CN1032494C

CN1032494C - Method and device for dyeing carpet

Info

Publication number: CN1032494C
Application number: CN 91105362
Authority: CN
Inventors: B·F·福勒
Original assignee: Individual
Current assignee: Individual
Priority date: 1990-08-01
Filing date: 1991-07-30
Publication date: 1996-08-07
Anticipated expiration: 2006-07-30
Also published as: CN1128279A; AU8314091A; WO1992002674A1; CN1058625A; TW223133B

Abstract

A method and apparatus for dyeing carpets with novel dye solutions wherein the dye solution is heated to a temperature above the boiling point of water to fix the dye to the carpet without the use of a steam fixing machine.

Description

Method and apparatus for dyeing carpet

The present invention relates to the dyeing of carpet, particularly the method for carpet dyeing and device by the dye bath more much higher than water of employing boiling point, and do not need the decatize carpet so that dyestuff is anchored on the carpet.

In the method and device of the present known and carpet dyeing that uses, need carry out decatize so that dyestuff anchors on the carpet after being applied on the carpet to carpet.Such as, typical carpet dyeing method and device comprise dyestuff be applied to the carpet matte, by decatize dyestuff anchored at the carpet matte, carpet carried out carpet is carried out all other last processing or post-treating and other steps before dry then.

A kind of this traditional carpet dyeing method prompting is in US Patent No 4,101, in 270.A kind of carpet dyeing method of this patent prompting comprises sent continuous fabric one preshrunk station, moisten fabric, makes textile dyeing, makes it to pass such as vapoury steaming vessel and make dyestuff anchor at the first-class step of fabric then with applicator roller or dyestuff supply machine.This basic skills generally is the basis of the carpet dyeing system of other prior aries, is well-known in this field.

Similarly, US Patent No 4,771, second example of having pointed out the carpet dyeing technical process that includes a vapour steaming colour fixing machine in 497.This patent has disclosed a kind ofly carries out processed continuously technical process to textile material, comprises dyestuff is applied on the carpet matte, carries out the fixation of dyestuff then on matte with steaming method.Many existing patents are the same with above-mentioned two patents to comprise this decatize process, and difference has just added all additional process processes of the confession selecting for use on this basic staining technique each other.

This class is existing to comprise that the weak point of the carpet dyeing method and apparatus of vapour steaming colour fixing is to be that they all need the vapour steaming colour fixing step.Vapour steaming colour fixing has several shortcomings, comprise coming heating steam with big energy, when devaporation becomes water and dyestuff make the dye liquor dilution when mixed, from material and on the time, the vapour steaming colour fixing in the carpet dyeing process has all increased the cost of dyeing.Also having a shortcoming is exactly that the carpet dyeing process that contains the vapour steaming colour fixing step is very uneconomic when the small lot carpet is dyeed.

The invention provides a kind of effectively and the lower carpet dyeing method and apparatus of cost.The present invention can be used for carpet dyeing, also can be used for other dyeing such as various types of yarns made from nylon, polyester, wool, cotton, artificial fibre and acrylic fiber and so on, fiber, fabric, knitting and other fiber-like materials.The present invention adopts the high temperature dye bath to carry out continuous dyeing, does not need decatize, and dye bath is delivered on the supply machine with specified temp and flow velocity, the liquid level and the temperature of control dye liquor on the supply machine.

The present invention includes a kind of novel dye bath and supply with machine, adopt high temperature dye liquor mixture to realize the dyeing and the fixation step of carpet, its temperature is higher than the boiling point of water.Device of the present invention also comprises a preheater of finishing preheating step basically, and mixer of realizing the heating of dye liquor and chemical substance heating steps, heat exchanger that before dye liquor enters the supply machine dye liquor is heated, one reclaim excessive dye liquor and send it back to the vacuum draw machine of heat exchanger, the washer box that overfall is arranged that makes the pH value neutralization of carpet and wash carpet before carpet enters drying stage.

The present invention by dye liquor being preheating to the boiling point that is higher than water temperature and it is applied to through on the fabric of preheating, and no longer need the vapour steaming colour fixing machine.Thereby the boiling point that the unique chemical mixture makes dye liquor can be heated to above water in the present invention can anchor on the carpet pile dyestuff when dyeing, thereby no longer needs decatize set machine behind the dyestuff supplying step.

The method and apparatus of novelty of the present invention has many advantages.These advantages of a part are included in the dye fixing process without any need for steam, do not need glue or thickener, do not need defoamer, and have reduced the quantity of the pollutant that produces in this system.Other advantages comprise has eliminated dye liquor waste material or chemical spent material, do not increase the content of chemical substance or coloring matter, and water is less in the system, and this water can recycle.Further advantage of the present invention comprises dyestuff has the definition of carpet decorative pattern profile preferably from being applied to more equably on the carpet to another side to central authorities on one side again, and dyeing machine is more cheap, and it is less that dyestuff is supplied with the required dyeing space of machine.

Many traditional dyestuffs supply machines or equipment are as long as use expense seldom just can be transformed into method and apparatus of the present invention.And method and apparatus of the present invention can dye to carpet yarn or 12 feet (12 ') wide or wideer carpets of sub-thread, also can the carpet between these sizes be dyeed, so product forms certain hierarchical structure.Because compared with prior art the time in the dye vat is wanted much shorter, so the present invention is also both economical when little dyeing is dyeed in batches.And the used preheater of the present invention is to supply with the heating system of machine and heat by being used for heating dye bath, so the heating expense is greatly saved in the whole system.

Therefore, an object of the present invention is to provide a kind of carpet dyeing method and apparatus that does not need vapour steaming colour fixing device and step.

Another object of the present invention provides a kind of carpet dyeing method and apparatus.This traditional required expense of carpet dyeing method and apparatus is few, comprises that energy cost is lower, the machine expense is lower, Master Cost is lower, operating cost is also lower.

Another object of the present invention provides a kind of carpet dyeing method and apparatus that does not need glue, thickener and defoamer.

Of the present invention also have a purpose to provide a kind of carpet dyeing method and apparatus that does not have dye liquor waste material or chemical spent material, and do not increase the content of chemical substance or coloring matter.

A further object of the present invention provide a kind of can from one side to central authorities again to applying dyestuff more equably and have the carpet dyeing method and apparatus of carpet decorative pattern contour sharpness preferably on one side.

A further object of the invention provides a kind of carpet dyeing method and apparatus, adopts more cheap dyeing machine, and it is less that dyestuff is supplied with the shared ground space of machine, and the few and water of water can be recycled.

Another object of the present invention provides a kind of carpet dyeing method and device, and the sub-thread carpet yarn is reached 12 feet (12 ') even wideer carpet dyes up to wide, and when small lot dyes less expensive.

A further object of the present invention provides a kind of carpet dyeing method and device, and pre-heater is wherein supplied with the heater of machine and heated by being used for heating dye bath.

The dye solution that also has a purpose to provide a kind of uniqueness of the present invention, can be heated to above water boiling point temperature and need not vapour steaming colour fixing and just can be affixed on the fabric.

By reading below in conjunction with accompanying drawing the detailed description that the present invention carried out, the one skilled in the art just will become to these purposes of the present invention and other purposes and be perfectly clear, among the figure to the identical numbering of similar parts employing.

Fig. 1 is method of the present invention and schematic representation of apparatus.

Fig. 1 is the total signal that has shown the inventive method and device Figure shows and implements the required various parts of the method. Usually, The present invention adopts a kind of dyestuff, water and multiple as dyeing auxiliaries of comprising The new dye solution of chemical substance, this dye solution has than water height Many boiling points. This higher boiling dye solution is used for carpet is dyed Look. This dye solution is to make the present invention be unique to traditional carpet to dye The main aspect of color method. Carpet one word in this specification comprises institute Fabric, yarn and textile are arranged and have more than the common carpet of finger.

In the present invention, carpet is painted in the higher boiling dye bath. Height boils The point dye bath just can make dyestuff anchor on the carpet in this step of dye bath, So just do not need the vapour steaming colour fixing machine. In addition, with the traditional dye bath of heating Method compare the side that this higher boiling dye bath is unique with a kind of novelty Method heats. Such as, dye bath with electrically-heated coil or heating, Perhaps arrive the temperature of the boiling point of big solid carbon dioxide with the closed steam system heating, Do not reach this temperature with legacy equipment. These heating means also provide one Plant more direct heating source.

The existence of vapour steaming colour fixing machine makes the dye solution dilution. Therefore, disappear Except decatize fixation step also is very important to the present invention, because dyestuff Solution has dyestuff, chemical substance and the water of given concentration, and this Any dilution of dye solution is heated to height to the painted and dye liquor of carpet Ability in the boiling point of water is all influential. When carpet leaves dye bath, The extruding carpet is to remove excess dye, and this dyestuff is recycled to dye bath In. Carpet enters in the cold bath then, stops or set was dyeed Journey. In case after the dyestuff set, just can not take place carpet from one side to The centre is arrived the variation of the color of another side again, and this is adopting vapour steaming colour fixing Very common during the continuous dyeing of step. Then carpet is placed on one Rinsing in individual or a plurality of washer boxs with overfall.

Again please referring to Fig. 1. Dye solution used in the present invention stores 26 li of staining baths (dye barrel). Dyestuff of the present invention is molten Liquid is that a kind of uniqueness that is made up of particular dye, chemical substance and water is mixed Compound. General by molten in being used for a part of water of dye bath 18 Separate dyestuff and form dye solution. To be used for controlling then dye solution The acid of pH value and dyeing auxiliaries be dissolved in water for dye bath 18 Remainder. And then with the dissolving dyestuff and dyeing auxiliaries and acid with A certain amount of ethylene glycol is mixed and mixing mutually. Ethylene glycol is with dye solution Boiling point bring up to the temperature of the boiling point that is higher than water. This dye solution adds Heat is to the temperature of the boiling point that just is lower than dye solution, because dyestuff is molten The mixing of all compositions in the liquid, its boiling temperature are higher than the boiling point temperature of water Degree, this dye solution is added in dye liquor supplying machine part 17 then On the carpet, this will be described below more fully.

According to required dyeing requirement, can prepare many kinds and dye The mixture of material, chemical substance and water. Available dyestuff comprise such as Acid dyes, disperse dyes, direct dyes, basic-dyeable fibre, reduction Dyestuff, fibre-reactive dyes and other can heat be executed on the matrix Dyestuff. Be two routine representational dye solutions below:

Example 1 weight percentages grams per liter dyestuff (through selected ACID DYES) XX.X X.XX phenyl alcohol (747-alcohol, DEG ethylene glycol, anion 0.2 2.00 and ionic surfactant) Fulgcn SDM (ethoxylation C ₁₂-C ₁₅0.2 2.00 primary alconols and coconut condensate liquid) sulfamic acid 15% solution 1.0 10.00 water 23.6 316.00 dyestuffs sums 25.0% 330.00 diethylene glycol (DEG) SP.grl.12) or 75.0 670.00 other class glycol summations 100.0% 1000.00

As mentioned above, selected ACID DYES at first is dissolved in a part of water of 316.00 grams (or 316 milliliters), and this part water is enough to allow dyestuff dissolve.To join in dyestuff/water mixture such as the acid of dyeing auxiliaries phenyl alcohol and the FulgcnSDM and the control pH value such as sulfamic acid then.Then with these and mixed mutually with the remainder of 316.00 gram water in advance diethylene glycol (DEG) or other glycol mixing or mixed, to form dye solution.The boiling temperature of this specific dye solution is near 228-230F.This specific dye solution is particularly useful to nylon tufted carpet or other nylon fabrics.

Example 2

The weight percentages of components grams per liter

Dyestuff XX.X X.X

Fulpon GP (ethyoxyl phosphoric acid wine

Smart sylvite) (phosphate DA-4) 0.2 2.0

Water 10.0 130

Fulpal ME anionic surfactant

(P-NP-9) 0.5 5.0

Sulfamic acid 15% solution 0.5 5.0

Water 13.8 188.0

Dyestuff sum 25.0% 330.0

Diethylene glycol (DEG) or other glycol 75.0 670.0

Sum 100.0% 1000.0

The same with example 1, dyestuff at first is dissolved in a part to be enough to make in the water of dyestuff dissolving.What be used for this specific dyestuff should be hot, and generally needs the mark agent, such as FulponGP, to help the dissolving fully of doing it.The acid of levelling agent that then will be such as FulpalME and control pH value such as sulfamic acid, is added in dyestuff/water mixture.This solution mixes to improve the boiling point of dye solution with mixed mutually the reaching of glycol, and glycol is mixed mutually with the remainder of water in advance.The boiling point of this particular dye solution is also near 228-230 °F.This particular dye solution is particularly useful to polyester carpet or other fabrics.

Any glycol that allows heat to transmit all can be used for this dye solution.Select suitable dyeing auxiliaries with auxiliary dyeing of waiting to dye fiber.When adopting certain dyeing auxiliaries, some stock-dye is dyed better, and this is as you know in the present technique field.Anionic, non-ionic, cationic, wetting agent, levelling agent and retarding agents etc. all are the dyeing auxiliariess that can select for use according to fiber to be dyed.Although most of acid all are suitable for adding dye solution, only acid comprises methyl alcohol, amino sulphur alcohol, citric acid, acetic acid, phosphoric acid, and pure propellant.

The carpet of totally representing with carpet circle roller 10 was introduced into preheater 14 before entering dye bath supply machine 17 in the drawings.Preheater 14 generally is the extension that machine 17 is supplied with in dye bath, and it generally comprises an entrance door 12, a preheating chamber 13 and transfer roller 16.Entrance door 12 generally is the door that spring is housed, or the door with unidirectional hinge, opens to inner room 13 directions of preheater, so that reduce to minimum from preheating chamber 13 by the thermal loss that door 12 enters atmosphere.It is supported by running roller 16 when carpet 10 passes through preheater 14.

The purpose of preheater 14 is to be used for before carpet 10 enters dye bath supply machine 17 carpet 10 being heated.The preheating of carpet 10 makes dye bath 18 keep not cooling off and the color bits that is subjected to that helps to open on the carpet 10 is put, and carpet 10 just is easy to obtain dyestuff from dye bath supply machine 19 like this.Preheater 14 and preheating chamber 13 adopt with heating dye bath supply machine part 17 same heating systems 30 and heat.Heating system 30 can be any traditional heating system, such as electrical heating coil or closed steam.Preheater 14 is heated to arbitrary chosen temperature till about 220F with carpet 10.

Carpet 10 comes out and enters dye bath to supply with machine 17 from preheater 14.Dye bath is supplied with machine 17 and is generally comprised dye bath 18, dye liquor supply machine 19a, 19b, 19c, dye inlet 22, pressure roller 32 and pull roll 34.

Dye solution supplies to dye bath by dye solution import 22 and supplies with machine 17.When leaving dye barrel 26, dye solution is fed into heat exchanger 20 by service pipe.Heat exchanger 20 can be any traditional heat exchanger, is used for entering dye bath 18 and dye liquor at dye solution and dye solution is heated to a higher temperature before supplying with machine 19a, 19b, 19c, generally is heated to about 240 °F.One flowmeter (not drawing among the figure) is supplied with the flow that enters the dye solution of dye bath 18 between the machine part 17 with adjusting at heat exchanger 20 and dye bath, so that the height of dye bath 18 remains unchanged.

Supply with 17 li of machine parts at dye liquor, carpet 10 passes the dyeing melting bath of high temperature and supplies with machine 19a, 19b, 19c, and the supply machine is applied to dye solution on the carpet 10.Supply with machine part 17 in dye bath, dyestuff is further heated between about 160 °F and about 240 °F.Machine 19a is supplied with in carpet 10 and dye bath, 19b, 19c are immersed in the dye bath 18, is convenient to dyestuff is applied on the carpet 10 equably.Carpet 10 passes the second donor rollers 19b and the 3rd donor rollers 19c again after passing under first donor rollers (applicator roller) 19a, to guarantee dyestuff to apply evenly thoroughly.Supply with 17 li of machine parts in dye bath, carpet 10 all is being immersed in the dye bath 18 through out-of-date on donor rollers 19a, 19b, 19c or down respectively.

After dye solution was added to carpet 10, carpet 10 left dye bath 18 and mixes 32 to remove excessive staining solution through hydraulic fluid.Squeezer roll 32 is positioned at dye bath 18 tops, uses for reclaiming will fall back to dye bath 18 from any excess dye solution that carpet 10 is extruded.After with squeezer roll 32 excess dye solution being extruded from carpet 10, the carpet that dyed look is supplied with machine part 17 by pull roll 34 from dye bath and is drawn, and pull roll 34 is used for removing some excess dye solution and prevents to supply with from dye bath the thermal loss of machine parts 17.

The carpet that dyed 10 that excess dye solution is arranged that may still have the process of supplying with from dyestuff is then again through a vacuum draw machine 36.Vacuum draw machine 36 is a kind of common devices, and it further removes excess dye solution by vacuum plant from the carpet 10 that had dyed.The excess dye solution of being removed from carpet 10 by vacuum draw machine 36 is back into heat exchanger 20 by circular route 38.Therefore, excessive dye solution is circulated back to dye bath supply machine part 17 to dye other carpet.

The carpet that dyed enters into one or more washer boxs 40 from vacuum draw machine 36.Washer box 40 is used for excess dye solution and chemical substance flush away, and other clast flush awaies that carpet may be stained with in dyeing course.Washer box 40 adopts the cold bath with pH neutral to clean.Another effect of cold bath is to help to stop dyeing course also helping dyeing is anchored on carpet 10 surfaces.

When washing, advance between one or more rollers 44 of carpet 10 in washer box 40, to prolong the time of carpet in cold bath.When leaving washer box 40, carpet 10 is from jetter 46 other processes, and jetter 46 also plays a part water is imported the water guider of washer box 40.Carpet 10 after by jetter 46 usefulness cold water hydro-peenings through squeeze roll(s) to remove excessive water.In some applications, a plurality of washer boxs 40 are arranged preferably, these washer boxs 40 are generally mutually the same.Overfall 42 is also arranged each washer box 40 so that the water level in the washer box 40 keeps constant.Carpet 10 adopts traditional carpet drying device to carry out drying with traditional method after leaving washer box 40.

When adopting appropriate device to carry out said process, can dye to nylon, polyester, cotton, wool and other fibers with acidity, dispersion, direct or alkaline dyestuff.When adopting appropriate device, said process also can reach present acceptable COLOR FASTNESS and rub resistance decolouring degree without the decatize device or with the required decatize of other satisfactory fixation.And when adopting appropriate device, technical process of the present invention can be used dye solution in 100% ground, and it is nearly 75% that polluting waste in the dyeing course has been reduced, and some existing device also can be suitable for after transformation.When dye bath 18 was come out, shade (level) fully showed and can not continue hyperchromic at carpet 10.In addition, 40 li of washer boxs with water can not carry out recirculation with simple pipeline (drawing among the figure).

Device of the present invention can be transformed the existing continuous dyeing range group type carpet dyeing device of great majority.Main improvement is according to existing device dye bath to be installed to supply with machine 17.Owing to no longer need, can remove existing steamer in the existing apparatus, and dye bath supply machine 17 just can be contained on its position, perhaps, machine 17 is supplied with in dye bath can be contained in the front that nestles up existing steamer, allow carpet 10 at first supply with machine 17, pass through existing steamer then, arrive the carpet washing system then through dye bath.If adopt this mode, needn't use existing steamer, because do not need steamer.Similarly, dye bath is supplied with machine 17 and can be positioned at immediately following after existing steamer and reach same result.

The present invention can be used for all continuous dyeing range groups and carpet is dyeed and is used for various types of yarn dyeings, tears open such as warp thread, reeled yarn, braided fabric and compiles space dyeing etc.The present invention can produce the good color that is complementary to another side from one side on the continuous dyeing range group, and produces the definition of improved tufting and produce good hand feeling in Saxony and cut velvet clipping structure.And, except the device speed restriction, the present invention aspect speed in fact without limits.It is more good to compare chromatic characteristic with this method or device carpet that dyes and the carpet that dyes with traditional staining bath and continuous dyeing range group.

Obviously, person skilled in the art do not depart under the situation of the scope of the invention of being set forth by the appended claim book and just can be used to illustrate that the embodiment of optimised form of the present invention does various modifications and variation to being intended to.

Claims

1. A device for carpet dyeing, which does not need to steam and fix the dye to the fabric material, the device comprising:

a dye bath containing dye;

a dyeing mechanism for applying dyes to textile materials;

- means for removing excess dyestuff from textile materials;

- recovery devices for recovery of excess dyestuffs from textile materials;

- dyeing process stopping devices that stop the dyeing process and help to fix the dyestuffs on the fabric;

It is characterized by:

Also includes a heating means for heating the dye to a temperature greater than 212F at standard temperature and pressure;

The dye bath device, dyeing mechanism, removal device, recovery device and dyeing process stop device are open to the atmosphere.

2. A device for carpet dyeing, which does not need to steam and fix the dye to the fabric material, the device comprising:

a dyebath containing dyes with a boiling point above 212F;

a dyeing mechanism dipped in a dye in a dyebath apparatus to apply the dye to a fabric material;

- means for removing excess dyestuff from textile materials;

- recovery devices for recovery of excess dyestuffs from textile materials;

a preheating device for preheating the fabric material to a temperature of about 220°F, wherein said preheating device is located prior to said dyebath device and adjacent to the fabric material;

a dyeing process stopping device for stopping the dyeing process and assisting in fixing the dyestuff to the fabric;

It is characterized in that,

also including a heating means adjacent to said dye bath means and heating the dye in said dye bath means to a temperature greater than 212F at standard temperature and pressure;

The dye bath device, dyeing mechanism, removal device, recovery device, preheating device and dyeing process stop device are open to the atmosphere.

3. dyeing device as claimed in claim 2, is characterized in that, also comprises a dyestuff mixing device and a dyestuff heating device, and described dyestuff mixing device comprises the mechanism that dyestuff is imported into described dyestuff heating device, and described dyestuff mixing device Located in front of the mechanism to direct the dye to a dye bath, the dye heating device is located in front of the dye bath.

4. Dyeing device according to claim 3, characterized in that said removal device is located downstream of said dyeing device.

5. Dyeing apparatus according to claim 4, characterized in that said means for recovering excess dyestuff from the fabric material is a vacuum means, said vacuum means being located downstream of said removal means.

6. The dyeing apparatus according to claim 5, further comprising recycling means for recycling said recovered excess dye to said mixing means.

7. The dyeing apparatus according to claim 5, further comprising washing means for washing the fabric material, said washing means being located downstream of said vacuum means.

8. The dyeing device according to claim 1, wherein the dyestuff is a dye solution comprising dyestuff, dyeing assistant, acid and water, and the dyestuff is selected from the group consisting of acid dyestuffs; The dye is selected from the group consisting of alcohols, glycols, glycerols and ionic surfactants and coconut condensate; the acid is sulfamic acid.

9. The dyeing device according to claim 2, characterized in that, the preheating device and the heating device have the same heating system.

10. The dyeing device according to claim 2, wherein the preheating device is separate from the heating device.

11. dyeing device as claimed in claim 2, is characterized in that, also comprises the fabric material preheating area before described dye bath device, and described fabric material is preheated by described preheating device in described preheating area hot.

12. Dyeing device according to claim 2, characterized in that said recovery device is located after said removal device with respect to said dye bath device.

13. The dyeing device according to claim 2, wherein the dyestuff is a dye solution comprising dyestuff, dyeing assistant, acid and water, and the dyestuff is selected from the group consisting of acid dyes; The dye is first freed from a substance composed of alcohol, ethylene glycol, glyerols and ionic surfactants and coconut condensate; the acid is sulfamic acid.

14. A method for carpet dyeing, which is carried out under atmospheric conditions, characterized in that the method comprises the steps of:

a. Provide a dyeing solution having a boiling point of 212°F at standard temperature and pressure;

b. providing a fabric material;

c. heating said dye solution to a temperature greater than 212°F at standard temperature and pressure;

d. applying said heated dye solution to said fabric material; and

e. Fixing the dye to the fabric material without the need for steam curing.

15. The dyeing method according to claim 14, further comprising the step of preheating said fabric material to the temperature of said heated dye solution before step d.

16. Dyeing method according to claim 15, characterized in that the fabric material is heated to a temperature above the boiling point of water.

17. The dyeing method according to claim 14, further comprising a step of preheating the dye solution before step c.

18. The dyeing method of claim 17, wherein the dye solution is preheated to a temperature higher than the boiling point of water.

19. The dyeing method of claim 14, further comprising the step of removing excess dye solution from the fabric material after step d.

20. The dyeing method of claim 19, further comprising the step of recycling said excess dye solution.

21. The dyeing method according to claim 14, further comprising a step of washing said fabric material after step d.

22. The dyeing method according to claim 14, further comprising a step of neutralizing the pH values of the dye solution and the fabric material after step d.

23. The dyeing method according to claim 14, further comprising a step of drying the fabric material after step d.