Note: Descriptions are shown in the official language in which they were submitted.
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CONTINUOUS_CARPET DYEING PROCESS
BACKGROUND OF THE INVENTION
This invention relates to a continuous process of
dyeing carpet and is more particularly concerned with a process
for selectively dyeing a carpet ally one oE a numbcl- of ~olors.
One prior art continuous dyeing process is performed
by advancing material to be dyed along a predetermined path
through a vat containing liquid dye material, with the material
leaving the vat, then being advanced through a steam oven for
fixing the dye to the material. Another prior art carpet dyeing
process is performed by lowering a batch of carpet ln a vat
containing dye and then transferring the carpet to a steam oven
for fixation.
In the vat applicator process, when -the dyeing
apparatus is being changed for applying a second color of dye
material, the complete dyeing process must be stopped, the
vat and dye applicator means must be thoroughly cleaned beEore
a second color dyeing process can be started.
The above disadvantages of the vat dye applicator
process increased the cost of dyeing carpet since the complete
dyeing line must be shut down during the change-over from one
color dye to a second color dye. Further, due to the e~treme
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cost of changing from one color dye -to a second color dye,
it is not economically feasible to dye short runs or small
amounts of carpet.
SUMMARY OF THE INVENTION
The above disadvantages have been overcome by the
present invention which basically includes in one broad aspect
a process Eor use in dyeing carpet with a pile surEace,
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i.nclud:ing acivancing a length of caxpet to be dyed along a
predetermined path with its pile fibers facing upwardly,
applying a foam mixture containing dye material to the pile
fibers of length of carpet moving ~long the predetermined
path, applying a vacuum to the side of the length of carpet
opposite to the side thereof to which the foam mixture is
applied at a pressure sufficient to draw the foam into the
pile fibers and fixing the dye material to the pile fibers
of the length of carpet.
The invention also comprehends a process
for use in dyeing carpet with a pile surface a selected
one of a number of colors including providing at
least two applicator means operable for applying a foam
mixture containing dye material, advancing a length of carpet
to be dyed along a predetermined path adjacen-t the applicator
means with the pile~ fibers facing the applicator means,
operating one of the applicator means a predetermined period
of time to apply a foam mixture containing one color of dye
to the pile fibers o the length of carpet moving along the
predetermined path, fixing the first color dye to the ~ile
fibers of the len~th of carpet, operating the other one oE
the applicator means a predetermined period of time to apply
a foam mixture containing a second color dye to the pile
fibers of the length of carpet moving along the predetermined
`: path and fixing the second color dye to the pile fibers of
the length of carpet.
A still further aspect of the inventioll pertaills
to a process of dyeing carpet wi-th a pile surface comprising
the steps of moving a length of carpet to be dyed along its
length in an approximately horizontal attitude -through a
predetermined path with its pile fibers facing upwardly,
progressively applying a first foam mixture containing dye
to the top surface of the length of carpet as the length
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of carpet moves along the preclcterMinecl patll, pro~.rossively
applying a second foam mixture containing a dye to the top
surface of the length of carpet as the length of carpet movès
along the predetermined path after~the step of applying the
first oam mixture to the length of carpet has been completed,
and progressively fixing the dyes to the length of carpet as
the length of carpet moves along its path.
~lore particularly, in usin9 thc COllt.inllOUS d~o~
proeess of the present invention for dyeing a lenc]th of carpet
with a number of colors, the two dye applieator means are used,
with a dye applicator means being easily moved from a position
adjaeent the upper surfaee of the earpet movi.ng along the
prede-termined path to an adjus-ted position located remotely
from the earpet for eleaning. One oE the clye applieator means
may be eleaned while the seeond dye applieator meal~s is
applying a seeond eolor to the length of material moving
al.ong the predetermined path thus allowing the remaini.ng
apparatus assoeiated with a carpet dyeing proeess to continue
: to run without a long period of shutdown.
A further aspeet of the invention is that by
providing means for applying a foam mi~ture containing dye
material through a number of applicator means, with the
applicator means being selectively operable, a short run of
earpet can be eeonomieally dyed -thus offering a much more
diversified color eombination of earpet material.
It is therefore a primary object of the present
invention to provide a continuous dyeing process for use in
dyeing earpet a seleeted one of a number of colors.
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An additional objec-t of the present invention is to
provide a process for use in dyeing carpet a selected one of a
number of colors which is simple in operation, economical to
use and reliable in performance.
These and other aspects and advantages of the details
of construction will become apparent after reading the following
description of th~e illustrative embodiments with reference to
the attached drawings wherein like reference numerals have
been used to refer to like parts throughout the several figures
and wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic view of a carpet dyeing
process embodying the principles of the present invention;
Figure 2 is an elevational schematic view of one ~ :
applicator means;
Figure 3 is an elevational schematic view of a
second applicator means;
Figure 4 is an horizontal schematic view showing .
material confining means; and
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Figure 5 is a schematic view showing a further
embodiment of a carpet dyeing process embodying the principles
of the present invention.
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DESCRIPTION OF THE ILLUST~ATIVE E~BODI~ENTS
Referring to the drawing, the continuous carpet dyeing
process of the present invention will be described wi'_h reference
to the apparatus required to carry out the process, including
alternate applicator means and arrangements, followed by the
description of the steps of the process.
As shown in Figure 1, a length of carpet to be dyed
is generally represented by the reference numeral 10 and is
conveyed along a predetermined path by conventional carpet
conveying apparatus (not shown). Carpet support means 11 is
positioned beneath carpet 10 with a pair of foam mixture dye
applicators 12, 13 supported above carpet 10. A foam mixture
containing carpet dye is supplied to applicators 12, 13 by
conventional individual foam machines 14, 15, respectively.
Foam machines 14 and 15 are independently operable, with both of
the foam machines being connected to a common air supply means
16 which is used ir. developing a foam mixture. E'oam machine 14
is supplied with a mixture of material from batch means 17.
satch means 17 contains a mixture of predetermined amounts of
water, powder or liqiud thickner material, such as gum tragacanth
and selected color dye material supplied from supply sources 18,
19 and 20, respectively.
Foam machine 15 is supplied with a mixture of material
` from batch means 21, which contains a mixture of predetermined
amounts of water, thickner material and another selected color
dye material. Batch means 21 is supplied from a water source
22, thickner material source 23 and dye material source 24.
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As shown in Figure 1, the carpet material 10 being
advanced along the predeterm~ned path beneath applicators 12,
13 and above support 11 ls then advanced through a conventional
steam oven 30. Carpet 10 is guided through oven 30 by a
plurality of roller guide means 31, with oven 30 including a
steam supply source 32 operable for developing sufficient
temperature and moisture conditions to cause fixation of dye
material contained in a foam mixture to the carpet pile or nap.
The applicators 12, 13 can be constructed in a number
of embodiments. One embodiment of an applicator is shown in
Figure 2 and generally represented by number 40. Applicator
40 includes an elongated tray or container having a longitudinal
dimension equal to the width of the carpet being dyed. The
applicator tray is provided with a vertical side wall 41 and a
sloping wall 42 and includes a pair of end walls (not shown).
Applicator 40 has a top entrance opening 43 and a bottom discharge
opening 44. Vertical wall 41 includes an adjustable bottom edge
45 adjacent discharge opening 44. Adjustable edge 45 is adapted
to be held in a selected adjusted position by conventional
locking screw means 46 so that the height or amount of foam
mixture being applied to carpet 10 can be varied. The foam
mixture containing dye is supplied to applicator tray 40 through
conduit 48. In operation~ the foam mixture containing dye is ~ ;
supplied through conduit 48 from one of the foam machines 14, 15
in a sufficient amount and in a matter to reach a predetermined
height in the applicator tray. As carpet 10 is advanced beneath
applicator 40 the foam mixture containing dye will be applied
to the upper or the pile surface of the carpet. The amount of
foam mixture will be controlled by adjustable edge 45, with edge
45 being operable to doctor the foam mixture evenly across the
width of the carpet and evenly along the length of the carpet.
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Figure 3 shows a second embodiment of a foam mixture
applicator which is generally represented by number 50. Appli-
cator 50 includes an elongated doctoriny blade 51 supported
across the width of carpet 10. Blade 51 is adjustably supported
adjacent its opposite ends by a crank and threaded screw adjust-
ment mechanism 52. A foam mixture is supplied from one of the
foam machines 14, 15 through conduit means 53 which discharges
the foam mixture on the upper carpet surface. Conduit means 53
is supported by conventional carriage means (not shown) for r
; 10 reciprocating movement across the width of the carpet to form -~
a puddle of the foam mixture on the carpet with the puddle being
doctored to a predetermined height by doctoring blade 51 during
advancement of the carpet beneath blade 51. The puddle of the
foam mixture is confined to the width of the carpet by lateral
confining blade 55, 56. Blades 55, 56 can be adjusted by a
conventional threaded shaft support means to acccm~odate various
width carpet.
Figure 5 shows a third modification of a foam mixture
applicator generally represented by number 60, with applicator
60 being associated with an alternate arrangement of a carpet
dyeing process. Applicator 60 is constructed in the form of an
extruder 61 entending across the width carpet. Applicator
extruder 61 is connected in closed conveying relationship to
conduit 62. Conduit 62 is connected to one of the foam machines
14, 15. Applicator extruder 61 is provided with one adjustable
wall portion 63 which is held in a selected adjusted position
by conventional locking screw means 64. Adjustable wall portion
63 will permit the amount of foam mixture extruded to be varied.
Applicator extruder 61 can be supported above carpet 10, as
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shown in Figure 1, or can be supported adjacent an angled pile
opening portion of carpet 10, as shown in Figure 5~
The alternate arrangement of the carpet dyeing process
shown in Figure 5 includes means for advancing the carpet around
a roller guide 70 and along an upwardly angled path adjacent
guide means 71 and beneath pre heat means 72. Guide means 71
includes an upwardly angled portion 71a and a horizontal guide
portion 71b joined to form an apex adjacent applicator extruder
61. As shown in Figure 5, vacuum conduit means 80 having an
elongated slot 81 is supported beneath carpet 10. Vacuum means
80 can be used to aid in effecting penetration of the foam
mixture into the carpet pile. Additional heating means 85, 86
is supported above carpet 10 as it moves along the upper surface
of horizontal guide portion 71b and prior to movement into the
steam oven 30.
Either of the above described applicator means 40,
50 or 60 can be used in a carpet dyeing process embodying the
principles of the present invention. In a carpet dyeing process,
`1 a first amount of material containing a first carpet dye color
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is mixed to form one of the batches 17, 21. The batch of material
is calculated for the amount of carpet to be dyed. The batch of
material is then introduced to one of the foam machines 14, 15
with air being mixed therein to form a foam mixture. The foam
mixture is then applied to carpet 10 through one of the appli- `
cator means 12, 13 as the carpet is advanced therebeneath. After
the foam mixture containing dye has been applied to the carpet,
the carpet is then advanced through steam oven 30 for fixation ,
of the dye material to the carpet.
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While a first length of carpet is being dyed, a second
batch of materlal containing calculated amounts of water,
thickner and another color dye material is mixed to form the
second batch. After the first length of carpet is dyed, the
first applicator means and foam machine is cleaned. While the
first applicator means and foam machine is being cleaned the
second batch of material is introduced to the second foam machine,
mixed with air to form a foam mixture and then applied to a
second length of carpet through the second applicator means.
By using two foam machines and two applicator means,
one foam machine and one applicator means can be cleaned while
the others are in use. Thus, providing for a continuous carpet
dyeing process to obtain maximum utilization of the carpet
conveying means, carpet guiding means and the steam oven. The
use of the foam mixture containing clye which is applied pro-
gressively to only the upper surface oE the carpet being advanced
along a predetermined path will permit calculated mixture of
small amounts of dye material and wi.ll provide a carpet dyeing
process which can be economically used for dyeing short runs of
carpet material.
It now becomes apparent that the above described -
process and apparatus are capable of obtaining the above stated
objects and advantages. It is obvious that those skilled in the
art may make modifications in the details of construction without
departing from the spirit of the invention which is to be limited
only by the scope of the appended claims.
