sulfonic acid, should be present in the fiber
degrading composition in a preferred amount of from about 10
percent to about 70 percent by weight, and more preferably in an
amount from about 15 to about 50 percent by weight, based upon the
weight of the fiber degrading composition.
[0031] The fiber degrading agent is present in the fiber degrading
composition together with a suitable diluent. The diluent may be a
solvent or a solute for the fiber-degrading agent. If the agent is
not soluble, the agent should be present in the composition in a
finely pulverized form, that is, it should be present in a
micro-pulverized form, which indicates particle diameter in the
order of 100 microns or smaller, preferably even 20 microns or
smaller. Such dispersion of the fiber-degrading agent will assure
that the agent becomes uniformly dispersed on the desired portions
of the fiber. The fiber degrading composition may preferably
include predominant amounts of water as a solvent for the
fiber-degrading agent, although other solvents (including methanol
and ethanol) may be employed. In any event, it is believed that the
alteration of the tensile strength of the fiber is caused by a
hydrolysis reaction, which results in breakage of the bonds of the
molecules that make up the fiber. For this reason, it is believed
that hydrogen ions should be present at the site of the reaction
together with the fiber-degrading agent, and this may be
conveniently accomplished by using water as a solvent.
[0032] The composition may further include a thickening agent
(e.g., natural and synthetic gums and cellulose derivatives) by
means of which the viscosity of the composition may be varied in a
manner well known in the art in order to obtain the viscosity
characteristics demanded in some textile printing technologies. The
characteristics exhibited by a composition of a certain viscosity
enable the fiber-degrading agent to adhere to, and operate on, the
fiber in order to generate a sculptured pattern. Further, if the
composition had a low viscosity, it may be more likely to bleed or
migrate into adjacent areas and compromise the clarity of the
desired pattern. In general, the viscosity of the composition may
preferably be from about 100 to about 1000 centipoise, at
25.degree. C., as measured by a Brookfield No. 3 spindle at 30
rpm.
[0033] The fiber degrading composition may be applied to the pile
fabric in an amount from about 50 percent to about 500 percent,
preferably about 150 to about 250 percent, by weight based upon the
weight of the area of the substrate to be sculptured. The fiber
degrading composition may be applied to the pile fabric in the form
of a substantially transparent composition so that the only
visually apparent alteration of the product is the sculpturing
effect. Without dyestuffs, the sculpting process results in an
undyed or solid shade fabric, having a sculpted surface as depicted
in FIG. 2.
[0034] Alternatively, and more preferably, the fiber degrading
composition may be applied in registry with a dye or pigment
composition used in printing the fabric, so that the color appears
in perfect registry in areas adjacent to where the fiber degrading
composition has been selectively applied (as shown in FIG. 1).
Acceptable dyestuffs include acid dyes, acid premetallized dyes,
acid milling dyes, dispersed dyes, direct dyes, and fiber reactive
dyes. Viscosity and dye concentration should be controlled. The
resultant effect is an embossed design in registry with the printed
pattern.
[0035] With regard to the selected areas where the fiber degrading
agent has been applied, the extent of pile removal (and hence the
depth of sculpturing) may be controlled by varying the amount of
fiber degrading composition applied, by varying the concentration
of fiber degrading agent in the fiber degrading composition, or
both. Furthermore, the amount of pile removed in the selected areas
can also be controlled to a certain extent by the depth of
penetration of the fiber degrading composition into the pile of the
fabric. Penetration can be controlled by varying, for instance, the
viscosity of the chemical fiber degrading composition.
[0036] Application of the fiber degrading composition to the pile
fabric may be accomplished by utilizing one of the many types of
known printing devices, thereby eliminating the need for expensive
embossing or sculpturing equipment. Because the sculpturing is due
to the removal of portions of the pile rather than the shrinkage of
the pile in certain areas, the product typically has a much softer
hand than would otherwise be provided for a given depth of
sculpturing. Also, the product exhibits all of the advantages of
products made by range printing techniques as opposed to woven
fabric or hand sculptured fabric. The preferred apparatus for
application of the fiber degrading composition may be a jet dyeing
apparatus such as that disclosed in U.S. Pat. Nos. 4,084,615 to
Norman E. Klein and William H. Stewart and 4,984,169 to Harold L.
Johnson, Jr., both of which are assigned to Milliken-Research
Corporation, the disclosures of which are herein incorporated by
reference. Other acceptable, but perhaps less preferred application
methods, include the Chromojet.TM. printing apparatus by Zimmer,
any screen printing apparatus, and any other printing apparatus,
which are capable of selectively applying dye or chemical
compositions to a fabric substrate.
[0037] After the fiber degrading composition has been applied to
the pile fabric, the fabric is heated to a temperature sufficient
to cause a substantial reduction of the tensile strength of the
fibers. Heating also affixes the dyestuffs, which, optionally, may
also have been applied. Although the temperatures from about
120.degree. F. to about 250.degree. F. may be employed, atmospheric
steaming conditions, using temperatures above about 180.degree. F.
to about 212.degree. F., are preferred.
[0038] Generally, the pile fabric may be subjected to heating for a
time sufficient to cause degradation of the selected portions of
the pile fabric. Where the heating means is steam, it has been
found that heating should be for at least one minute, preferably
about three to about 30 minutes. The time for heating should be
adjusted to result in the desired degree of degradation for the
particular fiber substrate. Thus, if the time of treatment is too
short, insufficient degradation will occur to allow for subsequent
removal of the pile by mechanical means. If the time is too long,
the pile may completely decompose resulting in an undesirable
product having either no residual pile in the treated areas or an
unpleasant hand in the embossed areas.
[0039] Following heating, the pile fabric is then washed in water
of ambient temperature (say, for example, about 75.degree. F.), in
order to remove any residual components of the fiber degrading
composition.
[0040] As mentioned above, the selected areas of the pile fabric to
which the fiber-degrading agent has been applied may be removed by
mechanical means. Mechanical action to cause such removal may be
initiated or accomplished totally during the washing step described
above by simply spraying the washing solution onto the entire
surface of the substrate at a high velocity. Alternatively, the
mechanical means by which the degraded portions are removed may be
a simple beater, which applies such action to the entire surface of
the fabric from which the degraded fibers are to be removed. A
preferred means for removal is a vacuum system, such as the
Spray-Vac system manufactured by E-Vac, in which water is sprayed
onto the fabric and then vacuumed off the fabric. In general, the
degree of mechanical action required, and the preferred means used,
will depend upon the resultant tensile strength of the fiber after
degradation in the areas to be sculptured. Mechanical removal of
the degraded pile may be performed during the washing step as
mentioned above or alternatively after washing but prior to drying
of the fabric.
[0041] After washing but prior to drying (and preferably after
mechanical removal), the pile fabric is preferably neutralized with
an acid-neutralizing solution containing, as a component, a
composition selected from the group consisting of a hydroxide,
carbonate, or phosphate of Group I and II metals. To halt the
activity of the fiber degrading agent, this step in the process has
been found to be important in (a) preventing further degradation of
the fiber of the pile fabric during the lifetime of the finished
pile fabric and (b) minimizing the loss of color in areas
immediately adjacent to the sculptured areas (i.e., boundary
areas), due to the action of residual quantities of the fiber
degrading agent. The pile fabric may then be washed to remove the
components of the fiber degrading composition from the pile
fabric.
[0042] It is known that the fiber-degrading agent is capable of
causing dye degradation in the areas adjacent to the selectively
treated areas. To address this undesirable degradation, an
additional dye application is utilized that eliminates the effects
of dye degradation caused by the fiber-degrading agent. This dye
application can be thought of as a "tea stain" process, in which a
dilute dye (that is, a dye having a low concentration) is applied
uniformly over the entire substrate. The fibers in those areas in
which the fiber degrading composition has been applied show a
greater affinity for this dilute dye than do the fibers of the
non-sculptured areas. Since the relative dyeability of fibers in
the sculptured areas is increased, the appearance of the
sculpturing effect is emphasized, making the sculpturing more
visually apparent, especially when viewed from a distance.
Acceptable dyestuffs include those that may have been used in the
patterned dyeing process, namely, acid dyes, acid premetallized
dyes, acid milling dyes, dispersed dyes, direct dyes, and fiber
reactive dyes. For purposes of explanation, the dilute dye shall be
referred to as the second dye, because in many cases it will be the
second dye to be applied to the substrate. However, as mentioned
hereinabove, the fabric prior to the sculpturing step may already
be dyed in a solid shade or in one or more colors in a pattern
configuration, or the fabric may be sculptured and undyed.
[0043] The second dye is applied to the pile fabric by means of a
solid shade applicator, an overflow applicator, a chem-pad or nip
applicator, a foam applicator, a Chromojet.TM. printing apparatus
by Zimmer, the printing apparatus described in U.S. Pat. Nos.
4,084,615 and 4,984,169, or any other appropriate dyeing or
chemical applicator known to those of skill in the art. The second
dye can be applied in a hot form, so as to be instantly fixed, or
can be applied at an ambient temperature and fixed in a subsequent
step with heat or steam. In fixing, temperatures from about
120.degree. F. to about 250.degree. F. may be employed, although
atmospheric steaming conditions, using temperatures from about
180.degree. F. to about 212.degree. F., are preferred. With steam
heating, it has been found that heating should be for at least one
minute, preferably about two to about five minutes. Alternatively,
infrared heating may be used for the period of time necessary to
achieve a fabric surface temperature of about 120.degree. F. to
about 200.degree. F.
[0044] Following heating, the pile fabric is then washed, in order
to remove any residual components of the second dye. It may also be
desirable, at this time, to mechanically remove any residual
chemical or fiber components that may be present in the fabric.
[0045] Finally, the sculptured, printed pile fabric is dried,
according to conventional techniques. Specifically, the fabric may
be dried at a temperature in the range of about 220.degree. F. to
about 310.degree. F., and preferably in the range of about
230.degree. F. to about 260.degree. F. Effective drying times have
been found to be in the range of about three to fifteen minutes.
Any appropriate means of drying the fabric may be used, including,
but not limited to, drying by evaporation or by infrared or
microwave sources.
[0046] A large number of products can be produced by the process of
the present invention. The products can be used for floor, wall,
and ceiling coverings, drapery, upholstery, apparel, and the like,
and, in fact, wherever pile fabrics are utilized. They are readily
adaptable to decorate any surface on which the pile fabrics can be
placed or fitted. Many additional applications will occur to those
skilled in the art.
[0047] The following examples are provided for illustrative
purposes only and are not to be construed as limiting the subject
matter of the invention in any way. Unless otherwise indicated, all
parts and percentages are by weight.
EXAMPLE 1
[0048] In this example, the process was performed on a tufted
carpet comprised of 100% DuPont Filament, Stainmaster.TM. nylon
6,6, type 896AS, Semi Dull, Trilobal, 17 dpf. The carpet had a 1/8
inch tufting gauge, a weight of 40.0 ounces per square yard, and a
construction in which the nylon 6,6 yarns were tufted into a woven
polypropylene back.
[0049] The carpet was first wetted to approximately 70% based on
the dry weight of the carpet (hereafter referred to as percent dry
basis), with a Cationic Polymer Solution to enhance the print color
of the dyeing of the carpet. A fiber degrading composition was then
applied, at approximately 250% dry basis, to preselected areas of
the carpet. Several different colors of a conventional aqueous acid
dye solution were then applied to the remainder of the carpet to
create a printed carpet. The application of the fiber degrading
composition and the acid dye solution was by means of the apparatus
described in U.S. Pat. Nos. 4,084,615 and 4,984,169.
[0050] The fiber degrading composition was composed of Xanthan gum
in sufficient amount to effect a viscosity of approximately 450
centipoise (as read by a Brookfield II viscometer, No.3 spindle at
30 rpm), 2 weight percent mineral oil ("Ortholube," available from
Milliken Chemical, a division of Milliken & Company), and a
fiber-degrading agent having a concentration of approximately 38%
para-toluene sulfonic acid. The aqueous acid dye solutions
consisted of Xanthan gum in sufficient amount to effect a viscosity
of approximately 450 centipoise and acid premetallized dyes varying
in concentration from about 0.5% to about 3% depending on the color
and depth of the different shades.
[0051] The carpet was then steamed at about 212.degree. F. for 8
minutes to activate the reaction between the fiber and the
sculpturing liquor and to fix the dye. It was then washed with
water at ambient temperature (about 75.degree. F.) and vacuumed to
remove any degraded fibers, chemicals and thickening agents present
on the fabric. To neutralize any unreacted fiber-degrading agent,
the carpet was then run through a wash bath with a pH controlled to
10 S.U. by addition of a 50% sodium hydroxide solution. The carpet
was then washed and vacuumed again to remove any additional dyeing
and neutralizing chemicals.
[0052] With an overflow applicator, an aqueous acid dye solution
was then applied to the entire carpet substrate at 350% dry basis.
The aqueous acid dye solution consisted of Xanthan gum in
sufficient amount to effect a viscosity of approximately 40
centipoise, 0.2% by weight of a surfactant for wetting, 0.5% by
weight of a defoamer, and 0.01% by weight of acid dyes. The carpet
was conventionally steamed for 3 minutes to fix the dye. The carpet
was washed and vacuumed once more to remove the thickener and
excess dye chemicals from the over flow dyeing and conventionally
dried at 280.degree. F.
[0053] During and after the process the following observations were
made:
[0054] (1) There was no reduction in pile height in the sculpturing
areas or weight loss observed prior to steaming.
[0055] (2) A reduction of about 20 to 30 percent in pile height in
the sculptured area was observed after steaming. In these areas,
the fiber integrity was not altered, but the fiber strength was
dramatically reduced.
[0056] (3) After the washing and neutralizing steps, approximately
70 percent of the pile was removed in the pre-selected sculptured
areas.
[0057] (4) Before the over-dyeing step, the sculptured areas were
white, and the dye around the sculptured areas exhibited a slight
bleached effect where the dye had been degraded.
[0058] (5) The over-dyeing step dyed the white areas, covered the
bleached effect and enhanced the texturing effect making it more
visually prominent when viewed at a distance.
EXAMPLE 2
[0059] Example 1 was repeated except that the carpet was dyed with
a solid shade applicator (a Fluid Dyer manufactured by Kusters)
before the application of the fiber degrading composition and the
print pastes. The printed dyes were weaker and appeared more
washed-out, and the sculptured areas appeared lighter than the rest
of the carpet.
EXAMPLE 3
[0060] Example 1 was repeated except the carpet was not dyed
overall in-line, but instead was dried, rolled up, and taken
through a dye range to apply the overall dye with the solid shade
applicator of Example 2. The results were the same as in Example
1.
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