Jet reduction discharge of dye color

The process for producing patterns on ground dye colored textile fiber pile substrates, particularly wherein the pile fibers are in the form of yarns comprised predominantly of polyamide fiber, and wherein at least some of the ground dye component is at least partially color dischargeable and selected from vat, reactive, direct, acid, premetallized or mordant dyes, the process comprising contacting selected portions of the colored pile fibers with a reducing system which optionally can contain one or more reduction resistant dye or pigment materials for in situ coloring of the substrates, the contacting being characterized by jet forcing the reducing system interstitially of the pile fibers to deposit the reducing system thereon substantially below the surface thereof, and to effect the color discharge of at least a portion of the ground dye component.

This invention relates to the selective area discharge of dye color for 
producing color patterns on various dyed substrates, and particularly 
concerns the discharging of dye color deep into carpet or upholstery pile 
or other heavy fabric substrates by means of jet forcing a dye reducing 
system of unique composition interstitially of the yarn or fiber piles, 
with or without concurrent dyeing of the substrates with other chemically 
stable dyes and/or pigments. 
The technique of producing color patterns on various dyed fabric 
substrates, herein termed ground shade or ground dyed, by contacting 
selected portions of the substrate with a dye reducing system to discharge 
the color within a desired pattern, is known to the art as exemplified by 
U.S. Pat. Nos. 2,248,128; 4,441,883; and 4,610,802; the article by P. 
Krug, pp 606-611, entitled Thiourea Dioxide (Formamidinesulphinic Acid) A 
New Reducing Agent for Textile Printing, J.S.D.C. 69, December 1953; and 
the article by G. Bertolina, et al, Coloured Discharge Technique, Dyer, 
114, pp 775-779 (1955), the disclosures of all of which are incorporated 
herein by reference. 
The application methods heretofore employed for contacting the various 
substrates with dye reducing agent include screen, roller, pad, or the 
like, printing techniques which are somewhat effective for substantially 
flat or relatively mildly textured substrates, but which are ineffective 
for pile fabrics such as deep pile rugs, carpets, upholstery or the like. 
In this regard, attempts to discharge all or substantially all of the 
ground dye color within a pattern from pile carpeting using the above 
known techniques, in a reasonable number of passes through the reducing 
apparatus and in a reasonable processing time, with a reasonable degree of 
effectiveness have not been successful, particularly where heavy ground 
shades are involved and where discharge of substantially all color in the 
treated area is desired. 
Objects, therefore, of the present invention are: to provide a commercially 
viable process for the effective redox discharging of dye color from 
difficult substrates such as polyamide, polyester, wool or acrylic fiber 
pile substrates; to provide specially adaptable equipment for carrying out 
the process in continuous or semi-continuous manner; and to provide 
specially formulated reducing systems for use in the aforesaid equipment, 
which systems per se, possess improved reducing and color discharge 
capability. 
These and other objects hereinafter appearing have been attained in 
accordance with the present invention through the discovery, which in its 
process embodiment of producing patterns on ground dye colored textile 
pile substrates, particularly wherein the pile yarns thereof are comprised 
predominately of polyamide fiber, and wherein at least some of the ground 
dye component is color dischargeable (i.e., totally or partially) and is 
selected from vat, reactive, direct, disperse, acid, premetallized or 
mordant dyes, comprises contacting selected portions of the colored pile 
yarns with an aqueous reducing system, the contacting being characterized 
by jet forcing the reducing system interstitially of the pile fiber or 
yarns to deposit the system thereon substantially below the outer surface 
or loops of the pile or outer ends of the fibers and effecting the color 
discharge of at least a significant portion of the ground dye component. 
In certain preferred embodiments of the process: 
(a) the pile fibers or yarns (substrate) are steamed after treatment with 
the reducing system to enhance the color discharge; 
(b) the reducing system comprises an aqueous composition of water soluble 
reducing materials, with or without reduction resistant dye, and is 
metered onto the pile yarns at a velocity from about 2.0 to about 20.0 
meters per second, most preferably from about 4.0 to about 12.0 meters per 
second; 
(c) the pile fibers or yarns are contacted and substantially coated with a 
reducing system to at least about one half of their lengths; 
(d) the aqueous reducing system composition comprises in grams/kilogram 
from about 1.0 to about 50 zinc sulfate, from about 3 to about 30 thiourea 
dioxide, from about 1.0 to about 20 xanthan gum, and up to about 20 of 
non-reducible dye; 
(e) the pile fibers or yarns are pre-dyed to a ground shade with color 
dischargeable dyes and the process discharges essentially all of the color 
of said ground shade; 
(f) the substrate of (e) is concurrently dyed with reduction resistant dye; 
and 
(g) the reducing agent is selected from thiourea dioxide, zinc formaldehyde 
sulfoxylate, or sodium formaldehyde sulfoxylate.

Referring to FIGS. 12 and 13, an exemplary, simplistic form of jet dyeing 
machine is shown for purposes of illustrating the pattern of jetted 
reduction system of the present invention with respect to the pile 
substrate. In this machine an aqueous reducing system 8' of a composition 
in accordance with the present invention such as recipe 3 described in 
detail below, is loaded into a pressure plenum generally designated 10' 
which is provided with a plurality of fluid jets 12' sealingly affixed in 
the plenum floor 14'. The jets are provided with flow passages 16' and jet 
orifices 18' of dimensions suitable for metering a prescribed reductant 
system spray pattern such as is generally designated 20'. For the 
preferred reductant recipes or compositions given below, an orifice 
diameter of from about 0.006 to about 0.30 inches is satisfactory for 
general pile substrate applications. 
In this rudimentary but operable apparatus, the inlet ends of the jet 
passages are closed or opened by valve plungers 22' provided with sealing 
discs 24' of suitable tough and chemically resistant material such as 
Teflon or the like. These plungers may be connected in a bank so as to 
operate in unison or they may be individually controlled by camshaft means 
or the like, including computer controlled means, to open and close the 
flow passages in any sequential or intermittent pre-programmed manner. 
The textile pile substrate (carpet) shown generally as 26' is typical of 
the pile configuration for which the present invention offers unusually 
marked advantages. It is noted that the pile is shown as individual 
fibers, however, the term pile as used herein include looped pile fibers 
and any other such substrate configuration. The dotted, spray pattern jet 
lines 20' shown in FIG. 12 illustrate the depth to which the jetted 
reducing system is readily forced interstitially of the yarn piles 28'. 
Depending, for example, on the viscosity of the reducing recipe, the 
pressure in the plenum 10', the jet orifice size, or any combination of 
such parameters, the reducing system can be readily jetted all the way 
down the yarn pile to the backing generally designated 29'. In this regard 
it is particularly noted that markedly superior uniformity in final dyeing 
and color appearance of the carpet is unexpectedly achieved when the 
present jet reduction process is applied to a ground shade dyed carpet, 
both when a concurrent non-reducible dye component is included in the 
reducing system, or when the final dyeing is made in a subsequent dyeing 
operation. It is believed that this improvement in final color appearance 
results from color discharge of the ground shade to a greater pile depth 
as well as to a more uniform discharge shade or non-color, through a more 
intimate contacting of the individual fibers with the present 
comparatively low viscosity and highly mobile reducing system. In 
contrast, a screen, roller, pad or the like contact applicator such as 
shown in FIG. 13 as screen 30', roller 32', and discharge paste 34', 
provides no means for achieving deep and uniform penetration of the 
reducing system, except perhaps by multiple, e.g., as many as 10-20 passes 
of the applicator across the carpet, as compared to a single pass through 
the present jet applicator. It has been Applicant's experience that such 
application methods as shown in FIG. 13 gives only little pile penetration 
as indicated at 36'. 
The plenum 10' is preferably maintained at a pressure of from about 3-15 
psi and the jets are dimensioned to provide the aforesaid reductant 
velocity of from about 2.0 to about 20.0, preferably from about 4.0 to 
about 20.0 meters per second. The plenum is preferably integral with a 
closed loop pressure feed apparatus in which the reducing system is 
continuously replenished and circulated by suitable pumping means. Such 
pressure feed apparatus useful in the present invention is described in 
several U.S. patents referred to below. The number of jets 12', their 
size, number and geometrical arrangement or pattern relative to the 
substrate can be varied by one skilled in the art to achieve a desired 
reductant lay-down pattern. Also, as aforesaid, the sequence or plan of 
their operation can be widely and intricately varied, as can the 
mechanical or other control means for actuating the valve plungers or 
other equivalent valving devices. 
In the more sophisticated jet apparatus as shown in FIGS. 1-11, wherein the 
chemical jet streams are of the continuous flow type, each individual 
chemical jet stream may be intermittently interrupted or diverted in 
accordance with pattern information. The apparatus generally comprises a 
conveyor which transports the substrate to be chemically treated, e.g., 
with reducing system and/or dye, to and under a plurality of continuously 
flowing, discrete chemical solution or dispersion jet streams. In a 
preferred embodiment, a plurality of jet orifices, each directed at the 
substrate, are arranged in several individual linear arrays positioned 
generally above and across the substrate path in spaced, parallel 
alignment, with each array being associated with a separate source of 
chemical, e.g., a different reducing system and/or a different color of 
liquid dye material. Generally, each of the arrays is positioned in close 
proximity to the substrate to be treated, with typical clearance between 
the array and the substrate surface being substantially less than one 
inch. The individual continuously flowing chemical jet streams in a given 
array are normally directed onto the substrate surface, however, by means 
of a transverse intersecting stream of diverting air which is provided for 
each chemical jet stream and which is actuated or interrupted in response 
to externally supplied pattern information, each chemical jet stream may 
be readily re-directed in a pre-planned manner into a collection chamber 
or catch basin so as to prevent the chemical from inadvertently contacting 
the substrate. 
To accurately control the amount of chemical applied to a given location on 
the substrate during the treating operation, and to insure that each 
chemical jet stream strikes the substrate in a very small, precise spot, 
the lower portion of the collection chamber contains a collector plate 
supportably positioned in spaced relation above the lower wall of the 
collection chamber. This collector plate is adjustably attached to the 
lower wall of the collection chamber by way of an elongate collector plate 
support member which forms an extension of the lower wall of the collector 
plate relative to the collector plate support member. The leading edge of 
the collector plate can thus be accurately positioned relative to the 
chemical discharge or jet axes of the array to insure prompt and precise 
interception of the jet streams when deflected. Details of such apparatus 
and collection chamber construction are described and claimed in commonly 
assigned U.S. Pat. No. 3,942,343 further referred to below. As described 
therein, each chemical jet stream, when deflected, passes across the edge 
of the collector plate and into the collection chamber. Upon removal of 
the deflecting air stream, the chemical jet stream moves back across the 
plate edge and resumes its normal path of travel toward the substrate to 
be dyed. 
Referring to FIGS. 1-11 hereof which show a highly preferred and advanced 
jet machine of the type described immediately above, FIG. 1 depicts, in a 
side elevation view, a set of eight individual arrays 26 positioned within 
frame 22. These arrays form part of a pattern dyeing machine to which the 
present invention is particularly suited. The term "dyeing" as used herein 
is also inclusive of other chemical treatments such as dye reducing and 
color discharge. Each array 26 is comprised of a plurality of dye jets, 
arranged in spaced alignment, and extends generally above and across the 
width of substrate 12. Substrate 12 is supplied from a feed unit such as 
roll 10 and is transported in turn under each array 26 by conveyor 14 
driven by a suitable motor and/or pulley arrangement indicated generally 
at 16. After being transported under array 26, substrate 12 may be passed 
through other chemical treating or dyeing-related process stations or 
steps such as drying, fixing, or the like. 
FIG. 2 depicts, in schematic form, a side elevation of one dye-emitting 
array of the machine of FIG. 1. For each such array shown generally at 26, 
a separate dye reservoir tank 30 supplies liquid dye under pressure, by 
means of pump 32 and dye supply conduit means 34, to a primary dye 
manifold or plenum assembly 36 of the array. Primary manifold assembly 36 
communicates with and supplies dye to dye sub-manifold assembly or plenum 
40 (shown in greater detail in FIGS. 5 and 6) at suitable locations along 
their respective lengths. Both manifold assembly 36 and sub-manifold 
assembly 40 extend across the width of conveyor 14 on which the substrate 
to be dyed is transported. Sub-manifold assembly 40 is provided with a 
plurality of spaced, generally downwardly directed dye passage outlets 52 
(shown, e.g., in FIG. 6) positioned across the width of conveyor 14 which 
produce a plurality of parallel dye streams which are directed onto the 
substrate surface to be patterned. 
As shown in FIGS. 2 and 6, positioned in alignment with and approximately 
perpendicular to each dye passage outlet 52 in sub-manifold assembly 40 is 
the outlet of an air deflection tube 62. Each tube 62 communicates by way 
of an air deflection conduit 64 with an individual air valve, illustrated 
collectively at "V" in FIG. 2, which valve selectively interrupts the flow 
of air to air tube 62 in accordance with pattern information supplied by 
pattern control device 20. Each valve is, in turn, connected by an air 
supply conduit to a pressurized air supply manifold 74 which is provided 
with pressurized air by compressor 76. Each of the valves V, which may be 
of the electromagnetic solenoid type, are individually controlled by 
electrical signals from a pattern control device 20. The outlets of 
deflection tubes 62 direct streams of air which are aligned with and 
impinge against the continuously flowing streams of dye flowing from dye 
passage outlets 52 and deflect such dye streams into a primary collection 
chamber or through 80, from which liquid dye may be removed, by means of a 
suitable dye collection conduit means 82, to dye reservoir tank 30 for 
recirculation. 
The pattern control device 20 for operating solenoid valves V may be 
comprised of various pattern control means, such a computer with pattern 
information storage capabilities. Desired pattern information from control 
device 20 is transmitted to the solenoid valves of each array at 
appropriate times in response to movement by conveyor 14 which is detected 
by suitable rotary motion sensor or transducer means 18 operatively 
associated with the conveyor 14 and connected to control device 20. 
Details of one means to perform this function may be found in commonly 
assigned U.S. Pat. No. 4,033,154, issued Jul. 5, 1977, which disclosure is 
hereby incorporated by reference. 
In a typical dyeing operation utilizing such apparatus, so long as no 
pattern information is supplied by control device 20 to the air valves V 
associated with the array of dye outlets 52, the valves remain "open" to 
permit passage of pressurized air from air manifold 74 through air supply 
conduits 64 to continuously deflect all of the primary collection chamber 
80 for recirculation. When the substrate 12 initially passes beneath the 
dye outlets 52 of the individual arrays 26, pattern control device 20 is 
actuated in suitable manner, such as manually by an operator. Thereafter, 
signals from transducer 18 prompt pattern information from pattern control 
device 20. As dictated by the pattern information, pattern control device 
20 generates control signals to selectively "close" appropriate air valves 
so that, in accordance with the desired pattern, deflecting air streams at 
specified individual dye outlets 52 along the array 26 are interrupted and 
the corresponding dye streams are not deflected, but instead are allowed 
to continue along their normal discharge paths to strike the substrate 12. 
Thus, by operating the solenoid air valves of each array in the desired 
pattern sequence, a colored pattern of dye is placed on the substrate 
during its passage under the respective array. 
FIGS. 3 through 7 depict end views, in partial or full section, of the 
arrays 26 of FIGS. 1 and 2 which are equipped with the invention disclosed 
herein. Individual support beams 102 for each array 26 extend across 
conveyor 14 and are attached at each end to diagonal frame members 24. 
Perpendicularly affixed at spaced locations along individual support beams 
102 are plate-like mounting brackets 104, which provide support for 
primary dye manifold assembly 36 and associated apparatus, primary dye 
collection chamber 80 and associated apparatus, and the apparatus 
associated with the instant invention. In a preferred embodiment, valve 
boxes 100, supported by beams 102, may be used to house collectively the 
plurality of individual valves V, as well as the air manifold 74 
associated with each array. 
As depicted most clearly in FIGS. 4 through 7, primary dye manifold 
assembly 36 is comprised of a pipe having a flat mating surface which 
accommodates a corresponding mating surface on sub-manifold assembly 40. 
Sub-manifold assembly 40 is comprised of sub-manifold module section 42, 
grooved dye outlet module 50, and an elongated sub-manifold section 46 
cooperatively formed by elongated mating channels in sub-manifold section 
42 and outlet module 50. Sub-manifold module 42 is attached to primary dye 
manifold assembly 36 by bolts (not shown) or other suitable means so that 
drilled outlet conduits 37 in the mating surface of manifold assembly 36 
and corresponding drilled passages 44 in the mating surface of 
sub-manifold module section 42 are aligned, thereby permitting pressurized 
liquid dye to flow from the interior of manifold assembly 36 to elongated 
sub-manifold 46. 
Associated with the mating face of dye outlet module 50 are a plurality of 
grooves or channels 51 which, when dyes outlet module 50 is mated to 
sub-manifold module 42 as by bolts or other appropriate means (not shown), 
form dye passage outlets 52 through which uniform quantities of liquid dye 
from sub-manifold 46 may be directed onto the substrate in the form of 
aligned, parallel streams. The relative position or alignment of dye 
channels 51 with respect to primary dye collector plate 84 and collector 
plate support member 86 may be adjusted by appropriate rotation of jacking 
screws 106 associated with mounting brackets 104. 
Associated with dye outlet module 50 is deflecting air jet assembly 60, 
shown most clearly in FIG. 6, by which individual streams of air from air 
tubes 62 may be selectively directed, via an array of valves in valve box 
100 and connecting supply conduits 64, across the path of respective dye 
streams. Assembly 60 is comprised of an air supply tube support plate 66 
and air tube clamp 68, intended to align and secure individual air 
deflecting tubes 62 immediately outside dye outlets 52. By rotating air 
tube clamp screw 67, the pressure exerted by clamp 68 on air tubes 62 may 
be adjusted. Airfoil 72, positioned generally opposite air tubes 62, is 
intended to reduce the degree of turbulence within the region of the array 
due to the action of the transverse air streams issuing from tubes 62. 
Although not shown, the protruding portion of dye outlet module 50 against 
which air tube clamp 68 urges tubes 62 is preferably configured with a 
series of V-shaped notches into which tubes 62 may partially be recessed. 
Further details of a similar alignment arrangement may be found in 
commonly assigned U.S. Pat. No. 4,309,881. 
Also associated with dye outlet module 50 is dye by-pass manifold 56 and 
by-pass manifold conduit 54, shown most clearly in FIG. 5, which 
collectively act as a pressure ballast and provides for a uniformly 
pressurized dye supply within sub-manifold 46. 
When the liquid dye stream is deflected, the liquid dye exiting from dye 
passage outlets 52 is directed into primary dye collector chamber 80, 
which may be formed of suitable sheet material such as stainless steel and 
extends along the length of the array 26. Associated with collection 
chamber 80 is a primary dye collector plate 84 which is comprised of a 
thin flexible like blade-like member which is positioned parallel and 
closely adjacent to dye passage outlets 52. Primary collector plate 84 may 
be adjustably attached at spaced locations along its length, as by bolt 
and spacer means 85, to wedge-shaped elongate collector plate support 
member 86, which forms an extension of the floor of primary collection 
chamber 80 and which is sharpened along the edge nearest the outlets 52 of 
dye discharge channels 51 and extends along the length of array 26. Any 
suitable adjustment means by which a thin, blade-like collector plate 84 
may be mounted under tension along its length and aligned with the axes of 
dye outlet module grooves 51 may be employed; one such means is disclosed 
in commonly assigned U.S. Pat. No. 4,202,189. 
As shown in FIG. 5, primary dye collection chamber 80 is positioned 
generally opposite the array of air deflection tubes 62 for the purpose of 
collecting liquid dye which has been diverted from the dye streams by the 
transverse air stream from tubes 62. Primary dye collection chamber 80 
also captures and collects partially diverted water sprayed at high 
pressure from manifold assembly 36, as well as water sprayed from 
staggered cleaning water nozzles 96 associated with wash water manifold 
94, whenever the array is cleaned, e.g., when use of a different color dye 
is to be used. Primary dye collection chamber 80 may be attached by 
conventional means to mounting brackets 104 as well as to sharpened 
collector plate support member 86, which may be rabbeted to accommodate 
the floor of chamber 80, as shown, and forms a cavity into which dye or 
wash water may be collected and removed from the interior of the array via 
primary dye collection conduit 82. Mist shield 90, which generally extends 
the length of the array, is attached to the bottom of the valve box 100 
using bolts or other suitable means, not shown. Shield 90 prevents wash 
water or dye, either in the form of droplets or airborne mist, from 
traveling between the manifold 36 and the valve box 100 and dripping onto 
and staining the substrate from that side of the array. Mist shield 92, 
also attached to valve box 100, uses spring force to compress elastomeric 
seal 93 which is attached to the dye collection chamber 80. Shield 92 and 
seal 93 prevent wash water, primarily in the form of airborne mist, from 
exiting the top of the dye collection chamber 80 and settling onto the 
substrate below. Both shields 90 and 92 and dye collection chamber 80 are 
preferably open at both ends so as to allow the pressurized air from air 
deflection tubes 62 to escape without undue restriction. 
A principal component of the instant invention, secondary drain tray 110 
extends along the length of primary dye collection chamber tray 80 and is 
attached thereto by means of hinge 112, which allows secondary drain tray 
110 to swing away from the underside of array 26 for occasional cleaning 
and maintenance. When in position under array 26, secondary drain tray 100 
may be secured through apertures (shown in FIG. 7) in the underside of 
tray 110 which are aligned with corresponding holes (not shown) in the 
primary dye collection chamber 80 by means of bolts or other suitable 
means, not shown. A fixed distance is held between the secondary drain 
tray 110 and primary dye collection chamber 80 through use of spacers. 
Liquid collected by secondary drain tray 110 may be collected by gravity 
and discharged through drain pipe 114, as indicated in FIG. 5. This liquid 
is transported through a suitable conduit to a waste water drain. 
Associated with the unhinged end of secondary drain tray 110 is a movable 
shutter or shield 120, which is comprised of a thin elongate plate to 
which, in a preferred embodiment, tension is applied in a lengthwise 
direction in order to reduce sag and assure proper alignment and fit. Such 
tension may be introduced by a series of spring washers, as shown at 124 
in FIG. 10, similar to the means by which collector plate 84 may be 
tensioned. As best shown in FIG. 6, shield 120 is positioned to move 
freely within the elongate gap 121 between the inside surface of secondary 
drain tray 110 and the lower surface of primary dye collector plate 
support member 86. When in an extended position, as when a cleaning 
operation is underway, the leading edge of shield 120 abuts tubular seal 
70 in liquid-tight association. Seal 70 may be affixed to air tube support 
plate 66 via seal bracket 69, and air tube clamp screw 67. The trailing 
edge of shield 120 remains within gap 121 to an extent sufficient to 
assure that liquid flowing along the surface of shield 120 and under 
collector plate support member 86 towards the trailing edge of shield 120 
must continue to flow within gap 121 and along the inside surface of 
secondary drain tray 110 toward hinge 112, and not flow between shield 120 
and tray 110 and thereby into the substrate 12. When the operation is 
completed and liquid dye is again to be directed onto the substrate, 
shield 120 is moved to a position substantially totally within gap 121 
formed by the inside surface of secondary drain tray 110 and collector 
plate support member 86, as depicted in the left hand array of FIG. 3 and 
4. 
As best shown in FIGS. 9 and 10, shield 120 extends under the side portions 
80A of primary dye collection chamber 80, under a wear plate 128, and 
under shield shuttle 130, which contains an internal chamber suitable for 
accommodating a stack of opposing Bellville-type spring washers 124 
surrounding a tensioning bolt 125. Tensioning bolt 125 also pass through 
pressure plate 122, to which is attached the end-most portion of shield 
120, via a conventional clamp and screw arrangement shown generally at 
126. The configuration provides for the controlled application of tension 
on shield 120 by the compression of washers 124, and also couples shield 
120 to moveable shuttle 130. When shuttle 130 is driven along the length 
of rotating shuttle guide threaded shaft 132, as described in more detail 
below, shield 120 is constrained to follow, without change in the tension 
applied to shield 120. 
The means by which shield 120 may be reversibly and reliably moved from a 
"closed" to an "open" position (and vice versa) without skewing is best 
described with reference to FIGS. 3, 9, and 11. At each outside end of 
array 26, shield 120 is attached to a moveable shuttle 130 which is 
associated with shuttle guide threaded shaft 132, which extends alongside 
array 26 in a direction generally aligned with conveyor 14 within the 
region of dye outlets 52. Shuttle guide shaft 132 is supported at one end 
by shaft support plate and bearing 134 which allows for the free rotation 
of shaft 132. The opposite end of shuttle guide shaft 132 is supported by 
gear box 140. Both shaft support plate 134 and gearbox 140 are permanently 
attached to gearbox mounting plate 135 which, in turn, is adjustably 
attached with bolts 136 to the end plates 80A of the primary dye 
collection chamber 80. If desired, a bellows or similar sleeve may be used 
to protect threaded shaft 132 from dirt, dyestuffs or other contaminants. 
The gearboxes 140 on either side of the dye collection chamber 80 are 
connected together by a conventional flexible drive shaft assembly as 
better shown in FIGS. 7, 8, 9, and 11. The flexible drive shaft assembly 
consists of a spirally wound inner steel core 146 which rotates within and 
is protected by an impermeable casing 145. The steel core is rigidly 
attached at both ends to shaft couplings 144 and 144a. The flexible drive 
shaft assembly is supported neat its midpoint by shaft alignement collar 
147. As seen in FIG. 11, motor 160 is directly connected to rigid drive 
shaft 142 to which is also connected worm 141. Rotation of the motor 160 
imparts a direct rotation of worm 141 which in turn drives worm gear 143 
with a corresponding fixed speed reduction. Worm gear 143 is directly 
attached to the shuttle guide threaded shaft 132. The torque of motor 160 
may therefore be enhanced by the combined mechanical advantages imparted 
by the worm gearing and the screw threads on threaded shaft 132, which 
threads serve to drive shuttle 130 (and shield 120) in the desired linear 
direction. Through the connection offered by the flexible drive shaft 
assembly, the gearboxes on each side of the array 26 are constrained to 
rotate in unison, which, in turn, synchronously propels the shuttle 130 on 
each side of the array in the direction appropriate to the direction of 
guide shaft 132 rotation. A particular advantage of this system is that it 
minimizes any skewing of the shield 120 due to movement of the ends of the 
shield 120 at different rates. A further advantage is the slow even 
movement of the shuttle 130 which does not impart vibration or shock to 
the sensitive dye manifold assembly. 
Reversible motor 160 may use any appropriate type of drive; a pneumatic 
motor has been found to be particularly satisfactory in terms of size and 
reliability. 
As depicted in FIG. 9, a set of inductive proximity switches 131 or the 
like may be adjustably positioned to detect the arrival of shuttle 130 at 
the desired end points of travel, and to disengage motor 160 as 
appropriate. Connecting proximity switches 131 and motor 160 to pattern 
control device 20 allows pattern control device 20 to sense the position 
of shield 120. It is intended, using such switches 131, that the motion of 
shield 120 may be controlled (i.e., both initiated and terminated) in 
response to the pattern control device 20, as appropriate, thereby 
providing for the automatic cleaning/color changing of arrays which are no 
longer needed to produce a given pattern, in preparation for the 
production of a different pattern. The details of automatically and 
electronically changing from one pattern to another is set forth in U.S. 
Pat. No. 4,170,883, the disclosure of which is hereby incorporated by 
reference. 
Suitable other jet type apparatus is disclosed in U.S. Pat. Nos. 4,084,615; 
4,034,584; 3,985,006; 4,059,880; 3,937,045; 3,942,342; 3,939,675; 
3,892,109; 3,942,343; 4,033,154; 3,969,779; 3,894,413; and 4,019,352, 
4,033,154; 4,116,626; 4,434,632; 4,584,854; the disclosures of each of 
said patents hereby being expressly incorporated by reference. 
Reducible dyes which can be used singly or in admixture to provide the 
ground dye component to which the present process is applicable include 
vat, reactive, mordant, acid, metallized, direct and disperse, and 
exemplary ones are those disclosed in U.S. Pat. Nos. 3,104,150; 3,077,370; 
2,164,930; 2,206,535; 2,248,128; 4,610,802; 4,441,883; and in the 
following articles: "MANO FAST IN TEXTILE PRINTING," P. Krug, Rayon and 
Synthetic Fibres Supplement; pp. 939-947; "G. Bertolina, et al., Coloured 
Discharge Technique, Dyer, 114, pp 775-779 (1955); "Thiourea Dioxide 
(Formamidinesulfinic Acid) A New Reducing Agent For Textile Printing," P. 
Krug, J.S.D.C. 69, December 1953, pp. 606-611, the disclosures of all of 
which are hereby expressly incorporated herein by reference. 
Dyes particularly useful and preferred as the reduction resistant colorant 
component in the reduction system of the present invention, and which are 
also resistant, for the most part, to oxidation, include the following: 
Direct Yellow 28, Direct Yellow 58, Acid Red 226, Acid Violet 90, Acid 
Blue 61:1, Direct Blue 106, Acid Green 84, Acid Green 28, Intrachrome 
Black RPL. Other useful non-dischargeable dyes include, Acid Yellow 151, 
Direct Yellow 119, Direct Yellow 68, Acid Yellow 79, Direct Blue 108, Acid 
Yellow 5, Acid Black 188, Acid Blue 25, Acid Blue 59, Acid Blue 193, Acid 
Blue 278, Acid Blue 324, Acid Red 50, Acid Red 52, Acid Red 91, Acid Red 
92, Acid Red 94, Acid Violet 103, Acid Green 41. 
Dyes which are preferred for the dischargeable ground shades are: Acidol 
Scarlet ML, Acidol Yellow M5RL, Acidol Red MBR, Irgalan Bordeaux EL 200, 
Isolan Navy Blue, Telon Violet BL, Isolan Gray KPBL 200, Isolan Yellow 
KPRL, Isolan Yellow 8GL, Erional Rubine 5BLF, Irgalan Yellow GRL 200, 
Lanasyn Red SG, Lanasyn Orange S-RL, Lanasyn Dark Brown SGL, Lanasyn 
Yellow S-2GL, Nylasyn Red FMRL, Nylasyn Yellow, and Telon Fast Yellow 
A2GL. 
Below are four typical and preferred structural and operating parameter 
sets for the jet apparatus described in the above in regard to FIGS. 1-11. 
______________________________________ 
Production operating 
reductant velocities 
Jet gauge orifice diameter 
(meters/second) 
(jets/inch) 
in inches low high 
______________________________________ 
10 0.020 4.52 6.58 
16 0.008 6.17 11.31 
10 0.024 4.57 8.28 
20 0.014 4.20 6.71 
______________________________________ 
It has been found that many types of previously known reductant systems 
such as described in the above Bertolina, et al article, which are 
typically applied by screen, pad or the like cannot be employed in the 
present process due to unmanageable setting up of its components in the 
applicator, clogging of the jets and unacceptably inadequate reducing 
power with respect to the recipe requirements of the present apparatus, 
particularly on polyamide pile substrate such as Nylon 6 or 66. A highly 
preferred reductant recipe is shown in the aqueous recipe table below as 
number 3, employed in a series of comparative runs wherein the ingredient 
contents are expressed in grams/kilogram, on weight of the reductant 
system total recipe. A preferred range for the recipe 3 ingredients is 
also noted in the recipe table. 
Recipe 1 in the table is taken from page 4513 Dyes and Textile Chemistry, 
cited above. Recipe 2 is identical to recipe 1 except zinc sulfate was 
added. Recipe 3 is a preferred reductant system of the present invention 
for use on medium to heavy ground shades. 
______________________________________ 
Grams/Kilogram 
of Total Preferred 
Reductant System 1 2 3 Range For 3 
______________________________________ 
Non-Reducible Dye (optional) 
Zinc Sulfate (Redox assistant) 
-- 50.0 10.0 
1-50 
Thiourea Dioxide 50.0 50.0 15.0 
3-30 
Thiodiglycol 100.0 100.0 -- -- 
Water 300.0 250.0 725.0 
500-1000 
Anthraquinone Paste 30% 
10.0 10.0 -- -- 
active 
British Gum (dextrin), 50% 
540.0 540.0 -- -- 
active 
Xanthan Gum, 2% active 
-- -- 250.0 
150-350 
______________________________________ 
Note: 
1 The anthraquinone paste is prepared by dispersing with high energy 
shearing and/or ball milling for, e.g., twelve hours, 80 parts by weight 
of the 30% active aqueous anthraquinone, 10 parts by wt. Synfac 8216 (a 
Milliken Chemical nonionic surfactant), and 10 parts by wt. Tamol SN (a 
Rohm and Haas sulfonated naphthalene dispersant). The anthraquinone is a 
redox component. 
2 The British gum was prepared as a 50% wt. paste from soluble starch 
(dextrin) from Fisher Scientific. 
3 The Xanthan gum was prepared as a 2% wt. hydrolyzed Kelzan S product 
from Kelco. 
PREATION OF SUBSTRATE SAMPLES 
The Nylon 66 fiber was stock dyed (pot dyed) and the dyed fiber then 
blended, spun into yarn and fabricated into a pile substrate. Three 
different ground shade colors of pile substrates were prepared and used in 
the discharge tests. 
______________________________________ 
Blue Substrate: 80% dyed fiber and 20% undyed fiber. 
The dyed fiber composition was as follows with 
the dye weight percentage being on weight of fiber: 
Lanasyn Navy Blue SBL (C.I. Acid Blue 296) 
0.12% 
Lanasyn Black SRL 80% wt. (C.I. Acid Black 218) 
0.24% 
Lanasyn Yellow S-2GL (C.I. Acid Yellow 235) 
0.07% 
Burgundy Substrate: 100% dyed fiber 
of the following composition: 
Lanasyn Rubine S-5BL 0.48% 
Lanasyn Red SG (C.I. Acid Red) 
0.40% 
Lanasyn Yellow S-2GL 0.17% 
Lanasyn Black SHL 80% 0.19% 
Camel Substrate: 63% dyed fiber and 7% undyed fiber 
The dyed fiber composition was as follows: 
Lanasyn Yellow S-2GL 0.21% 
Lanasyn Red SG 0.04% 
Lanasyn Black SHL 80% wt. 
0.14% 
______________________________________ 
REDUCTANT RECIPE PREATION AND DISCHARGE TEST PROCEDURE 
Recipe 1 
To approximately one half of the total water of the recipe in one container 
the thiourea dioxide, the thiodiglycol and anthraquinone paste were added 
and thoroughly mixed. In another container were mixed thoroughly the 
remainder of the recipe water and the British gum. The contents of both 
containers were thoroughly mixed. The resulting reducing system was then 
pattern applied with a flat screen to each substrate which was then 
atmospherically steamed for 8 minutes, washed, and dried at 235.degree. F. 
The resulting patterned discharge area showed little to no color discharge 
effects and virtually all of the color in each of the ground shades 
remained. 
An identical reducing system was prepared as above and loaded into a jet 
printing machine of the general type described above in FIGS. 1-11. The 
reducing system would not circulate at all in the machine and hence no jet 
discharge tests were performed. Consequently, in an attempt to obtain a 
reasonable comparison, and as experience has shown, the technique of 10-12 
passes in repetition of a flat screen which approximates the depth of pile 
penetration and wet pick-up achievable on the aforesaid machine was 
employed. Although it is obvious that this technique is not commercially 
practical, it is a useful laboratory tool and one that allows at least an 
approximate evaluation of the reduction efficacy of the prior art 
reductant systems and application methods as compared to the present 
invention. This multi-pass technique will henceforth be referred to as 
"jet simulation". 
Jet simulation was performed using recipe 1 on each of the colored 
substrates which were then atmospherically steamed for 8 minutes, washed, 
and dried at 235.degree. F. The patterned discharge areas of the 
substrates remained highly colored with the original ground color. 
Recipe 2 
Recipe 1 was repeated except that zinc sulfate 50 g/kg was added thereto. 
The resulting reducing system was then applied to each substrate with a 
flat screen, and the substrate then atmospherically steamed for 8 minutes, 
washed and dried at 235.degree. F. The resulting discharge patterns were a 
vivid yellow on all three substrates after steaming and remained a dull 
pastel yellow color after drying. The discharge patterns had only 
penetrated into the yarn piles approximately 5% of their depth. 
An identical reducing system was prepared using recipe 2 and loaded into 
the aforesaid jet printing machine. The reducing system would not 
circulate at all in the machine and hence no jet discharge tests were 
performed. 
Jet simulation was performed using recipe 2 on each of the substrates, and 
the substrates then atmospherically steamed for 8 minutes, washed, and 
dried at 235.degree. F. The substrates were highly colored upon removal 
from the steamer and the patterned discharge areas retained a dull yellow 
coloration after drying. 
Recipe 3 
Both jet simulation and actual jet application from the aforesaid machine 
were performed using recipe 3 on each of the substrates, which were then 
atmospherically steamed for 8 minutes, washed, and dried at 235.degree. F. 
The substrates were substantially uncolored upon removal from the steamer 
and remained substantially uncolored for both the blue and camel ground 
shades. There was slight coloration on the substrates colored burgundy. It 
was clearly evident that the single pass through the jet machine had 
forced the reductant system substantially below the surface of the yarn 
piles. 
In a preferred embodiment, the addition of a small amount of aldehyde, 
e.g., formaldehyde or benzaldehyde in concentrations of from about 0.5 to 
about 10.0 grams/kilogram of recipe is employed in the recipe to assist in 
eliminating residual color from substrates which are initially highly 
colored, e.g., as with the burgundy dye. 
The best operation of the jet apparatus and method is achieved with the 
following aqueous reduction system and machine operating specifications: 
______________________________________ 
(a) Viscosity at 25.degree. C. 
300-1200 cps 
(b) Temperature 50-95.degree. F. 
(c) Solids particle size (average diameter) 
&lt;10 microns 
(d) Concentration of Thiourea Dioxide on 
&lt;30 g/kg 
weight of reduction system 
(e) PH 6.0-7.0 
(f) Concentration of Zn SO.sub.4 on weight of 
1.0-50 g/k 
Reduction System 
______________________________________ 
It is noted that the solids particle size refers to the various materials 
which are either brought into the system or formed therein and include 
insoluble agglomerations of gum materials, salts and gels, all of which in 
larger sizes can cause the jet apparatus to clog and fail. 
Alternative materials to the ZnSO.sub.4 include the various water soluble 
salts of zinc and other transition metals including Co, Cd, Cu, Zr, and 
the like. 
It is preferred that xanthan gum or guar be used to adjust the viscosity of 
the reductant system; however, in general, aqueous system thickners of 
both the naturally derived organic type and synthetically derived organic 
polymeric type may be employed. The Xanthan gum is of course commercially 
available and well known and described, e.g., in Condensed Chemical 
Dictionary, 9th Edition, Van Nostrand, 1977, as a synthetic biopolymer 
made by fermentation of carbohydrates. Typical examples of useful aqeuous 
system thickners are as follows: 
I. Organic-Naturally Derived Type 
Includes: "Alginates," such as "Carrageenan," and agar, and their salts; 
algin alkyl-carbonates, acetates, propionates and butyrates; pectins, 
amylopectin, and derivatives; gelatin; starches and modified starches 
including alkoxylated forms, such as esters and ethers; Cellulose 
derivatives, such as sodium carboxymethylcellulose (CMC), 
hydroxyethylcellulose (HEC), carboxymethylhydroxyethyl cellulose (CMHEC), 
ethylhydroxyethyl cellulose (EHEC), and methylcellulose (MC); Casein and 
its derivatives; Xanthomonas gums, such as xanthan gum; Dextrans of low 
molecular weights; and Guar gums. 
II. Organic-Synthetically Derived Type 
Includes polymers of acrylic acid or methacrylic acid, and their metallic 
salts, esters, and amides; copolymers of acrylic/methacrylic acids and/or 
their metallic salts, esters amides, and/or polymers of any or all of 
these forms; polyamides (e.g. see U.S. Pat. No. 2,958,665); vinyl 
polymers, such as substituted vinyls, vinyls ester polymers, etc.; 
polyalkoxylated glycol ethers of high molecular weight; and amine salts of 
polycarboxylic acids (Alginates, polyacrylates, glycolates, etc.). 
III. Combinations Of Above Types 
(A) Includes resins prepared by crosslinking one or more of the above 
organic polymers with each other or with other polyhrdric materials 
(aldehydes, alcohols, diols, ethers, etc.). For example: 
(1) crosslinked 1:1 maleic anhydride-methyl vinyl ether copolymer with 
diethylene glycol divinyl ether or with 1,4-butanediol divinyl ether; 
(2) methyl cellulose with glyoxal crosslinks; 
(3) hydrolyzed polyacrylonitrile crosslinked with formaldehyde or 
acetaldehyde (e.g. see U.S. Pat. No. 3,060,124); 
(4) polyacrylate polymers with maleic anhydride and styrene; and 
(5) Carrageenan with cellulose methyl ether. 
(B) Include the addition of certain inorganic salts to one or more of the 
above organic polymers. For example: 
(1) calcium phosphate added to an aqueous solution of Alginate salts; 
(2) Carageenan with alkali metal salts (e.g. KCI) added; 
(3) increased gelation of gums or polyvinyl polymers by addition of 
borates; and 
(4) Xanthomonas gum with trivalent metal salts such as Al.sub.2 
(CO.sub.4).sub.3 and a H-displacing metal such as Zn or Ni. 
Of these, the gum type thickeners, such as guar gum and Xanthomonas gums 
are preferred. Representative of these include the products sold under the 
tradenames: V60-M Gum, from HiTek Polymer Co., a modified guar 
polygalactomannon gum; and Kelzan from Kelco division of Merke & Co., San 
Diego, Calif., an anionic biopolysaccharide Xanthomonas gums. 
The amount of thickner added to the aqueous reducing solution is selected 
to provide the desired visosity which can range between about 20 to about 
20,000 centipoise as measured at 25.degree. C., with a No. 3 spindle in a 
Brookfield LVT viscometer. In general, amounts of thickener in the range 
of from about 0.1 to about 5.0 weight percent, based on the weight of the 
solution, can be most effectively employed. For jet machines, such as 
described above, thickener concentrations ranging from about 0.1 to about 
1.0 weight percent of the reducing recipe provide viscosities at 
25.degree. C. of from about 50 to about 1,000 centipoise. 
This invention has been described in detail with particular reference to 
preferred embodiments thereof, however, it is understood that variations 
and modifications can be effected within the spirit and scope of the 
invention.