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Bleach Safe, Stain Free, Quick Drying Drylon Rugs

a technology of drylon rugs and which is applied in the field of dyeing safe, stain-free, and quick drying drylon rugs, can solve the problems of affecting the use of dope dyed micro-denier filaments, affecting the effect of dyeing, and affecting the color of dyeing

Inactive Publication Date: 2011-05-12
WELSPUN GLOBAL BRANDS
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0010]In view of above, the main object of the invention is to provide a process for manufacturing of bleach safe, quick drying, stain resistant DRYLON rugs using dope-dyed, micro-denier per filament, cabled, heat set polyester yarn and / or micro-denier per filament, cabled, heat set, yarn dyed polyester yarn with antimicrobial treatment, in tufting of DRYLON rugs, thus eliminating the process of batch dyeing after formation of rugs.

Problems solved by technology

The batch dyeing results in surface penetration, whereby the dyes are vulnerable to bleach and to bleeding or staining during wet or dry washing.
However, the patent does not teach use of dope dyed micro-denier filament, with master batch dyeing during extrusion, cabled heat set polyester filament yarn and / or micro-denier per filament, cabled, heat set, yarn dyed with antimicrobial treatment, polyester yarn in manufacture of bleach fast, stain resistant, antimicrobial and bulky rugs.

Method used

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  • Bleach Safe, Stain Free, Quick Drying Drylon Rugs
  • Bleach Safe, Stain Free, Quick Drying Drylon Rugs

Examples

Experimental program
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Effect test

example 1

[0051]A DRYLON rug made of DRYLON yarn which has properties of bleach fastness, stain resistance and quick drying. The DRYLON tufting yarn is B. S. Blue colored, dope dyed 1.0 micro denier per filament fiber, which is further twisted with 900×2, micro filament to form 1800 (900×2) denier tufting yarn.

[0052]The process for making the rug of instant invention comprises of tufting of 1.0 DPF×900><2 B. S. blue dope dyed filament, creeled on 1280 cheeses to form tufted fabric roll. The tufted rolls are further loaded on latex coating machine followed by application of latex at 20.0 Oz / sq. yard or 687 GSM to form a rug fabric. The latex coated tuft rolls are cut on infra-red guided cutting machine as per pre-determined specification fed in the computer to form rugs. Lastly the rugs are stitched on four sides on a stitching machine and finally, the stitched rugs are then, washed, checked, mended folded, passed through needle detectors and packed in to poly bags before packing in to cartons...

example 2

[0055]The following Table 2 details the physical and chemical properties of DRYLON yarn of 1.0 to 10.0 denier per filament.

TABLE 2Thermal propertiesSp. HeatKJ / kg ° k1.1--1.4Tg° c.70-80Tm° c.260Heat setting° c.180-230Dyeing temperature° c.120-180MoistureAt 21° c. / 65% RH%0.2-0.524° c. / 95% RH%0.8-1.0Water retention% 3-5.ShrinkageIn water 95° C.%0.5-8  Hot air 150° C.%  2-15.Hot air 190° C.%  3-20.Degree of elasticityAt E = 22%90-98E = 25%70-90E = 10%50-80Densitygm / cm31.36--1.38R. I.1.54LOI index%21--22FinenessDPF  1-10.Cable denier1800-2400Elongation%20-45TenacityGMF / Den2.8-3.6Cross sectionCircular & trilobalCable twist per meter 70-200Resistance to:AcidGood, attacked by concentrationacidsAlkaliGood, degradable by concentrationalkaliBacteria & fungusVery goodDye stuffDispersion with carrier at high tempSolubilitySulfuric acid, tetrachloro ethanephenol, dmf, teg

example 3

[0056]A DRYLON rug made of DRYLON yarn which has properties of bleach fastness, stain resistance and quick drying. The DRYLON tufting yarn is yarn dyed in W. Denim shade, consisting of 1.0 micro denier per filament fiber, which is further twisted with 900×2, micro filament to form 1800 (900×2) denier tufting yarn and dyed.

[0057]Dyeing process for yarn dyeing is as below in Table 3. Dyeing of 1800 / 180 tpm and 1800 / 100 tpm of Semi Dull and Bright luster yarn. The dyeing is done at 132° C. and the rate of raising temperature is not more than 1.0° C. / min.

TABLE 3StepsDetailsSetting DyebathSet Machine with water at 50° C. to 60° C.Adding ChemicalsAdd dispersing agent 0.5 TO 1 GPLAdd leveling agent 0.5 TO 1 GPLAdjust the pH to 4.5 TO 5 with buffer.Adding DyesAdd sieved dispersion dyesRaising temp.Raise the temperature up to 132° C.Continue DyeingAt 132° C. hold 30 minute.Then drain at 132° C.Reduction ClearingReduction clearing with: Caustic soda and Sodium hydrosulfiteFor optimum fastness...

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Abstract

A process for making a Drylon rug is disclosed, wherein the said process comprises use of dope dyed, micro-denier filament, cabled and heat set polyester yarn or micro denier filament, cabled heat set dyed with antimicrobial treatment for tufting of rugs, thereby eliminating the process of batch dyeing after the formation of rugs and further ensuring that the rugs are bleach safe, quick drying, anti microbial and stain resistant. The present invention also discloses Drylon rugs as manufactured using yarns of invention. Further, the present invention discloses the process for manufacture of Drylon yarns.

Description

FIELD OF THE INVENTION[0001]The present invention relates to rugs and rug manufacturing. More particularly, the present invention relates to process for manufacturing rugs that comprise of tufted, dope-dyed, micro-denier per filament, cabled and heat set polyester yarn and / or micro-denier per filament, cabled, heat set, yarn dyed polyester yarn with antimicrobial treatment thereby inculcating properties of bleach fastness, stain resistance and quick drying. Rugs manufactured thereof are also covered. Further, the invention covers the process for manufacturing of the DRYLON yarns.BACKGROUND OF THE INVENTION[0002]Rugs are thick woven floor mats of shaggy or thick piled surface. Rugs are tufted floor covering used in specific areas of application. Rugs may have thick piles on one or both sides of the backing fabric. The thick piled surface is also sheared to give the surface soft velvety touch.[0003]Rugs may have tufting on one surface and latex or rubber coating on the other surface t...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D05C15/00
CPCD05C17/026D06N7/006D05D2209/10D02G3/445D06N7/0036D10B2331/04D06N2209/0823D06N2201/0254D06N2209/106D06N7/0073D06N2209/147D06N2201/0263D06N2201/02D06N2205/04D06N7/0068D06N2201/06D06N2207/123D06N2209/1671Y10T428/23986
Inventor MANDAWEWALA, RAJESH RAMESHKUMAR
Owner WELSPUN GLOBAL BRANDS
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