U.S. patent application number 13/277484 was filed with the patent office on 2012-08-09 for process for dyeing carpets with unused yarns.
This patent application is currently assigned to MANNINGTON MILLS, INC.. Invention is credited to Robert W. Brinkley, Robert D. Hutchison.
Application Number | 20120198634 13/277484 |
Document ID | / |
Family ID | 46599641 |
Filed Date | 2012-08-09 |
United States Patent
Application |
20120198634 |
Kind Code |
A1 |
Hutchison; Robert D. ; et
al. |
August 9, 2012 |
Process For Dyeing Carpets With Unused Yarns
Abstract
Overdyed carpets, as well as other textiles, and methods of
producing the same are provided. Overdyeing can be performed on
predyed and/or undyed fibers to produce an overdyed carpet with a
predominant hue throughout. Predyed fibers can differ in hue,
saturation, or value, or any combination thereof from each other
and/or from the overdye. The overdyed carpet can include at least
one auxiliary 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. These carpets and methods provide aesthetic, financial,
and environmental benefits by allowing for utilization of waste
fiber, yarn, carpet, and other textiles that would otherwise
require resale at substantial discount or landfill disposal.
Inventors: |
Hutchison; Robert D.;
(Calhoun, GA) ; Brinkley; Robert W.; (Calhoun,
GA) |
Assignee: |
MANNINGTON MILLS, INC.
Salem
NJ
|
Family ID: |
46599641 |
Appl. No.: |
13/277484 |
Filed: |
October 20, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61439614 |
Feb 4, 2011 |
|
|
|
61481773 |
May 3, 2011 |
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Current U.S.
Class: |
8/494 ;
8/636 |
Current CPC
Class: |
D06P 1/40 20130101; D06P
1/0004 20130101; D06P 1/39 20130101 |
Class at
Publication: |
8/494 ;
8/636 |
International
Class: |
D06P 1/39 20060101
D06P001/39; D06P 1/40 20060101 D06P001/40 |
Claims
1. A method of preparing an overdyed carpet having a predominant
hue throughout the overdyed carpet, the method comprising:
contacting at least one carpet comprising a plurality of fibers
with a dye bath comprising at least one dye, the dye bath having a
pH from about 1.5 to about 6.5; heating the dye bath to a target
temperature of from about 140.degree. F. to about 240.degree. F.;
adding at least one auxiliary chemical in an amount of less than 25
wt. % of the weight of the at least one carpet to the dye bath
after at least 1 wt % of the at least one dye by weight of the at
least one dye has been exhausted from the dye bath, wherein the at
least one auxiliary chemical provides stain resistance, color
fastness, or bleach resistance, or any combination thereof.
2. The method of claim 1, further comprising preparing the dye bath
by: adding water to a bath, the water having an initial temperature
of from about 35.degree. F. to about 120.degree. F.; adding at
least one water treatment chemical to the bath; adding at least one
acid to the bath to achieve a pH from about 1.5 to about 6.5;
adding the at least one dye to the bath.
3. The method of claim 1, wherein the plurality of fibers comprise
predyed fibers.
4. The method of claim 3, wherein at least a portion of the predyed
fibers differ in hue, saturation, or value, or any combination
thereof from a different portion of the predyed fibers.
5. The method of claim 4, wherein the portion and the different
portion differ in hue prior to overdyeing.
6. The method of claim 3, wherein the predyed fibers comprise
fibers predyed with at least one pigment.
7. The method of claim 3, wherein the predyed fibers comprise
fibers predyed with at least one acid dye.
8. The method of claim 3, wherein from about 25 wt. % to about 100
wt % of the predyed fibers comprise pigment and from 0 wt % to
about 75 wt % of the predyed fibers comprise acid dye based on the
total weight of the predyed fibers.
9-11. (canceled)
12. The method of claim 1, wherein the plurality of fibers comprise
undyed fibers.
13. The method of claim 1, wherein the plurality of fibers comprise
cationic-dyeable fibers.
14. The method of claim 1, wherein the plurality of fibers comprise
polyamide fibers.
15. (canceled)
16. The method of claim 1, wherein the plurality of fibers comprise
polyester fibers.
17. (canceled)
18. The method of claim 1, wherein the plurality fibers comprise
polyolefin fibers, polyvinyl fibers, or a combination thereof.
19. The method of claim 1, wherein the plurality of fibers comprise
waste yarn.
20. The method of claim 1, wherein the plurality of fibers comprise
predyed yarn.
21. The method of claim 20, wherein the predyed yarn comprises
space dyed yarn, solution dyed yarn, dyeable yarn, or recycled
yarn, or any combination thereof.
22. The method of claim 1, wherein the at least one dye comprises
at least one acid dye.
23. The method of claim 22, wherein the at least one acid dye
comprises at least one leveling acid dye, at least one premetalized
acid dye, or at least one milling acid dye, or any combination
thereof.
24. The method of claim 1, wherein the at least one dye differs
from the plurality of fibers in hue, saturation, value, or any
combination thereof.
25. The method of claim 1, wherein the at least one dye comprises
at least one dye darker than at least one of the plurality of
fibers.
26. The method of claim 1, wherein the at least one dye comprises
at least one yellow dye, at least one red dye, or at least one blue
dye, or any combination thereof.
27. The method of claim 1, wherein the dye bath further comprises
at least one treatment chemical.
28. (canceled)
29. The method of claim 2, wherein the acid comprises acetic acid,
sulfuric acid, or a combination thereof.
30. The method of claim 29, wherein the sulfuric acid is provided
by at least one organic sulfate, at least one inorganic sulfate, or
any combination thereof.
31. The method of claim 1, wherein the at least one auxiliary
chemical comprises at least one stain blocker.
32. The method of claim 1, wherein the at least one auxiliary
chemical is added after at least 50 wt % of the at least one dye
based on the weight of the at least one dye has been exhausted from
the dye bath.
33-35. (canceled)
36. The method of claim 1, wherein the at least one auxiliary
chemical is added to the dye bath in an amount of from about 0.5 wt
% to about 25 wt % based on the weight of the at least one
carpet.
37-39. (canceled)
40. The method of claim 1, wherein the at least one auxiliary
chemical comprises substituted acrylic acid in the presence of a
sulfonated aromatic aldehyde condensation polymer.
41. The method of claim 1, wherein the at least one auxiliary
chemical is anionic.
42. (canceled)
43. The method of claim 1, wherein the dye bath has a pH of from
about 1.75 to about 3.0.
44-46. (canceled)
47. The method of claim 1, wherein the at least one auxiliary
chemical is added after the target temperature is reached.
48-50. (canceled)
51. The method of claim 1, wherein the target temperature is a
temperature of from about 140.degree. F. to about 212.degree. F.
and the temperature of the dye bath is held at the target
temperature with a deviation of less than 5.degree. F. from about 5
seconds to about 1 hour.
52-53. (canceled)
54. The method of claim 1, wherein the dye bath is in the absence
of a cationic dye.
55. The method of claim 1, wherein the dye bath is in the absence
of a cationic auxiliary chemical.
56. (canceled)
57. The method of claim 1, further comprising: forming the at least
one carpet from fibers prior to placing the at least one carpet in
the dye bath.
58-67. (canceled)
68. An overdyed carpet produced by the method of claim 1.
69. (canceled)
70. An overdyed carpet having a predominant hue throughout the
carpet, the carpet comprising 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.
71-72. (canceled)
73. The overdyed carpet of claim 70, wherein the acid dye is
present from about 10 wt % to about 20 wt % based on the total
weight of dye in the carpet.
74. The overdyed carpet of claim 70, wherein at least a portion of
the plurality of predyed fibers differ in hue, saturation, or
value, or any combination thereof from a different portion of the
plurality of predyed fibers.
75. The overdyed carpet of claim 74, wherein the portion and the
different portion differ in hue.
76. The overdyed carpet of claim 70, wherein the carpet comprises
cationic-dyeable fibers.
77. The overdyed carpet of claim 70, wherein the carpet comprises
polyamide fibers.
78. (canceled)
79. The overdyed carpet of claim 70, wherein the carpet comprises
polyester fibers.
80. The overdyed carpet of claim 79, wherein the polyester fibers
comprise triexta fibers.
81. The overdyed carpet of claim 70, wherein the carpet comprises
polyolefin fibers, polyvinyl fibers, or a combination thereof.
82. The overdyed carpet of claim 70, wherein the carpet comprises
waste yarn.
83. The overdyed carpet of claim 70, wherein the plurality of
predyed fibers comprise predyed yarn.
84. The overdyed carpet of claim 83, wherein the carpet comprises
space dyed yarn, solution dyed yarn, dyeable yarn, or recycled
yarn, or any combination thereof.
85. The overdyed carpet of claim 70, wherein the at least one dye
comprises at least one acid dye.
86. The overdyed carpet of claim 85, wherein the at least one acid
dye comprises at least one leveling acid dye, at least one
premetalized acid dye, or at least one milling acid dye, or any
combination thereof.
87. The overdyed carpet of claim 70, wherein the at least one dye
differs from the plurality of predyed fibers in hue, saturation,
value, or any combination thereof.
88. The overdyed carpet of claim 70, wherein the at least one dye
comprises at least one dye darker than at least one of the
plurality of predyed fibers.
89. (canceled)
90. The overdyed carpet of claim 70, wherein the carpet comprises
at least one auxiliary chemical that provides stain resistance,
color fastness, or bleach resistance, or any combination
thereof.
91. The overdyed carpet of claim 90, wherein the at least one
auxiliary chemical comprises at least one stain blocker.
92. The overdyed carpet of claim 90, wherein the at least one
auxiliary chemical is present in an amount of from about 0.5 wt %
to about 25 wt % based on the weight of the carpet in the absence
of the at least one auxiliary chemical and overdye.
93-94. (canceled)
95. The overdyed carpet of claim 90, wherein the at least one
auxiliary chemical is present in an amount of from about 13 wt % to
about 20 wt % based on the weight of the carpet in the absence of
the at least one auxiliary chemical and overdye.
96. The overdyed carpet of claim 90, wherein the at least one
auxiliary chemical comprises substituted acrylic acid in the
presence of a sulfonated aromatic aldehyde condensation
polymer.
97. The overdyed carpet of claim 90, wherein the at least one
auxiliary chemical is anionic.
98-99. (canceled)
Description
[0001] This application claims the benefit under 35 U.S.C.
.sctn.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.
BACKGROUND OF THE INVENTION
[0002] 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.
[0003] 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.
SUMMARY OF THE PRESENT INVENTION
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a diagram showing an example of various steps that
can be performed in accordance with methods of the present
invention.
[0012] FIG. 2 is a diagram showing an example of various additional
steps that can be performed in accordance with methods of the
present invention.
[0013] FIG. 3 is a diagram showing another example of various
additional steps that can be performed in accordance with methods
of the present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
[0014] 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.degree. F. to
about 240.degree. 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. FIG. 1. shows an example of
various steps that can be performed in accordance with the methods
of the present invention. Not all steps shown in FIG. 1 need to be
performed, other step(s) can be substituted or otherwise added, one
or more steps can be eliminated, one or more steps can be repeated,
two or more steps can be performed simultaneously, and/or the
ordering of steps can be varied in any way and still remain within
the scope of the present invention. For example, FIG. 1 shows the
steps of contacting a starting carpet with a dye bath (120),
heating the dye bath (130), and adding auxiliary chemical to the
dye bath (140).
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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.degree. F.
to about 120.degree. 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.
[0019] FIG. 2 shows an example of steps that can be followed in
preparing a dye bath suitable for use with the methods of the
present invention. The order of the steps can be varied; two or
more steps can be performed simultaneously. Steps can be added,
repeated, and/or eliminated. For example, FIG. 2 shows the steps of
adding water to a dye bath (215), adding at least one water
treatment chemical to the dye bath (225), adding at least one acid
(with optional buffer) to the dye bath (235), and adding at least
one dye to the dye bath (245). The starting carpet to be overdyed
can be brought into contact with the dye bath before, during,
and/or after the preparation of the dye bath. The starting carpet
can be contacted with the dye bath using any suitable process
and/or apparatus. The starting carpet can be contacted with the dye
bath by operatively associating the starting carpet with a roller
system that cycles the starting carpet through the dye bath. A
beck, sample beck, jet beck, jig beck, and/or rope dye apparatus
can be employed or a continuous metered application system.
[0020] 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.
[0021] 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.
[0022] 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.a r.l. (Wichita, Kans.) including
ANTRON.RTM. 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.
[0023] 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.
[0024] 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.
[0025] 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.TM.), C.I. Acid Red 251
(Lanacron Bordeaux EL.TM.), C.I. Acid Blue 271 (Lanacron Blue
N-3GL.TM.), C.I. Acid Black 172 (Erionyl Black AMR.TM.), C.I. Acid
Orange 162 (Lanacron Yellow N-3RL.TM.), C.I. Acid Black 244
(Lanacron Black N-RBLN.TM.), and C.I. Acid Red 211 (Lanacron Red
N-2GL.TM.). 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.
[0026] 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.
[0027] 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.
[0028] "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.
[0029] 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.).
[0030] 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.).
[0031] 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.
[0032] 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).
[0033] 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.
[0034] 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.degree. F., from about 32.degree.
F. to about 212.degree. F., from about 35.degree. F. to about
210.degree. F., from about 40.degree. F. to about 205.degree. F.,
from about 50.degree. F. to about 200.degree. F., from about
60.degree. F. to about 195.degree. F., from about 70.degree. F. to
about 190.degree. F., from about 80.degree. F. to about 185.degree.
F., from about 90.degree. F. to about 180.degree. F., from about
100.degree. F. to about 175.degree. F., from about 110.degree. F.
to about 170.degree. F., from about 120.degree. F. to about
165.degree. F., from about 125.degree. F. to about 160.degree. F.,
from about 130.degree. F. to about 155.degree. F., from about
140.degree. F. to about 150.degree. F., greater than 212.degree.
F., or any temperature value there between.
[0035] 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.degree. F./min. to about 25.degree. F./min., from about
1.0.degree. F./min. to about 10.degree. F./min., from about
1.5.degree. F./min. to about 5.0.degree. F./min, from about
2.0.degree. F./min. to about 4.5.degree. F./min., from about
3.0.degree. F./min. to about 4.0.degree. F./min., about 2.5.degree.
F./min., less than about 0.05.degree. F./min., or greater than
about 25.degree. 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.
[0036] 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.degree. F., from about 120.degree. F. to about
260.degree. F., from about 120.degree. F. to about 240.degree. F.,
from about 140.degree. F. to about 220.degree. F., from about
150.degree. F. to about 212.degree. F., from about 160.degree. F.
to about 205.degree. F., from about 175.degree. F. to about
200.degree. F., from about 180.degree. F. to about 195.degree. F.,
from about 185.degree. F. to about 190.degree. F., about
140.degree. F., about 150.degree. F., about 155.degree. F., about
160.degree. F., about 165.degree. F., about 170.degree. F., about
175.degree. F., about 180.degree. F., about 185.degree. F., about
190.degree. F., about 195.degree. F., about 200.degree. F., about
202.degree. F., about 205.degree. F., about 210.degree. F., about
boiling, about 212.degree. F., about 230.degree. F., about
250.degree. F., or greater than about 260.degree. 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.
[0037] 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.degree. F. to about 250.degree. F., of about
180.degree. F., from about 185.degree. to about 230.degree. F.,
from about 195.degree. F. to about 215.degree. F., to about
205.degree. F., to about a boil, to less than about 175.degree. F.,
or to greater than about 250.degree. F., or any temperature value
therein. The target temperature can be a temperature of from about
140.degree. F. to about 212.degree. F. and the temperature of the
dye bath can be held at the target temperature with a deviation of
less than 5.degree. F. from about 5 seconds to about 1 hour. The
target temperature can be a temperature of from about 170.degree.
F. to about 205.degree. F. and the temperature of the dye bath can
be held at the target temperature with a deviation of less than
5.degree. F. from about 5 minutes to about 45 minutes. The target
temperature can be a temperature of from about 180.degree. 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.
[0038] 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.degree. F., from about 40.degree. F. to about 200.degree.
F., from about 80.degree. F. to about 190.degree. F., from about
100.degree. F. to about 180.degree. F., from about 120.degree. F.
to about 170.degree. F., from about 140.degree. F. to about
160.degree. F., less than about 40.degree. 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.
[0039] 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.degree. F. to about
320.degree. F., from about 50.degree. F. to about 300.degree. F.,
from about 75.degree. F. to about 250.degree. F., or from about
125.degree. F. to about 200.degree. 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.
[0040] FIG. 3 shows an example of various steps that can be
performed in accordance with the methods of the present invention.
Not all steps shown in FIG. 3 need to be performed, other step(s)
can be substituted or otherwise added, one or more steps can be
eliminated, one or more steps can be repeated, two or more steps
can be performed simultaneously, and/or the ordering of steps can
be varied in any way and still remain with the scope of the present
invention. For example, FIG. 3 shows the steps of forming a
starting carpet (310), contacting the starting carpet with a dye
bath (320), heating the dye bath to a target temperature (330),
adding at least one auxiliary chemical to the dye bath (340),
heating the dye bath to a peak temperature (350), cooling the dye
bath (360), draining the dye bath (365), rinsing the overdyed
carpet (370), rinsing the overdyed carpet (375), finishing the
overdyed carpet (380), and cutting the overdyed carpet into desired
shaped and/or sized pieces (385).
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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.
[0045] 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.
[0046] The present invention includes the following
aspects/embodiments/features in any order and/or in any
combination: [0047] 1. The present invention relates to a method of
preparing an overdyed carpet having a predominant hue throughout
the overdyed carpet, the method comprising: contacting at least one
carpet comprising a plurality of fibers with a dye bath comprising
at least one dye, the dye bath having a pH from about 1.5 to about
6.5; heating the dye bath to a target temperature of from about
140.degree. F. to about 240.degree. F.; adding at least one
auxiliary chemical in an amount of less than 25 wt. % of the weight
of the at least one carpet to the dye bath, such as after the dye
is at least partially exhausted, such as at least 1 wt %, or after
at least 25 wt % of the at least one dye by weight of the at least
one dye has been exhausted from the dye bath, wherein the at least
one auxiliary chemical provides stain resistance, color fastness,
or bleach resistance, or any combination thereof. [0048] 2. The
method of any preceding or following embodiment/feature/aspect,
further comprising preparing the dye bath by: [0049] adding water
to a bath, the water having an initial temperature of from about
35.degree. F. to about 120.degree. F.; [0050] adding at least one
water treatment chemical to the bath; [0051] adding at least one
acid to the bath to achieve a pH from about 1.5 to about 6.5;
[0052] adding the at least one dye to the bath. [0053] 3. The
method of any preceding or following embodiment/feature/aspect,
wherein the plurality of fibers comprise predyed fibers. [0054] 4.
The method of any preceding or following embodiment/feature/aspect,
wherein at least a portion of the predyed fibers differ in hue,
saturation, or value, or any combination thereof from a different
portion of the predyed fibers. [0055] 5. The method of any
preceding or following embodiment/feature/aspect, wherein the
portion and the different portion differ in hue prior to
overdyeing. [0056] 6. The method of any preceding or following
embodiment/feature/aspect, wherein the predyed fibers comprise
fibers predyed with at least one pigment. [0057] 7. The method of
any preceding or following embodiment/feature/aspect, wherein the
predyed fibers comprise fibers predyed with at least one acid dye.
[0058] 8. The method of any preceding or following
embodiment/feature/aspect, wherein from about 25 wt. % to about 100
wt % of the predyed fibers comprise pigment and from 0 wt % to
about 75 wt % of the predyed fibers comprise acid dye based on the
total weight of the predyed fibers. [0059] 9. The method of any
preceding or following embodiment/feature/aspect, wherein from
about 1 wt % to about 50 wt % of the predyed fibers comprise acid
dye based on the total weight of the predyed fibers. [0060] 10. The
method of any preceding or following embodiment/feature/aspect,
wherein from about 5 wt % to about 35 wt % of the predyed fibers
comprise acid dye based on the total weight of the predyed fibers.
[0061] 11. The method of any preceding or following
embodiment/feature/aspect, wherein from about 10 wt % to about 20
wt % of the predyed fibers comprise acid dye based on the total
weight of the predyed fibers. [0062] 12. The method of any
preceding or following embodiment/feature/aspect, wherein the
plurality of fibers comprise undyed fibers. [0063] 13. The method
of any preceding or following embodiment/feature/aspect, wherein
the plurality of fibers comprise cationic-dyeable fibers. [0064]
14. The method of any preceding or following
embodiment/feature/aspect, wherein the plurality of fibers comprise
polyamide fibers. [0065] 15. The method of any preceding or
following embodiment/feature/aspect, wherein the polyamide fibers
comprise nylon-6,6 fibers, nylon-6 fibers, or any combination
thereof [0066] 16. The method of any preceding or following
embodiment/feature/aspect, wherein the plurality of fibers comprise
polyester fibers. [0067] 17. The method of any preceding or
following embodiment/feature/aspect, wherein the polyester fibers
comprise triexta fibers. [0068] 18. The method of any preceding or
following embodiment/feature/aspect, wherein the plurality fibers
comprise polyolefin fibers, polyvinyl fibers, or a combination
thereof [0069] 19. The method of any preceding or following
embodiment/feature/aspect, wherein the plurality of fibers comprise
waste yarn. [0070] 20. The method of any preceding or following
embodiment/feature/aspect, wherein the plurality of fibers comprise
predyed yarn. [0071] 21. The method of any preceding or following
embodiment/feature/aspect, wherein the predyed yarn comprises space
dyed yarn, solution dyed yarn, dyeable yarn, or recycled yarn, or
any combination thereof. [0072] 22. The method of any preceding or
following embodiment/feature/aspect, wherein the at least one dye
comprises at least one acid dye. [0073] 23. The method of any
preceding or following embodiment/feature/aspect, wherein the at
least one acid dye comprises at least one leveling acid dye, at
least one premetalized acid dye, or at least one milling acid dye,
or any combination thereof. [0074] 24. The method of any preceding
or following embodiment/feature/aspect, wherein the at least one
dye differs from the plurality of fibers in hue, saturation, value,
or any combination thereof. [0075] 25. The method of any preceding
or following embodiment/feature/aspect, wherein the at least one
dye comprises at least one dye darker than at least one of the
plurality of fibers. [0076] 26. The method of any preceding or
following embodiment/feature/aspect, wherein the at least one dye
comprises at least one yellow dye, at least one red dye, or at
least one blue dye, or any combination thereof. [0077] 27. The
method of any preceding or following embodiment/feature/aspect,
wherein the dye bath further comprises at least one treatment
chemical. [0078] 28. The method of any preceding or following
embodiment/feature/aspect, wherein the at least one water treatment
chemical comprises at least one water softener, at least one
leveler, at least one wetter, at least one lubricant, or at least
one defoamer, or any combination thereof. [0079] 29. The method of
any preceding or following embodiment/feature/aspect, wherein the
acid comprises acetic acid, sulfuric acid, or a combination
thereof. [0080] 30. The method of any preceding or following
embodiment/feature/aspect, wherein the sulfuric acid is provided by
at least one organic sulfate, at least one inorganic sulfate, or
any combination thereof. [0081] 31. The method of any preceding or
following embodiment/feature/aspect, wherein the at least one
auxiliary chemical comprises at least one stain blocker. [0082] 32.
The method of any preceding or following embodiment/feature/aspect,
wherein the at least one auxiliary chemical is added after at least
50 wt % of the at least one dye based on the weight of the at least
one dye has been exhausted from the dye bath. [0083] 33. The method
of any preceding or following embodiment/feature/aspect, wherein
the at least one auxiliary chemical is added after at least 75 wt %
of the at least one dye based on the weight of the at least one dye
has been exhausted from the dye bath. [0084] 34. The method of any
preceding or following embodiment/feature/aspect, wherein the at
least one auxiliary chemical is added after at least 90 wt % of the
at least one dye based on the weight of the at least one dye has
been exhausted from the dye bath. [0085] 35. The method of any
preceding or following embodiment/feature/aspect, wherein the at
least one auxiliary chemical is added after at least 95 wt % of the
at least one dye based on the weight of the at least one dye has
been exhausted from the dye bath. [0086] 36. The method of any
preceding or following embodiment/feature/aspect, wherein the at
least one auxiliary chemical is added to the dye bath in an amount
of from about 0.5 wt % to about 25 wt % based on the weight of the
at least one carpet. [0087] 37. The method of any preceding or
following embodiment/feature/aspect, wherein the at least one
auxiliary chemical is added to the dye bath in an amount of from
about 6 wt % to about 15 wt % based on the weight of the at least
one carpet. [0088] 38. The method of any preceding or following
embodiment/feature/aspect, wherein the at least one auxiliary
chemical is added to the dye bath in an amount of from about 8 wt %
to about 10 wt % based on the weight of the at least one carpet.
[0089] 39. The method of any preceding or following
embodiment/feature/aspect, wherein the at least one auxiliary
chemical is added to the dye bath in an amount of from about 13 wt
% to about 20 wt % based on the weight of the at least one carpet.
[0090] 40. The method of any preceding or following
embodiment/feature/aspect, wherein the at least one auxiliary
chemical comprises substituted acrylic acid in the presence of a
sulfonated aromatic aldehyde condensation polymer. [0091] 41. The
method of any preceding or following embodiment/feature/aspect,
wherein the at least one auxiliary chemical is anionic. [0092] 42.
The method of any preceding or following embodiment/feature/aspect,
wherein the dye bath is maintained at a constant pH. [0093] 43. The
method of any preceding or following embodiment/feature/aspect,
wherein the dye bath has a pH of from about 1.75 to about 3.0.
[0094] 44. The method of any preceding or following
embodiment/feature/aspect, wherein the dye bath has a pH of from
2.0 to 2.5. [0095] 45. The method of any preceding or following
embodiment/feature/aspect, wherein the dye bath has a pH of about
2.25. [0096] 46. The method of any preceding or following
embodiment/feature/aspect, wherein the heating is at a rate of from
about 1.5.degree. F./min. to about 5.0.degree. F./min. [0097] 47.
The method of any preceding or following embodiment/feature/aspect,
wherein the at least one auxiliary chemical is added after the
target temperature is reached. [0098] 48. The method of any
preceding or following embodiment/feature/aspect, wherein the
temperature of the dye bath is further increased following the
addition of the at least one auxiliary chemical. [0099] 49. The
method of any preceding or following embodiment/feature/aspect,
wherein the temperature of the dye bath is further increased to a
peak temperature of from about 195.degree. F. to about 215.degree.
F. [0100] 50. The method of any preceding or following
embodiment/feature/aspect, wherein the target temperature is about
180.degree. F. [0101] 51. The method of any preceding or following
embodiment/feature/aspect, wherein the target temperature is a
temperature of from about 140.degree. F. to about 212.degree. F.
and the temperature of the dye bath is held at the target
temperature with a deviation of less than 5.degree. F. from about 5
seconds to about 1 hour. [0102] 52. The method of any preceding or
following embodiment/feature/aspect, wherein the target temperature
is a temperature of from about 170.degree. F. to about 205.degree.
F. and temperature of the dye bath is held at the target
temperature with a deviation of less than 5.degree. F. from about 5
minutes to about 45 minutes. [0103] 53. The method of any preceding
or following embodiment/feature/aspect, wherein the target
temperature is a temperature from about 180.degree. F. to about
boiling, and the temperature of the dye bath is held in that
temperature range from greater than 0 minutes to about 1 hour.
[0104] 54. The method of any preceding or following
embodiment/feature/aspect, wherein the dye bath is in the absence
of a cationic dye. [0105] 55. The method of any preceding or
following embodiment/feature/aspect, wherein the dye bath is in the
absence of a cationic auxiliary chemical. [0106] 56. The method of
any preceding or following embodiment/feature/aspect, wherein the
at least one carpet is contacted with the dye bath by operatively
associating the at least one carpet with a roller system that
cycles the at least one carpet through the dye bath. [0107] 57. The
method of any preceding or following embodiment/feature/aspect,
further comprising: [0108] forming the at least one carpet from
fibers prior to placing the at least one carpet in the dye bath.
[0109] 58. The method of any preceding or following
embodiment/feature/aspect, further comprising: [0110] draining the
contents of the dye bath after the addition of the at least one
auxiliary chemical. [0111] 59. The method of any preceding or
following embodiment/feature/aspect, further comprising: [0112]
rinsing the at least one carpet with water. [0113] 60. The method
of any preceding or following embodiment/feature/aspect, further
comprising: [0114] drying the at least one carpet. [0115] 61. The
method of any preceding or following embodiment/feature/aspect,
further comprising: [0116] finishing the at least one carpet.
[0117] 62. The method of any preceding or following
embodiment/feature/aspect, wherein the at least one carpet consists
of a single carpet. [0118] 63. The method of any preceding or
following embodiment/feature/aspect, wherein the at least one
carpet is a broadloom carpet. [0119] 64. The method of any
preceding or following embodiment/feature/aspect, further
comprising: [0120] cutting the overdyed carpet into a plurality of
carpet tiles. [0121] 65. The method of any preceding or following
embodiment/feature/aspect, wherein the method is a batch process.
[0122] 66. The method of any preceding or following
embodiment/feature/aspect, wherein the method is a continuous
process. [0123] 67. The method of any preceding or following
embodiment/feature/aspect, wherein the method is 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.
[0124] 68. An overdyed carpet produced by the method of any
preceding or following embodiment/feature/aspect. [0125] 69. A
carpet tile produced by the method of any preceding or following
embodiment/feature/aspect. [0126] 70. An overdyed carpet having a
predominant hue throughout the carpet, the carpet comprising 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. [0127] 71. The overdyed carpet of any preceding or
following embodiment/feature/aspect, wherein the acid dye is
present from about 1 wt % to about 50 wt % based on the total
weight of dye in the carpet. [0128] 72. The overdyed carpet of any
preceding or following embodiment/feature/aspect, wherein the acid
dye is present from about 5 wt % to about 35 wt % based on the
total weight of dye in the carpet. [0129] 73. The overdyed carpet
of any preceding or following embodiment/feature/aspect, wherein
the acid dye is present from about 10 wt % to about 20 wt % based
on the total weight of dye in the carpet.
[0130] 74. The overdyed carpet of any preceding or following
embodiment/feature/aspect, wherein at least a portion of the
plurality of predyed fibers differ in hue, saturation, or value, or
any combination thereof from a different portion of the plurality
of predyed fibers. [0131] 75. The overdyed carpet of any preceding
or following embodiment/feature/aspect, wherein the portion and the
different portion differ in hue. [0132] 76. The overdyed carpet of
any preceding or following embodiment/feature/aspect, wherein the
carpet comprises cationic-dyeable fibers. [0133] 77. The overdyed
carpet of any preceding or following embodiment/feature/aspect,
wherein the carpet comprises polyamide fibers. [0134] 78. The
overdyed carpet of any preceding or following
embodiment/feature/aspect, wherein the polyimide fibers comprise
nylon-6,6 fibers, nylon-6 fibers, or any combination thereof.
[0135] 79. The overdyed carpet of any preceding or following
embodiment/feature/aspect, wherein the carpet comprises polyester
fibers. [0136] 80. The overdyed carpet of any preceding or
following embodiment/feature/aspect, wherein the polyester fibers
comprise triexta fibers. [0137] 81. The overdyed carpet of any
preceding or following embodiment/feature/aspect, wherein the
carpet comprises polyolefin fibers, polyvinyl fibers, or a
combination thereof. [0138] 82. The overdyed carpet of any
preceding or following embodiment/feature/aspect, wherein the
carpet comprises waste yarn. [0139] 83. The overdyed carpet of any
preceding or following embodiment/feature/aspect, wherein the
plurality of predyed fibers comprise predyed yarn. [0140] 84. The
overdyed carpet of any preceding or following
embodiment/feature/aspect, wherein the carpet comprises space dyed
yarn, solution dyed yarn, dyeable yarn, or recycled yarn, or any
combination thereof. [0141] 85. The overdyed carpet of any
preceding or following embodiment/feature/aspect, wherein the at
least one dye comprises at least one acid dye. [0142] 86. The
overdyed carpet of any preceding or following
embodiment/feature/aspect, wherein the at least one acid dye
comprises at least one leveling acid dye, at least one premetalized
acid dye, or at least one milling acid dye, or any combination
thereof. [0143] 87. The overdyed carpet of any preceding or
following embodiment/feature/aspect, wherein the at least one dye
differs from the plurality of predyed fibers in hue, saturation,
value, or any combination thereof. [0144] 88. The overdyed carpet
of any preceding or following embodiment/feature/aspect, wherein
the at least one dye comprises at least one dye darker than at
least one of the plurality of predyed fibers. [0145] 89. The
overdyed carpet of any preceding or following
embodiment/feature/aspect, wherein the at least one dye comprises
at least one yellow dye, at least one red dye, or at least one blue
dye, or any combination thereof. [0146] 90. The overdyed carpet of
any preceding or following embodiment/feature/aspect, wherein the
carpet comprises at least one auxiliary chemical that provides
stain resistance, color fastness, or bleach resistance, or any
combination thereof [0147] 91. The overdyed carpet of any preceding
or following embodiment/feature/aspect, wherein the at least one
auxiliary chemical comprises at least one stain blocker. [0148] 92.
The overdyed carpet of any preceding or following
embodiment/feature/aspect, wherein the at least one auxiliary
chemical is present in an amount of from about 0.5 wt % to about 25
wt % based on the weight of the carpet in the absence of the at
least one auxiliary chemical and overdye. [0149] 93. The overdyed
carpet of any preceding or following embodiment/feature/aspect,
wherein the at least one auxiliary chemical is present in an amount
of from about 6 wt % to about 15 wt % based on the weight of the
carpet in the absence of the at least one auxiliary chemical and
overdye. [0150] 94. The overdyed carpet of any preceding or
following embodiment/feature/aspect, wherein the at least one
auxiliary chemical is present in an amount of from about 8 wt % to
about 10 wt % based on the weight of the carpet in the absence of
the at least one auxiliary chemical and overdye. [0151] 95. The
overdyed carpet of any preceding or following
embodiment/feature/aspect, wherein the at least one auxiliary
chemical is present in an amount of from about 13 wt % to about 20
wt % based on the weight of the carpet in the absence of the at
least one auxiliary chemical and overdye. [0152] 96. The overdyed
carpet of any preceding or following embodiment/feature/aspect,
wherein the at least one auxiliary chemical comprises substituted
acrylic acid in the presence of a sulfonated aromatic aldehyde
condensation polymer. [0153] 97. The overdyed carpet of any
preceding or following embodiment/feature/aspect, wherein the at
least one auxiliary chemical is anionic. [0154] 98. The overdyed
carpet of any preceding or following embodiment/feature/aspect,
wherein the carpet is in the form of a carpet tile. [0155] 99. The
overdyed carpet of any preceding or following
embodiment/feature/aspect, wherein the carpet is a broadloom
carpet.
[0156] 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.
[0157] 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.
EXAMPLES
Example 1
[0158] 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.TM. 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.
[0159] 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.
[0160] 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.
[0161] 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.
[0162] 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.
[0163] 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.
[0164] 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.degree. F.
TABLE-US-00001 TABLE 1 Aux. Chem. Sample % % % Sequest
Wetter/Leveler Acid/Buffer pH @ (Stainblocker) # Yellow Red
Blue/Blk G Name % Name g Name start % Name 1 1.47 N3RL 0.45 EL 1.8
NRBLN 39 Reso. 2 AC 80 SA-8 2.23 1.0 NCL4 2 0.84 3R 0.455 2B .438
4R 1 CL-3 2 AC 2.5 SA-8 2.10 2.0 NCL4 3 0.84 3R 0.455 2B .438 4R 1
CL-3 0 -- 2.5 SA-8 2.10 2.0 NCL4 4 0.338 N3RL 0.096 EL 0.506 NRBLN
600 GSA 0 N/A 1200 484 2.03 4.0 NCL4 5 0.918 3R 0.497 - 2B 0.478 -
4R 39 CL-3 0 N/A 70 484 2.23 0.0 NCL4 6 0.918 3R 0.497 - 2B 0.478 -
4R 39 CL-3 0 N/A 70 484 2.23 4.0 NCL4 7 0.918 3R 0.497 - 2B 0.478 -
4R 39 CL-3 0.0 N/A 70 484 2.19 8.0 NCL4 8 0.918 3R 0.497 - 2B 0.478
- 4R 39 CL-3 0.0 N/A 70 484 2.23 12.0 NCL4 9 0.918 3R 0.497 - 2B
0.478 - 4R 39 CL-3 0 N/A 73 484 2.21 5.0 NCL4 10 0.578 SB 0.448 2B
0.526 4R 39 GSA 1.0 LPDS 75 484 2.21 8.0 LSR 11 0.285 N3RL 0 .82
N3GL 39 GSA 0.0 N/A 75 484 2.22 4.0 NCL4 12 0.108 N3RL 0.195 EL 1.6
NRBLN 39 GSA 0.0 N/A 75 484 2.24 4.0 NCL4 13 0.108 N3RL 0.195 EL
1.6 N3GL 39 GSA 0 N/A 75 484 2.08 4.0 NCL4 14 0.146 SB .226 MBR
0.860 4R 39 GSA 0 N/A 75 484 2.17 8.0 LSR 15 0.131 SB .203 MBR
0.774 4R 550 GSA 0 N/A 1000 484 2.05 8.0 NCL4 16 0.491 SB .426 MBR
0.605 4R 39 GSA 0 N/A 75 484 2.17 8.0 LSR 17 0.432 SB .443 MBR
0.605 4R 550 GSA 0 N/A 1000 484 2.10 8.0 NCL4 18 0.259 SB .594 MBR
0.308 4R 39 GSA 0 N/A 75 484 2.15 8.0 LSR 19 0.228 SB .710 N2GL
0.335 4R 39 GSA 0 N/A 75 484 2.17 8.0 LSR 20 0.049 N3RL .088 EL
0.72 N3GL 600 GSA 0 N/A 1200 484 2.07 4.0 NCL4 21 0.304 SB 0.517
2B(d) 0.268 4R 39 GSA 1.0 LPDS 7.5 484 3.06 8.0 LSR 22 0.159 SB
.612 MBR 0.293 4R 1.1 GSA 0 N/A 1.6 484 2.08 8.0 NCL4 23 0.159 SB
.612 MBR 0.293 4R 1.1 GSA 0 N/A 1.6 SA-8 2.04 8.0 NCL4 24 0.159 SB
.612 MBR 0.293 4R 1.1 GSA 2 AC 1.6 484 2.15 8.0 NCL4 25 0.159 SB
.612 MBR 0.293 4R 1.1 GSA 2 AC 1.6 SA-8 2.04 8.0 NCL4 26 0.159 SB
.612 MBR 0.293 4R 1.1 GSA 1 AC 1.6 484 2.12 8.0 NCL4 27 0.159 SB
.612 MBR 0.293 4R 1.1 GSA 1 AC 1.6 SA-8 2.02 8.0 NCL4 28 0.159 SB
.612 MBR 0.293 4R 1.1 GSA 0.5 AC 1.6 484 2.12 8.0 NCL4 29 0.159 SB
.612 MBR 0.293 4R 1.1 GSA 0.5 AC 1.6 SA-8 2.02 8.0 NCL4 30 0.263 SB
0.082 MBR 0.540 4R 39 WSA 0 N/A 75 484 2.14 8.0 NCL4 31 0.159 SB
0.612 MBR 0.293 4R 39 WSA 0.5 AC 75 SA-8 2.00 8.0 NCL4 32 0.159 SB
0.612 MBR 0.293 4R 39 WSA 0.5 AC 75 SA-8 2.00 0.0 N/A 33 0.131 SB
0.203 MBR 0.774 4R 39 WSA 0.5 AC 75 SA-8 1.99 8.0 NCL4 34 0.131 SB
0.203 MBR 0.774 4R 39 WSA 0.5 AC 75 SA-8 1.99 0.0 N/A 35 0.432 SB
0.443 MBR 0.605 4R 39 WSA 0.5 AC 75 SA-8 1.95 8.0 NCL4 36 0.432 SB
0.443 MBR 0.605 4R 39 WSA 0.5 AC 75 SA-8 1.95 0.0 N/A 37 0.263 SB
0.082 MBR 0.540 4R 39 WSA 0.5 AC 75 SA-8 1.95 8.0 NCL4 38 0.263 SB
0.082 MBR 0.540 4R 39 WSA 0.5 AC 75 SA-8 1.95 0.0 N/A 39 0.159 SB
0.612 MBR 0.293 4R 1 g/l WSA 0.5 AC 2 g/l SA-8 2.19 8.0 NCL4
TABLE-US-00002 TABLE 2 Sample # 1 Dark - 60 4.5 Dark - 80 4.5 Dark
- 100 4.5 WB - Water 4.5 WB - Tide 3.25
TABLE-US-00003 TABLE 3 Sample # 2 3 Light - 60 3.5 3.5 Light - 80
N/A N/A Light - 100 N/A N/A WB - H.sub.2O 1.5 4 WB - Tide 2 3.5
Acetic Acid 2.5 2.5
TABLE-US-00004 TABLE 4 Wet Bleed XENON Sample # H.sub.20 Tide 60
SFU 4 5.00 5.00 4.25 5 1.50 1.50 4.25 6 2.50 2.50 3.50 7 4.50 4.50
3.00 8 4.75 4.50 3.00 9 4.00 3.50 3.00
[0165] 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.
TABLE-US-00005 TABLE 5 Wet Bleed XENON Sample # H.sub.20 Tide 60
SFU dE 10 4.75 4.50 3.50 -- 11 5.00 5.00 4.00 1.81 12 4.50 4.00
4.50 1.24 13 5.00 5.00 3.75 4.97 14 5.00 4.00 4.50 2.35 15 5.00
4.75 4.50 3.36 16 5.00 5.00 4.00 2.35 17 5.00 4.50 4.00 1.41 18
5.00 5.00 4.50 1.75 19 5.00 5.00 4.50 0.63 20 5.00 5.00 4.00 1.74
21 3.50 3.25 4.00 5.58 22 5.00 5.00 4.00 5.59 23 5.00 5.00 4.50
4.86 24 5.00 5.00 4.00 7.64 25 5.00 5.00 4.25 5.17 26 5.00 5.00
4.00 6.69 27 5.00 5.00 4.00 5.12 28 5.00 5.00 4.25 6.35 29 5.00
5.00 4.00 4.49 30 5.00 4.50 4.00 2.00
[0166] 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).
TABLE-US-00006 TABLE 6 XE- Sam- NON 50 cc 20 cc 20 cc 20 cc ple Wet
Bleed 60 100% 100% 20% 10% # H.sub.20 Tide SFU dE Bleach Bleach
Bleach Bleach 31 5.00 5.00 4.00 2.91 8 10 10 10 32 2.50 2.50 4.00
1.99 2.5 6 7 8 33 4.50 3.25 4.50 2.03 8.5 10 10 10 34 1.50 1.25
4.75 1.74 3 6 7 9 35 5.00 4.50 4.50 5.90 8 10 10 10 36 1.50 1.00
4.00 5.65 2 7 8 9 37 4.75 4.50 4.75 2.26 8.5 10 10 10 38 2.25 1.50
4.50 2.24 2.5 6 7 8
[0167] 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.
[0168] 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.
[0169] 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.
* * * * *