Process for improving stain resistance and lightfastness of carpet yarn

Abstract

Disclosed is a method for dyeing solution dyed bulk continuous filament (BCF) fibers. The BCF fibers are twisted together to form a 2 or more ply strand prior to dyeing. After twisting the fibers together, the fiber is preferably spaced dyed to provide a multi-colored pattern along the length of the strand. Following the space dyeing step, the strand is heat set.

Description

TECHNICAL FIELD[0001]This invention relates generally to dyed textile fabrics. More particularly, the invention relates to processes for dying long striations of color onto solution dyed yarn and while maintaining stain resistance and lightfastness of the yarn.BACKGROUND OF THE INVENTION[0002]Nylon carpet and other fabrics made from synthetic yarns are commonly colored using one of several known processes, including dyeing with acid dyes, pre-metalized acid dyes, disperse dyes, and fiber-reactive dyes. For example, “space dyeing” is a dyeing process by which dyes of particular colors are applied intermittently along the length of the yarn, thus creating differently-colored “spaces” in the yarn. In the conventional space dyeing process, colorless white yarn is colored by applying multiple colors along the length of each strand of yarn. Those colors may or may not repeat after a fixed interval. Thus, the space dyeing process is used to give yarn a unique, multi-colored effect. When sp...

AI Technical Summary

Benefits of technology

The patent describes a method for dyeing carpet fibers by space dyeing and heat setting two or more solution dyed bulk continuous filament (BCF) fibers. The technical effect of this method is to provide a more uniform and consistent dyeing of carpet fibers, resulting in improved quality and appearance. This method can be applied to a variety of carpet fiber materials and can be modified as needed.

Problems solved by technology

However, dye applied in the space dyeing process is not applied throughout the yarn.

However, since color is formed as part of solution dyed yarn, these yarns do not have the multi-colored effect of spaced dyed yarn that is often desired.

The aesthetics of carpet made from solution dyed yarn is often limited to solid colored yarn or “barber pole” yarn comprised of two contrastingly-colored singles that are twisted together.

However, in order to meet consumer demand, the carpet mill may need to keep a costly inventory of colored yarns produced by the solution dye process.

Variable production demands and large inventory costs can impact inventory flexibility.

However, this limits color availability for carpets employing solution dyed yarn and may cause delays in delivering carpet of a particular color to a customer if the desired color of yarn is not on hand.