U.S. patent application number 14/068660 was filed with the patent office on 2014-03-27 for system and method for space-dyeing yarn.
This patent application is currently assigned to Shaw Industries Group, Inc.. The applicant listed for this patent is Shaw Industries Group, Inc.. Invention is credited to George Cavanaugh, Kenneth Keith, Bryan Morton.
Application Number | 20140082859 14/068660 |
Document ID | / |
Family ID | 50337414 |
Filed Date | 2014-03-27 |
United States Patent
Application |
20140082859 |
Kind Code |
A1 |
Morton; Bryan ; et
al. |
March 27, 2014 |
SYSTEM AND METHOD FOR SPACE-DYEING YARN
Abstract
A process for manufacturing spaced dyed yarn for use with tufted
or pile carpet including applying one or more colors of dye to one
or more yarns in a predetermined spaced relation to form a
colorized yarn having a predetermined color pattern.
Inventors: |
Morton; Bryan; (Dalton,
GA) ; Cavanaugh; George; (Dalton, GA) ; Keith;
Kenneth; (Chatsworth, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Shaw Industries Group, Inc. |
Dalton |
GA |
US |
|
|
Assignee: |
Shaw Industries Group, Inc.
Dalton
GA
|
Family ID: |
50337414 |
Appl. No.: |
14/068660 |
Filed: |
October 31, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13333396 |
Dec 21, 2011 |
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14068660 |
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Current U.S.
Class: |
8/483 |
Current CPC
Class: |
D06B 11/0023 20130101;
D06P 1/0096 20130101; D06P 5/12 20130101; D06P 7/005 20130101 |
Class at
Publication: |
8/483 |
International
Class: |
D06P 5/12 20060101
D06P005/12 |
Claims
1. A space-dyed yarn produced from a process comprising: providing
a yarn; feeding at least one strand of the yarn at a predetermined
and selectable speed along a machine direction to a dyeing station;
in the dyeing station, selectively applying one or more colors of
dye to the at least one strand of the yarn in a predetermined,
selectable pattern to form a colorized yarn having a predetermined
color pattern; and fixing the applied dye to the at least one
strand of yarn of the colorized yarn.
2. The space-dyed yarn of claim 1, wherein the process further
comprises winding the colorized yarn onto a creel.
3. The space-dyed yarn of claim 1, wherein the process further
comprises providing the polymeric yarn in a non-dyed form.
4. The space-dyed yarn of claim 1, wherein the yarn is formed from
a material selected from a group consisting of natural materials,
polymeric materials, and mixture thereof.
5. The space-dyed yarn of claim 4, wherein the polymeric materials
are selected from the group consisting of polyesters, polyamides
and polyolefins.
6. The space-dyed yarn of claim 5, wherein the polyesters are
selected from the group consisting of poly(ethylene terephthalate),
poly(butylene terephthalate) and copolymers and mixtures
thereof.
7. The space-dyed yarn of claim 5, wherein the polyamides are
selected from the group consisting of nylon 6, nylon 6/6, nylon
6/9, nylon 6/10, nylon 6/12, nylon 11, nylon 12 and copolymers and
mixtures thereof.
8. The space-dyed yarn of claim 5, wherein the polyolefins are
selected from the group consisting of polypropylene, polypropylene
derivatives, and copolymers and mixtures thereof.
9. The space-dyed yarn of claim 4, wherein the each yarn further
comprises an additive selected from the group consisting of
lubricants, nucleating agents, antioxidants, ultraviolet light
stabilizers, antistatic agents, soil resists, stain resists,
antimicrobial agents, flame retardants and mixtures thereof.
10. The space-dyed yarn of claim 1, wherein the provided polymeric
yarn is a textured yarn.
11. The space-dyed yarn of claim 1, wherein the step of feeding at
least one strand of the yarn at a predetermined and selectable
speed comprising feeding a simultaneously feeding, in the machine
direction, a plurality of strands of yarn along a plurality of
parallel pathways through a downstream dyeing process; wherein each
strand of yarn is feed along one pathway of the plurality of
parallel pathways.
12. The space-dyed yarn of claim 11, further comprising, prior to
selectively applying one or more colors of dye to the at least one
strand of the yarn, pre-steaming the at least one strand of the
yarn being feed at the predetermined and selectable speed to effect
a raise in the relative moisture content of the yarn to a desired
level.
13. The space-dyed yarn of claim 11, wherein the dye color is
applied to the strands of yarns within a tight directional
tolerance in a longitudinal length dimension of the supplied yarn
strand, which is parallel to the machine direction, and in the
transverse, width direction of the yard strand.
14. The space-dyed yarn of claim 11, wherein the dyeing station
comprises at least one color conduit positioned to overlie the at
least one strand of the yarn passing through the dyeing
station.
15. The space-dyed yarn of claim 14, wherein the at least one color
conduit is positioned substantially transverse to the machine
direction of the at least one strand of the yarn passing through
the dyeing station.
16. The space-dyed yarn of claim 15, wherein the at least one color
conduit comprises a plurality of color conduits in operative
communication with a source of pressurized dye color, and wherein
each color conduit of the plurality of color conduits is positioned
substantially parallel to the adjacent color conduit.
17. The space-dyed yarn of claim 16, wherein each respective color
conduit further comprises a plurality of selectively operated jets
that are positioned in overlying orientation with the respective
passing yarns passing along the plurality of parallel pathways,
wherein each respective jet is selectively opened and closed in
response to respective command signal received from a control
system, and wherein each respective jet delivers dye along a dye
delivery axis.
18. The space-dyed yarn of claim 17, wherein the control system is
programmed to selectively apply dye from each respective jet on
each respective color conduit in accord with a selectable design
program.
19. The space-dyed yarn of claim 17, wherein the control system is
programmed to selectively apply dye from each respective jet to an
individual strand of yarn in one actuation cycle of a respective
jet with a start point and stop point of the applied dye being
within about 0.500'' of the desired start/stop points.
20. The space-dyed yarn of claim 17, wherein the control system is
programmed to selectively apply dye from each respective jet to an
individual strand of yarn in one actuation cycle of a respective
jet with a start point and stop point of the applied dye being
within about 0.050'' of the desired start/stop points.
21. The space-dyed yarn of claim 17, further comprising guiding the
yarn being fed through the dyeing station to substantially center
each yarn under the dye delivery axis of one respective jet.
22. A space-dyed yarn produced from a process comprising: extruding
a plurality of filaments of polymeric material; combining the
filaments to form a plurality of polymeric strands; drawing the
plurality of polymeric strands; texturizing the plurality of
polymeric strands into one or more yarn plugs; and selectively
applying one or more colors of dye to each yarn plug at timed
intervals in a spaced relation to form a colorized yarn plug having
a predetermined color pattern.
23. The space-dyed yard of claim 22, wherein the process further
comprises cooling and pulling the colorized yarn plug to form a
colorized yarn.
24. The space-dyed yard of claim 22, wherein the process further
comprises winding the textured and colorized yarn onto a creel.
25. The space-dyed yard of claim 23, wherein the process further
comprises, prior to winding, tacking the individual colorized
yarn.
26. The space-dyed yarn of claim 22, wherein the polymeric material
is selected from the group consisting of polyesters, polyamides and
polyolefins.
27. The space-dyed yarn of claim 26, wherein the polyesters are
selected from the group consisting of poly(ethylene terephthalate),
poly(butylene terephthalate) and copolymers and mixtures
thereof.
28. The space-dyed yarn of claim 27, wherein the polyamides are
selected from the group consisting of nylon 6, nylon 6/6, nylon
6/9, nylon 6/10, nylon 6/12, nylon 11, nylon 12 and copolymers and
mixtures thereof.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
patent application Ser. No. 13/333,396, filed Dec. 21, 2011, which
claims priority to U.S. Provisional Patent Application No.
61/425,567, filed Dec. 21, 2010, both applications which are hereby
incorporated by reference in their entirety for all purposes.
FIELD OF THE INVENTION
[0002] The field of this invention relates generally to carpet
making, and more particularly to a system and method for
space-dyeing yarn for carpet manufacturing.
BACKGROUND
[0003] The production of yarn having different colors spaced along
its length is termed "space dyeing." Space-dyed yarns are desirable
because they easily may be formed into textile fabrics that have an
inherent random or pseudo-random pattern imparted by the patterning
of the yarns comprising the fabric.
[0004] Several methods for space dyeing of yarns are known. Among
conventional batch-type processes (in which a predetermined
quantity of yarn is treated at one time), it is known to inject
yarn packages with a number of different colored dyes to yield a
space-dyed product. However, such batch processes are often more
costly and require more product handling than continuous processes.
Continuous space-dyeing processes (in which moving yarns are
individually or collectively treated) are also known. In such
continuous space-dyeing processes, it is known to apply dye to yarn
via a plurality of rollers arrayed is series or by spraying the
yarn onto individual yarns or yarn sheets. While generally more
efficient than package dyeing techniques, these continuous
space-dyeing processes often experience difficulties with dye mist
and drips, which results in unwanted marks and wasted dye liquor.
Furthermore, dye overspray from the various colors being applied
often mixes together in a single collection system and must be
discarded, which results in added costs for replacement dye as well
as for waste handling and disposal.
[0005] In addition to the problems recounted above, none of these
methods has been able to solve the problems of imperfect
registration of the dye pattern. That is, the yarns produced by
conventional batch-type or continuous space-dyeing methods exhibit
undesired un-dyed areas, or areas in which an overlapping of
different dyes results in undesirable colorations. Conventional
solutions to the problem of having undesired un-dyed areas have
included providing a constant overspray of dye. This particular
solution causes more dye to be used than necessary, with the
attendant higher production cost per pound of yarn, in addition to
the necessity of adjusting dye formulations to compensate for the
color(s) imparted by the constant overspray. This "overspray"
solution has also tends to exacerbate the problem of undesirable
overlapping of adjacent dyed areas and lead to space-dyed yarns in
which the overall result is neither predictable nor controllable.
What is needed therefore is an in-line process for controlled,
efficient and repeatable space-dyeing of yarn during the
manufacturing process.
SUMMARY
[0006] In response to the deficiencies of the prior art, the
present invention is, in one aspect, a process for manufacturing a
space-dyed yarn for use with tufted or pile carpet comprising one
or more of the steps of extruding a plurality of filaments of
polymeric material, combining the filaments to form a plurality of
strands, drawing the strands, texturizing the strands into one or
more yarn plugs, selectively applying one or more colors of dye to
the one or more yarn plugs in a spaced relation, cooling and
pulling the plugs, and/or winding the textured and colorized yarn
onto a creel.
[0007] In one exemplary aspect, the process may also include the
step of tacking the strands prior to winding them. For example and
not meant to be limiting, an air entangling jet, as commonly known
in the art, may be used to tack the plurality of strands.
[0008] In another aspect, the present invention is directed to a
process for manufacturing a space-dyed yarn for use with tufted or
pile carpet comprising one or more of the steps of providing a
conventional yarn, feeding at least one strand of the yarn at a
predetermined and selectable speed, selectively applying one or
more colors of dye to the at least one strand of the yarn in a
predetermined, selectable pattern, fixing the applied dye to the at
least one strand of yarn, and/or winding the colorized yarn onto a
creel.
[0009] Other apparatus, methods, and aspects and advantages of the
invention will be discussed with reference to the Figures and to
the detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate several aspects
described below and together with the description, serve to explain
the principles of the invention. Like numbers represent the same
elements throughout the figures.
[0011] FIG. 1 a schematic view of one embodiment of a system for
space-dyeing yarn.
[0012] FIG. 2 is a schematic view of a second embodiment of a
system for space-dyeing yarn.
[0013] FIG. 3 is an expanded, schematic view of one embodiment of
dying station of the system for space-dyeing yarn illustrated in
FIG. 2.
[0014] FIG. 4 shows an exemplary schematic view of a portion of a
guide positionable under a dye jet of the dying station illustrated
in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention can be understood more readily by
reference to the following detailed description, examples, drawing,
and claims, and their previous and following description. However,
before the present devices, systems, and/or methods are disclosed
and described, it is to be understood that this invention is not
limited to the specific devices, systems, and/or methods disclosed
unless otherwise specified, as such can, of course, vary. It is
also to be understood that the terminology used herein is for the
purpose of describing particular aspects only and is not intended
to be limiting.
[0016] The following description of the invention is provided as an
enabling teaching of the invention in its best, currently known
embodiment. To this end, those skilled in the relevant art will
recognize and appreciate that many changes can be made to the
various aspects of the invention described herein, while still
obtaining the beneficial results of the present invention. It will
also be apparent that some of the desired benefits of the present
invention can be obtained by selecting some of the features of the
present invention without utilizing other features. Accordingly,
those who work in the art will recognize that many modifications
and adaptations to the present invention are possible and can even
be desirable in certain circumstances and are a part of the present
invention. Thus, the following description is provided as
illustrative of the principles of the present invention and not in
limitation thereof.
[0017] As used throughout, the singular forms "a," "an" and "the"
include plural referents unless the context clearly dictates
otherwise. Thus, for example, reference to "a yarn" can include two
or more such yarns unless the context indicates otherwise.
[0018] Ranges can be expressed herein as from "about" one
particular value, and/or to "about" another particular value. When
such a range is expressed, another aspect includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another aspect. It will be further understood that the
endpoints of each of the ranges are significant both in relation to
the other endpoint, and independently of the other endpoint.
[0019] As used herein, the terms "optional" or "optionally" mean
that the subsequently described event or circumstance may or may
not occur, and that the description includes instances where said
event or circumstance occurs and instances where it does not.
[0020] As used herein, and unless the context clearly indicates
otherwise, the term "carpet" is used to generically include
broadloom carpet, carpet tiles, and even area rugs. To that end,
"broadloom carpet" means a broadloom textile flooring product
manufactured for and intended to be used in roll form. "Carpet
tile" denotes a modular floor covering, conventionally in
18''.times.18,'' 24''.times.24'' or 36''.times.36'' squares, but
other sizes and shapes are also within the scope of the present
invention.
[0021] The present invention may be understood more readily by
reference to the following detailed description of preferred
embodiments of the invention and the examples included therein and
to the Figures and their previous and following description.
[0022] As summarized above, in one broad aspect, the present
invention provides a space-dyeing system and method for space dying
yarn at a select location in the manufacturing process of a
finished space-dyed yarn.
[0023] In one embodiment and referring to FIG. 1, the present
invention relates to a process for manufacturing yarn for use with
tufted or pile carpet. In this exemplary embodiment, the process
can comprises one or more of the steps of: extruding a plurality of
filaments of polymeric material, combining the filaments to form a
plurality of strands, drawing the strands, texturizing the strands
into one or more yarn plugs, applying one or more colors of dye to
the one or more yarn plugs in a spaced relation, cooling and
pulling the yarn plugs, and/or winding the textured yarn onto a
creel.
[0024] In one exemplary aspect, the process can also include the
step of tacking the strands prior to winding them. For example, and
not meant to be limiting, a conventional air entangling jet may be
used in the tacking process.
[0025] In this exemplary embodiment, it is contemplated that the
sequential steps of extruding a plurality of filaments of polymeric
material and the combining the filaments to form a plurality of
strands, can be accomplished conventionally in a conventional
extruding and combining apparatuses that are exemplarily and
schematically shown as steps 10 and 12 in FIG. 1. The extruding and
combining apparatuses can be any convenient or desirable extruding
and combining device without departing from the spirit of the
present invention.
[0026] The exemplary extruded polymeric filaments of the yarn
strands can be any man-made filaments made from fiber forming
thermoplastic materials, including, without limitation, polyesters,
polyamides and polyolefins. Suitable polyesters include, but are
not limited to, poly(ethylene terephthalate), poly(butylene
terephthalate) and copolymers and mixtures thereof. Suitable
polyamides include, but are not limited to, nylon 6, nylon 6/6,
nylon 6/9, nylon 6/10, nylon 6/12, nylon 11, nylon 12 and
copolymers and mixtures thereof. Suitable polyolefins include, but
are not limited to, polypropylene, polypropylene derivatives, and
copolymers and mixtures thereof.
[0027] The ordinarily skilled artisan will recognize that the
process conditions, e.g., temperatures, draw ratios, etc., can be
varied according to the standard operating procedures for the
respective type of fibers being spun. In one aspect, it is
contemplated that the fibers of the strands may be multicomponent
or monocomponent fibers and have any variety of arrangements of the
components, like sheath-core, islands-in-the-sea, side-by-side,
etc. It is further contemplated that the individual filaments may
be of any geometric cross-sectional shape, e.g., round, multilobal,
hexagonal, elongated, hollow, and the like.
[0028] As one skilled in the art will appreciate, optional
additives may be used forming the composition of the one or more of
the filaments. Exemplary additives comprise, without limitation,
lubricants, nucleating agents, antioxidants, ultraviolet light
stabilizers, antistatic agents, soil resists, stain resists,
antimicrobial agents, flame retardants, and the like.
[0029] In one aspect, the drawing step 14 can be exemplarily
accomplished in a conventional drawing apparatus using any
conventional draw ratio suitable for the type of fiber being made.
The drawing apparatus can be any convenient or desirable drawing
device without departing from the spirit of the present invention.
For example, when the yarn is nylon 6 yarn, a draw ratio of about 3
can be utilized. However, the desirable draw ratio will be apparent
to those of ordinary skill in the art. In a further aspect, drawing
of the yarn can include passing each feed yarn over heated draw
rolls that are paired with grooved separator rolls. In this aspect,
the separator rolls, when used, can have at least one grooved path
for each strand so that the strands remain separate during drawing
process. In another exemplary aspect, at least a portion of the
grooved paths of the separator rolls are rounded. It will be
appreciated that it is contemplated that conventional drawing
processes can be used.
[0030] Following drawing, one or more of the strands of yarn can be
textured in a texturing step 16. The texturing apparatus can be any
convenient or desirable texturing device without departing from the
spirit of the present invention. In one exemplary aspect, each yarn
strand exiting the drawing apparatus is feed into a texturing
chamber 17, within which the yarn is allowed to selectively pile
up, thereby forming a yarn plug 18. As is typical of known
texturing chambers, the movement of yarn into the texturing chamber
causes the yarn to collide initially with end wall, and
subsequently with itself, thus forming bends and similar shapes,
called crimps, in the yarn strand as it resides therein the
texturing chamber. Because the yarn has been exposed to heated air,
the yarn is softened. As a result, the formed can be substantially
permanent set therein the yarn strand as the yarn strand is
subsequently cooled. In one aspect, the yarn plug can be subjected
to heated airflow, and, at a relatively slow rate, yarn is pressed,
or allowed to exit, out of the texturing chamber. In one example
and without limitation, the ratio of the speed of the yarn exiting
the texturing chamber to the yarn entering the texturing device can
be about 1:10.
[0031] It is contemplated that conventional texturing processes can
be used. In one exemplary aspect, and not meant to be limiting, a
conventional texturing jet can be applied to the one or more of the
strands of yarn. In this aspect, those of ordinary skill in the art
will recognize that the texturing jet should be sized in proportion
to the operating denier of the yarn being textured and that the
conditions for texturing are dependent to a degree on the yarn
being textured. For example, texturing conditions for nylon 6 yarn
can comprise: an air temperature of about 215.degree. C.; duo 2
(second draw rolls) temperature of about 115.degree. C. to about
165.degree. C.; and a texturing jet pressure of about 6 to about 10
bar.
[0032] The textured yarn exits the respective texturing chambers 17
substantially in the yarn plug form and are then cooled by any
known method in a cooling step 19. The cooling apparatus can be any
convenient or desirable cooling device without departing from the
spirit of the present invention. In one example and without
limitation, the cooling process can comprise guiding the textured
yarns across respective porous surfaces of rotating cooling drums.
It is contemplated that the cooling drums may be any suitable
configuration presently known in the art. For example, a vacuum
drawn in the interior of the cooling drum can be used to cause
ambient air to flow through the yarn plug that is in contact with
the porous outer surface of the drum.
[0033] According to the present invention, while the yarn strand is
still in substantially plug form, each respective plug can be
selectively subjected to a spot dyeing process 20. It is
contemplated, in various aspects, that the dyeing process can occur
substantially simultaneously with at least one of the cooling
process, prior to the cooling process, or thereafter the cooling
process.
[0034] In one aspect, each respective yarn plug can be colored at
selected intervals along its length. In another aspect, the yarn
plug can be colored substantially along its length. In yet another
aspect, the dye can be applied such that it substantially
penetrates the plug throughout its entire depth. However, as one
skilled in the art will appreciate, it is contemplated that the
amount of dye to be applied can be chosen to penetrate the plug to
any desired depth.
[0035] In one aspect, it is contemplated that the dyeing apparatus
22 can comprise at least one conduit 24 that is positioned to
overlie the yarn plugs as the yarn plugs are carried or otherwise
urged downstream in the manufacturing direction MD. In this aspect,
each conduit is in communication with a pressurized source of dye
26. In another aspect, the at least one conduit can comprise a
plurality of conduits. It is contemplated that the plurality of
conduits can be positioned in a select array, such as, for example
and without limitation, in an array of substantially parallel
conduits that are positioned substantially transverse to the
manufacturing direction of the yarn manufacturing system. In this
aspect, each respective conduit is in communication with a
pressurized source of dye. It is contemplated that each respective
pressurized source of dye can be a different color or an identical
color. One will appreciate that this allows for the contemplated
supply of an identical color dye to one or more of the respective
conduits, or any select variation of supplied colored dyed to the
respective conduits.
[0036] In a further aspect, it is contemplated that each conduit 24
can have at least one nozzle or jet 28. It is also contemplated
that the at least one nozzle can comprise a plurality of nozzles or
jets. In one aspect, it is contemplated that the respective nozzles
or jets on a respective conduit can be spaced from each other such
that each respective nozzle or jet is positioned to substantially
overlie one respective yarn plug that is moving in the machine
direction.
[0037] Further, the dyeing apparatus 22 can comprise a processor 30
programmed to control the selective delivery of dye to each
respective conduit. In a further aspect, it is contemplated that
the plurality of nozzles or jets can be individually addressed and
controlled by the processor for selective application of the
pressurized dye from the individual nozzles or jets 28.
[0038] In one aspect, controlled and selective dyeing of the yarn
in its substantially plug form allows the moving yarn plug to be
dyed in timed intervals, which results in dyed potions that are
spaced relative to each other, i.e., space dyeing. In one aspect,
it is contemplated that the respective time intervals for each dye
application issuing, under control of the processor, from each
conduit and/or nozzle or jet can be constant, but optionally, in
another aspect, the respective time intervals are substantially
random. In addition and as one will appreciate, as the yarn plug
passes under the plurality of spaced conduits, the time intervals
for each conduit an/or nozzle or jet can be sequentially timed to
pattern the yarn plug with at least one color in accord with a
predetermined color pattern.
[0039] In one aspect, the yarn plug can be dyed and the dye can
subsequently be set with a conventional heating process 40, wherein
the plug is heated with conventional steam heat or the like. The
heating and/or dye setting apparatus can be any convenient or
desirable heating and/or dye-setting device(s) without departing
from the spirit of the present invention.
[0040] Optionally, in another aspect, the yarn plug can be dyed
using ink that is sensitive to ultraviolet light. In this aspect,
the yarn plug can be exposed to ultraviolet light sufficient to set
the dye into the filaments of the yarn. In still another aspect,
the dye can be introduced or sprayed thereon the respective yarn
plugs using a conventional digital jet-printing technique. It is
also contemplated that the application variables such as, for
example and without limitation, dye amount, color, dye, dye
penetration, and the like, can be selectively controlled by the
processor 30 via computer directed signals.
[0041] In one aspect, after conventionally cooling and pulling the
dye-set yarn plugs in a cooling step 42 and a pulling step 44, the
individual colorized yarns can optionally be subjected to a
conventional tacking process 46. The respective cooling, pulling
and tacking apparatuses can be any convenient or desirable cooling,
pulling and tacking devices without departing from the spirit of
the present invention. In one non-limiting example, each of the
respective yarns exiting the cooling step can be individually and
simultaneously tacked using a plurality of air-jet tacking nozzles.
After the tacking process, the yarns can be conventionally wound in
a winding process 44 onto a creel 48 or other storage rack.
[0042] In a second embodiment, as shown in FIGS. 2 and 3, a process
for manufacturing a space-dyed yarn for use with tufted or pile
carpet comprising one or more of the steps of: providing a
conventional yarn 50, feeding at least one strand of the yarn at a
predetermined and selectable speed 60, selectively applying one or
more colors of dye to the at least one strand of the yarn in a
predetermined, selectable pattern 70 to form a colorized yarn
having a predetermined color patter, fixing the applied dye to the
at least one strand of yarn, and/or winding the colorized yarn onto
a creel.
[0043] The exemplary conventional yarns 52 that can be supplied to
the for manufacturing a space-dyed yarn described in this
embodiment can comprise any conventional yarn that comprises
natural materials, polymeric materials, and/or a combination of
natural or polymeric materials. In one exemplary aspect, the
polymeric materials of the supplied yarn can comprise any man-made
filaments made from fiber forming thermoplastic materials,
including, without limitation, polyesters, polyamides and
polyolefins. Suitable polyesters include, but are not limited to,
poly(ethylene terephthalate), poly(butylene terephthalate) and
copolymers and mixtures thereof. Suitable polyamides include, but
are not limited to, nylon 6, nylon 6/6, nylon 6/9, nylon 6/10,
nylon 6/12, nylon 11, nylon 12 and copolymers and mixtures thereof.
Suitable polyolefins include, but are not limited to,
polypropylene, polypropylene derivatives, and copolymers and
mixtures thereof. In one aspect, it is contemplated that the yarn
strand can comprise multicomponent or monocomponent fibers and have
any variety of arrangements of the components, like sheath-core,
islands-in-the-sea, side-by-side, etc. It is further contemplated
that the individual filaments of the respective yarn strands can be
of any geometric cross-sectional shape, e.g., round, multilobal,
hexagonal, elongated, hollow, and the like.
[0044] As one skilled in the art will appreciate, each yarn strand
can further comprise at least one or more optional additives.
Exemplary additives comprise, without limitation, lubricants,
nucleating agents, antioxidants, ultraviolet light stabilizers,
antistatic agents, soil resists, stain resists, antimicrobial
agents, flame retardants, and the like. In a further aspect, the
conventional yarn can be tacked or otherwise textured yarn.
[0045] In one aspect, the conventional yarn 52 is supplied or
otherwise provided to the dyeing line 50 in a conventional manner
that is suitable for the selective unwinding of the yarn and the
selective feeding of the yarn to the dyeing line 50. In one aspect,
the supplied yarn 52 can be wound therefrom a conventional creel or
the like 54. Optionally, each yarn can be feed to a conventional
tensioning device 56, which can be configured to place tension on
the yarn by pulling the yarn strands while in warp form, that is,
in the form wherein the yarn is traveling in a substantially
straight or elongated path in an unraveled and uncoiled state.
[0046] The intake portion 56 of the dyeing line can be configured
to selectively accept one or more individual discrete strands of
the supplied yarn substantially simultaneously. In an optional
configuration, in which the intake portion 56 of the dyeing line is
configured to selectively accept a plurality of individual discrete
strands of yarns, each of the respective yarns are passed or
directed along separate paths at least through the downstream
dyeing process 70. In this aspect, it is contemplated that each of
the respective yarns are directed along defined parallel pathways
62 at least through the downstream dyeing process 70. The defined
parallel pathways 62 can be positioned substantially adjacent to
each other. In one example, the number of defined parallel pathways
can be at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33,
34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50,
51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, or 64 pathways.
Optionally, it will be appreciated by one skilled in the art that
the number of defined parallel pathways can be selectively limited
to not exceed the number of overlying jets of a respective color
conduit in the downstream dyeing process 70, as explained in more
detail below.
[0047] In one exemplary aspect, and at least through the downstream
dyeing process 70, the respective yarns passing in a machine
direction MC through the defined parallel pathways can be spaced
between about 1.000'' to 0.050'' inches apart between about 1.000''
to 0.0625'' inches apart, between about 0.999'' to 0.0833'' inches
apart, and optionally between about 0.0833'' to 0.0100'' inches
apart. Optionally, the respective yarns passing in a machine
direction MC through the defined parallel pathways can be spaced at
least about 0.050'' inches apart, at least about 0.075'' inches
apart, and at least about 0.100'' inches apart.
[0048] Further, in the feeding step, 60, it is contemplated that at
least one strand of the yarn can be fed and drawn through the
process line at a predetermined and selectable speed. It is
contemplated, in a multi-strand processing line operation, in which
multiple yarns are being simultaneously supplied and drawn through
the process line, all of the respective yarns will be fed and drawn
through the process line at substantially the same predetermined
and selectable speed. In one exemplary aspect, and at least through
the downstream dyeing process 70, the feeding and drawing speed of
the respective yarns passing in a machine direction MC through the
defined parallel pathways is between about 1 to 1,500 feet per
minute (FPM), between about 300 to 1250 FPM, and, preferably,
between about 500 to 1000 FPM. Optionally, the feeding and drawing
speed of the respective yarns passing in a machine direction MC can
be at least about 300 FPM, at least about 500 FPM, at least about
750, and preferably at least about 1000 FPM.
[0049] In one aspect, the supplied yarns, which can be warped form
as described above with respect to the tensioning device 56, can be
initially directed to pass through a conventional pre-dyeing
steamer 65. In this steaming operation, steam at a predetermined
temperature is directed thereon the yarn as the yarn passes through
the pre-dyeing steamer at the selected feeding and drawing speed of
the production line. In one aspect, the predetermined temperature
of the supplied steam to the pre-dyeing steamer 65 is between about
50 to 212.degree. F., between about 100 to 211.degree. F., and,
preferably, between about 205 to 210.degree. F. In a further
aspect, the pre-dyeing steamer 65 is sized to ensure sufficient
dwell time therein the pre-dyeing steamer as the yarn passes
through the pre-dyeing steamer at the selected speed of the
production line to effect a raise in the temperature of the yarn
exiting the pre-dyeing steamer to between 50 to 212.degree. F.,
between about 75 to 200.degree. F., and, preferably, between about
100 to 150.degree. F. In a further aspect, the pre-dyeing steamer
65 is sized to ensure sufficient dwell time therein the pre-dyeing
steamer as the yarn passes through the pre-dyeing steamer at the
selected speed of the production line to effect a raise in the
relative moisture content of the yarn to a desired level of at
least about 1%, at least about 2%, and preferably at least about
5%.
[0050] The steamed and heated yarn(s) are subsequently passed
therethrough a dyeing station 72 in the dyeing process 70. In one
exemplary aspect, the dyeing station can comprise a CHROMOSpace
Yarn printing device manufactured by Zimmer. In the dyeing process
70, one or more colors of dye can be selectively applied to each of
the at least one strand of the yarn passes through the dyeing
station 72 at the selected feeding and drawing speed of the
production line in a predetermined, selectable pattern. In one
aspect, it is contemplated that dye color can be selectively
sprayed onto the strands of yarn in accordance with the
predetermined pattern. It is contemplated that the dye color can be
applied to the strands of yarns within a tight directional
tolerance in the longitudinal length dimension of the supplied yarn
strand, which is parallel to the machine direction, and in the
transverse, width direction of the yard strand. This tight
directional spray dyeing tolerance allows for minimizing of dye
overspray and loss and for the selective ability to highly discrete
predetermined segments of colors on the respective yarn strands. As
one skilled in the art will appreciate, the ability to produce
colored segments on a respective yarn strand within a tight
tolerance allows for the possibility of selectively and repeatedly
dyeing a respective strand to minimize or eliminate undesired
overlap of adjacent colored segments of the yarn strand, to produce
a predetermined amount of overlap of adjacent colored segments of
the yarn strand, and the like.
[0051] In one aspect, the dyeing station 72 comprises at least one
color conduit 74 positioned to overlie the at least one strand of
the yarn passing through the dyeing station 72. In one aspect, the
at least one color conduit is positioned substantially transverse
to the machine direction of the at least one strand of the yarn
passing through the dyeing station 72. In an optional aspect, the
at least one color conduit can comprise a plurality of color
conduits. In this aspect, each color conduit 74 of the plurality of
color conduits can be positioned substantially parallel to the
adjacent color conduit. In a further aspect, it is contemplated
that each respective color conduit 74 can be is operative
communication with a source of pressurized dye color [not shown].
Of course, it is contemplated that the respective dye colors that
are in communication with the respective color conduits 74 of the
plurality of color conduits can be the same color, different
colors, or combinations of same and different colors, i.e., one or
more of the color conduits 74 can be in communication with one or
more sources of pressurized dye color of the same color, and/or one
or more color conduits 74 can be in communication with one or more
sources of pressurized dye color of different colors.
[0052] Each respective color conduit further comprises a plurality
of selectively operated jets 76 that are positioned in overlying
orientation with the respective passing yarns in the parallel
pathways 62. Each respective jet is configured to be selectively
opened and closed in response to respective command signal received
from a control system 80 to selectively apply dye along a dye
delivery axis. In one aspect, the control system 80 comprises a
central processor/memory 82 that is programmed to selectively apply
dye from each respective jet 76 on each respective color conduit 74
in accord with a selectable design program. Optionally, the
processor/memory 82 can be programmed to control dye pumps that
effect the pressurization of the dye in the respective sources of
pressurized dye color.
[0053] In one aspect, it is contemplated that the control system
can open and close a respective jet during one respective jet
application cycle as desired for the dyed length of yarn desired.
It is of course contemplated that the entire yarn strand can be
colored, in which case the cycle would initiate upon the initial
feed of the yarn and would terminate at the "end" of particular
yarn. It is also contemplated that the control system can open and
close a respective jet during one respective jet application cycle
such that time duration of a single respective application cycle
can be less than 60, less than 50 seconds, less than 40 seconds,
less than 30 seconds, less than 20 seconds, less than 10 seconds,
less than 1 second, less than 0.500 seconds, less than 0.250
seconds, less than 0.100 seconds, and preferably in less than 0.075
seconds.
[0054] As one will appreciate, the resultant length of dyed portion
of the yarn underlying the respective jet 76 is a function of both
the respective minimum duration of an application cycle and the
speed at which the at least one strand of the yarn passes through
the dyeing station 72. Since both these factors are known, the
tolerance of the directional application of the dye to an
individual strand of yarn can be very low. In operation, and with
the system operating at the nominal speeds described above, it is
contemplated that dye can be applied to an individual strand of
yarn in one actuation cycle of a respective jet with a start point
and stop point of the applied dye being within about 0.500'' of the
desired start/stop points, within about 0.250'' of the desired
start/stop points, within about 0.100'' of the desired start/stop
points, and preferably within about 0.050'' of the desired
start/stop points. In other various aspects, it is contemplated
that each respective jet 76 can selectively apply between about
1-100 g/min of dye, between about 5-75 g/min of dye, between about
7.5-50 g/min of dye, and preferably between about 10-40 g/min of
dye at pressurization levels of between about 0.5-5 bar, between
about 0.75-4.25 bar, and preferably about 1-3.5 bar.
[0055] As one skilled in the art will appreciate, this high level
of dye application control can allow for much more precise levels
of design applications. For example and without limitation, two
different colors can sequentially be applied adjacent each other
lengthwise such that the respective adjacent "ends" of the applied
color can be spaced from each other a particular and predetermined
distance without any color overlap. In one aspect, the particular
and predetermined distance can be substantially zero. Optionally
and without limitation, two different colors can sequentially be
applied adjacent each other lengthwise such the respective adjacent
"ends" of the applied color can overlap each other a particular and
predetermined distance to generate a colored section that is a
function of the different colors, i.e. if the two colors are yellow
and green, the colored section would be resultantly be some shade
of blue.
[0056] In another aspect, and as shown in FIGS. 2-4, as the
respective yarn pass under the distal end of the respective jets
76, each yarn can be precisely guided to substantially center the
yarn being fed in the machine direction under the dye delivery axis
of the respective jet 76. In one exemplary aspect, a guide 71 can
be positioned along each parallel pathway substantially under the
distal ends of each respective jet 76. The guide 71 can have a pair
of opposed vertical obstructions 73 that extend from an upper
surface of the guide that are positioned transverse to the machine
direction of the yarns passing thereunder the jets 76. In options
aspects, the vertical obstructions can comprise, for example and
without limitation, a pair of opposed, partially circular elements
that define opposing side surfaces that extend on a guide axis
substantially parallel to the machine direction through the dyeing
station, a pair of opposed posts, and the like. In a further
optional aspect, it is contemplated that the guide can further
define a bore 75 that extends downward from upper surface of the
guide. In operation, the bore 75 of each guide can be disposed
thereunder the distal end of a respective jet 76 and is sized and
shaped so that any extraneous or overspray dye being applied
thereto the yarn can be communicated, via the bore, to a coupled
waste pan for selective recovery of the overspray dye.
[0057] In another aspect, it is contemplated that the distal end of
each dye can be spaced from the yarn passing thereunder between
about 0.001'' to 6.000'' inches apart between about 0.005'' to
1.000'' inches apart, between about 0.0075'' to 0.500'' inches
apart, and optionally between about 0.010'' to 0.2500'' inches
apart.
[0058] After the color has been applied to the yarn in the dyeing
process 70, the yarn passes through a post-dyeing steamer 90, which
can comprises at least one of a dry heat fix process 92 and/or a
wet heat (steam) process 94. In one aspect, the dry heat fix
process 92 can comprise a housing containing heat elements that are
heated to at least about 212.degree. F., at least about 250.degree.
F., and preferably at least about 300.degree. F. In a further
aspect, the wet heat (steam) process 94 can comprise a housing 95
in the form of a box having steam flowing from the bottom, through
the yarn and up to the top. As one skilled in the art will
appreciate, the dyed yarn enters and exits through openings at the
front and rear of the post steamer housing that are in
communication with ambient atmospheric conditions and thus the
exemplified steamer can be an atmospheric steamer. In one aspect,
it is contemplated that the maximum temperature of the steam used
in the wet heat (steam) process 94 can be between about 200 to
220.degree. F., between about 210 to 213.degree. F., and preferable
is about 212.degree. F.
[0059] As one will appreciated the yarn is traveling very quickly
in warp form, e.g. in the order of the drawing speeds of the yarns
described above, and does not spend much time within the post
steamer 90. In one aspect, it is contemplated that the post steamer
90 can be sized to ensure that the dyed yarn dwells within the post
steamer 90 for a period of time sufficient for the applied dye to
be fixed to a degree necessary to substantially prevent smearing of
one color onto another when the yarn is subsequently coiled in rope
form in a coiler 96. In one aspect, and as one skilled in the art
will appreciate, the tension placed on the yarn by the tensioning
device results from the tensioning device pulling the yarn from the
coiler.
[0060] In one aspect, the coiler can be configured to deposit the
yarn in rope form onto a conveyor which slows down the movement of
the yarn so that when entering a main steamer 98, the yarn may
dwell therein for a selective period of time, which can be between
about 1 to 15 minutes, between 2 to 10 minutes, and preferably
between about 2.5 to 5 minutes. Such a dwell time is generally
sufficient for nylon type yarns; other yarns may require additional
dwell time within the final steamer to fix the dye. It is
contemplated, in one non-limiting example, that the main steamer 98
to the post dyeing steamer 90 used in the wet heat (steam) process
94 in that it comprises a housing that can be in the form of a box
or housing having an entrance and an exit for the dyed yarn
strands. The main steamer 98 is in operative communication with a
source of steam and the maximum temperature of the steam used in
the main steamer 98 can be between about 200 to 220.degree. F.,
between about 205 to 213.degree. F., and preferable is about
212.degree. F.
[0061] Completion of the dyeing process optionally includes at
least one of: a wash system 100, which sprays water onto the yarn
to wash off any excess dye or chemicals that can be on the yarn, a
lubricant system 110, which sprays lubricant, such as, for example
and without limitation, a 0.5%-1.5% solution of Lurol NF 8949 by
Goulston Technologies, Inc., thereon the passing yarn to improve
twisting and heat-setting processes downstream of space dyeing, and
a dryer 120 for removing the moisture from the yarn. Optionally,
after the wash system 100, the yarn can pass through a vacuum
system, which can comprise slot over which the yarn passes to
remove the excess dye, chemicals and the water on the yarn. In one
aspect, the yarn exiting the dryer can be conveyed to an
accumulator 130 in coiled rope form on a conveyor to be separated
thereafter into a warp configuration and subsequently wound on a
winder 140 having separate yarn take-ups for each strand of yarn.
In one aspect, and as one skilled in the art will appreciate, the
tension placed on the yarn by the tensioning device results from
the tensioning device pulling the yarn from the coiler.
[0062] One skilled in the art will appreciate that the respective
post-dyeing steamer apparatus, the coiler apparatus, the main
steamer apparatus, the wash system, the lubricant system, the dryer
apparatus, the accumulator device, and the winder device can be any
convenient or desirable systems and/or devices for competing the
respective process without departing from the spirit of the present
invention.
[0063] Although several embodiments of the invention have been
disclosed in the foregoing specification, it is understood by those
skilled in the art that many modifications and other embodiments of
the invention will come to mind to which the invention pertains,
having the benefit of the teaching presented in the foregoing
description and associated drawings. It is therefore understood
that the invention is not limited to the specific embodiments
disclosed herein, and that many modifications and other embodiments
of the invention are intended to be included within the scope of
the invention. Moreover, although specific terms are employed
herein, they are used only in a generic and descriptive sense, and
not for the purposes of limiting the described invention.
* * * * *