PROCESS AND APPARATUS FOR APPLYING AND SIMULTANEOUSLY FIXING A CHEMICAL TO A TEXTILE SUBSTRATE

Abstract: A chemical, such as a dye, is applied to a textile substrate, such as carpet, by continuously moving the substrate past an application position. At the application position the chemical is sprayed in vapor form in the presence of steam as a carrier or a liquid formulation containing the chemical, heated to a temperature below the boiling point thereof, is sprayed toward the substrate, thereby transporting the chemical into the substrate. The temperature of the spray is controlled such that the dye contacts the substrate at a temperature sufficient to achieve substantially instantaneous fixation.

Description: Process and apparatus for applying a chemical to a textil substrate Background of the Invention The present invention relates to a process and apparatus for applying a chemical to a textile substrate. More particularly, the present invention is directed to a process and apparatus for applying a dye to a continuous length of a textile substrate such as carpet, and such as made from a natural polyamide material, such as wool, or a synthetic polyamide material, such as nylon. Conventional systems for dyeing textile substrates such as carpet involve the application of the dye, by various processes, to the carpet, followed by passing the dyed carpet through a steamer to achieve fixation of the dye to the carpet. Conventional steamers have to be of a length sufficient to enable treatment of the dyed carpet for a sufficient time to achieve fixation. The residence time of a given carpet section generally is from approximately 4 to approximately 15 minutes. Since the carpet passes through the dyeing machine at a relatively high speed, for example up to approximately 30 meters a minute and even higher, these steamers must have a quite long length, even when the steaming path undulates. Typically, steamers are of a length off30 to 90 meters, and even longer. It will be apparent that the cost of providing and operating such steamers is quite high. Thus, the energy costs to maintain steam in such large enclosures is high. Furthermore, maintenance costs as well as initial capital costs are high. Even further, the cost of the large amount of factory space required for such steamers is high. Furthermore, various attempts have been made to improve conventional dyeing procedures, and specifically to improve the quality and reproducibility of dyeing operations. One system, the so-called "Otting" system sprays the -dye onto-the-carpet withrthe aid of air and then heats the dyed carpet. This system still however requires the use of a steamer. ^ - Another-system, the so-called "Artos" system, passes the carpet through a bath of dye liquor heated to a boiling point temperature. After the carpet passes through the dye bath, the carpet is rinsed and then dried. Another system is the so-called "PRINTAIRE" system wherein dye is applied to the carpet by creating a foam which is applied to the carpet. The thus dyed carpet then is passed through a steamer. All of the above prior art systems are expensive, both in initial investment and in operating cost. Summary of the Invention With the above discussion in mind, it is an object of the present invention to provide a novel process and apparatus for applying a chemical to a textile substrate whereby it is possible to overcome the above and other prior art disadvantages. A further object of the present invention is to provide a process and apparatus which makes possible better consistancy in dyeing than known processes and systems; particularly an improvement of quality such as for example superior levelness. A further object of the present invention is to provide a process and apparatus which requires a much lower capital investment than known systems and which may be operated much less expensively than known systems, particularly from the viewpoint of energy costs. A more specific object of the present invention is to provide a novel process and apparatus for dyeing carpet, particularly for applying an acid dye to a natural or synthetic polyamide carpet. These objects are achieved in accordance with the present invention by continuously moving a substrate past an application position or station, and at such application position or station spraying a chemical in vapor form, in the presence of steam as a carrier or spraying a heated liquid formulation containing said chemical toward the substrate, thereby transporting the chemical to be applied into the substrate and simultaneously fixing it. In accordance with a preferred arrangement of the present invention, the chemical comprises a dye and specifically an acid dye. The textile substrate comprises a natural or synthetic polyamide substrate, specifically carpet. In accordance with a particularly preferred embodiment of the present invention, the temperature of the vapor or of the liquid is controlled such that the chemical, such as a dye, contacts the substrate, such as carpet, at a temperature sufficient to achieve substantially instantaneous fixation. In other words, according to one preferred embodiment of the present invention, the steam functions both as a carrier or a driver to drive the dye i2n the textile fabric, and as an energy source to maintain the temperature of the dye as it contacts the carpet at a sufficiently high level to achieve substantially instantaneous fixation; or according to a further preferred embodiment of the present invention, the heated liquid dye formulation is transported into the textile fabric, and the liquid is heated to an extent such that the temperature of the dye as it contacts the carpet is at a sufficiently high level to achieve substantially instantaneous fixation. By "substantially instantaneous fixation" as employed herein is meant that fixation occurs within a matter of seconds, especially up to 5 seconds and 30 seconds at maximum of initial contact of the dye with the carpet. This temperature control may be achieved by enclosing the vapor of the dye spray, and thereby pre venting any substantial cooling of the dye and steam or the dye formulation before contact thereof with the substrate. This can be achieved by an enclosure surrounding the vapor spray or the spray of dye. Such enclosure may also enclose that portion of the carpet substrate at the application position, i.e. the carpet substrate may be passed through the enclosure. In accordance with a modification of this arrangement, the enclosure may have therethrough, in the area of the application position a plurality of holes enabling passage of the dye therethrough, and the carpet substrate may be moved in contact with the exterior of the enclosure to pass across such holes, if a dye in vapor form in the presence of steam is used; or in accordance with a further modification of this arrangement, the enclosure may have therethrough, in the area of the application position, a single large opening through which passes the dye spray, if a heated dye formulation is used. The carpet substrate is caused to move in contact with the exterior of the enclosure and to pass over such opening while forming a seal of such opening, thereby maintaining an optimum reaction temperature within the enclosure. In a further alternative arrangement, the enclosure comprises a confined channel having a discharge end. The carpet substrate is caused to move across the discharge end of the channel. The exterior of the channel may be heated, for example by steam, thereby maintaining a desired temperature of the heated dye formulation. The steam acts both as carrier of the chemical toward the substrate and provides sufficient energy to substantially instantaneously fix such chemical to the substrate. It has also been found that excellent results are often obtained if the chemical is applied from a liquid heated to near its boiling point rather than from steam vapor. This improvement results in substantial energy savings and simplifies the equipment requirements. The vapor of dye and steam may be formed by supplying the dye to a chamber, for example a blending chamber, and also supplying steam to such chamber, whereby the steam blend with the dye to form the vapor, and then discharging the vapor from the chamber toward the substrate. In another arrangement of the present invention, the dye may be in liquid form and may be heated to steam, thereby forming the vapor which then is directed toward the substrate. Dyes usable according to the invention are preferably anionic, water-soluble or at least dispersible in water. They can be reactive or preferably nonreactive, i.e. they are able or not able to form with the substrate a covalent bond, and they can belong to different classes of dyes. They are, for example, salts of metal-free or heavymetal-containing mono-, dis- or polyazo dyes, including the formazan dyes, as well as anthraquinone, nitro, triphenylmethane and phthalocyanine dyes. Of interest are also the 1:2metal complex dyes. The anionic character of these dyes can be caused by metal-complex formation alone and/or by acid salt-forming substituents, such as carboxylic acid groups, sulphuric acid groups and phosphoric acid ester groups, phosphoric acid groups or sulphonic acid groups. The dyes can be used alone or in combination with one another, especially in a trichromatic system. Advantages of the process and apparatus of the present invention include an approximately 5 to 10 percent dye savings compared with known continuous systems, energy savings, equipment savings and space savings. As pointed out above, the dye formulation is heated to a temperature sufficient to enable the obtaining of substantially instantaneous fixation. It is intended that such heating involve a temperature below the boiling point of the particular dye formulation. In other words, the formulation is heated to a temperature just below the particular flash point to steam. It is important that the formulation remains as liquid and is not vaporized. Preferred temperatures are between 88 and 100 C. Particularly preferred are temperatures between 96 and 1000C. In most embodiments of the present invention, it is possible to eliminate wetting and afterwashing or rinsing. Where rinsing is required, it is minimized relative to the state of the art. There is no frosting, and bulking and handling are improved. Prewetting is not required. BRIEF DESCRIPTION OF THE DRAWINGS Other objects, features and advantages of the present invention will be apparent from the following detailed description of preferred embodiments thereof, with reference to the accompanying drawings, wherein: Figures 1 through 7 are schematic, partially sectioned views illustrating various embodiments of the process and apparatus of the present invention. DETAILED DESCRIPTION OF THE INVENTION In Figure 1 there is shown a carpet 2 moved continuously in the direction indicated by the arrow by conventional moving structure. The carpet is moved past an application position or station indicated generally by 4. At station 4 there is sprayed onto the carpet in vapor form 6 and in the presence of steam as a carrier a dye. Thus, dye is introduced through a supply conduit 8 to a blending chamber 10. Advantageously the dye supplied to conduit 8 may be preheated. Steam is supplied to chamber 10 by means of a conduit 12. Within chamber 10 the steam blends with the dye to form vapor 6 which is discharged from chamber 10, for example through nozzle 14 toward the carpet 2 at the application position 4. A nozzle 14 as such is not necessarily required, and the spray 6 may be discharged from chamber 10 simply through an opening therein, or chamber 10 simply may be in the form of a tube having an open lower end. In accordance with a novel feature of the present invention, the temperature of the vapor spray 6 is controlled such that the dye contacts the carpet 2 at a temperature to achieve substantially instantaneous fixation. Temperature control specifically is achieved by enclosing the spray 6 by an enclosure 16. Enclosure 16 is of relatively small volume and maintains a temperature climate control to prevent the temperature of the dye and steam in the vapor spray 6 from substantially decreasing prior to contact with the carpet 2. The specific size of enclosure 6 is not particularly important, as long as it is small enough to achieve the above results. In actual practice, the length of enclosure 16 in the direction of movement of the carpet has been approximately 66 cm. The application of the dye by means of the steam achieves basically two functions. Firstly, the steam acts as a carrier of the dye and essentially drives the dye into the carpet. Secondly, the steam supplies the energy to achieve substantially instantaneous fixation of the dye to the carpet. The spacing of the nozzle 14 from the carpet, the ratio of steam to dye, and the pressure of the vapor being supplied from nozzle 14 will vary substantially from installation to installation, depending upon the dye employed, the carpet employed, the speed of the carpet, etc. It is believed that one of ordinary skill in the art, upon considering the present disclosure, would understand how to vary these parameters while achieving performance of the present invention. It generally is believed that the spacing from the nozzle 14 to the carpet 2 may vary from 2,5 to 18 cm, more preferably from approximately 6,4 to 12,7 cm. This however is considered to be exemplary only and not in any way limiting to the scope of the present invention. Such spacing obviously must be not so great as to prevent the steam from driving the dye into the carpet. Furthermore, the ratio of steam to dye must be sufficient to achieve such driving force. Additionally, the particular temperature of the steam supplied to chamber 10 and also the temperature of the vapor as it contacts the carpet will vary from situation to situation, depending on a number of parameters, for example the dye employed and the carpet employed. It is believed that those skilled in the art would understand how to achieve the substantially instantaneously fixation of the present invention for a particular dye and a particular carpet. The above discussion has been with regard to the application of a dye to a carpet. The present invention particularly is suitable for the application of an acid dye to a polyamide carpet, for example a natural polyamide such as wool, silk, hair or a synthetic polyamide such as nylon. It is believed that the steam in vapor 6 opens up cavities in such polyamide material, enabling the dye to diffuse into such cavities, and that this diffusion is enhanced by the polar attraction of the acid dye to the polyamide material. It is believed that the process and apparatus of the present invention could be employable with dispersed dyes and/or polyester substrate materials, but this probably would require additional steaming. It is to be understood however that the present invention is not limited to the application of a dye to a carpet, but may be employed for application of a dye to another type of textile substrate or for the application of another chemical to a carpet or other textile substrate. Specifically, it is intended that other chemicals which may be applied in accordance with the present invention are softeners, anti-static chemicals, anti-soiling chemicals, waterproofing chemicals, anti-microbial chemicals, etc. Furthermore, it is contemplated that the present invention add any of the above chemicals, or other chemicals, along with a dye. Thus, as shown in dashed lines in Figures 1, a chemical may be supplied by a conduit 18 to blending chamber 10 and blended with the steam and the dye for simultaneous application in vapor form with the dye. Furthermore, upon application of the vapor spray 6 to the carpet1 and the instantaneous fixation of the dye, the water condensed from the steam may be immediately recovered. Such recovered water may be at least partially returned to chamber 10, as by means of conduit 18, as an aid for controlling the formation of the vapor spray 6. It is to be understood that the carpet 2 has a substantial dimension in a direction into the plane of the figure. Accordingly, the apparatus of the present invention also will have a corresponding dimension in such direction. This may be by providing several chambers 8 spaced in such dimension, i.e. across the width of the carpet. Alternatively, the apparatus shown in Figure 1 could extend entirely across the width of the carpet. Figure 2 illustrates a modification of the embodiment of Figure 1. Thus, whereas in Figure 1 the carpet 2 passes through the enclosure 16, in the embodiment of Figure 2 the carpet passes around a portion of the periphery of an enclosure 16a which has therein, in the area of the application position, a plurality of small holes 20. The holes 20 are shown schematically only, and in actual practice such holes would be of a size and spacing to ensure that the entire surface of the carpet moving across the exterior of enclosure 16a is contacted by the vapor spray 6 passing through holes 20. The embodiment of Figure 2 otherwise is similar to the embodiment of Figure 1. Figure 3 illustrates another modification of the embodiment of Figures 1 and 2. In this embodiment, the enclosure 16b has therethrough, in the area of the application station, a single large opening 22. The carpet 2 is caused to move over the exterior of enclosure l6b and across opening 22 to form a seal of the opening. Thus, the vapor spray 6 passes through opening 22 to dye the carpet 2 moving therepast, and the carpet seals opening 22 to avoid any loss of temperature control within enclosure 16b. Figure 4 illustrates a further modification of the embodiment of Figure 1. Thus, in the embodiments of Figures 1-3, dye and steam are introduced separately into a blending chamber 10. However, it is possible to supply the vapor spray 6 simply by heating the dye, in liquid form, to steam and then supplying such heated dye, for example by a conduit lOa and nozzle 14, thereby discharging the vapor spray 6 toward the carpet. In other words, when the dye is in liquid form it may be heated to a suitable temperature to form a blend of dye and steam which may be discharged toward the carpet. It is to be understood that the embodiment of Figure 4 may include the other features discussed with regard to Figure 1. Furthermore, the type of supply of the vapor spray shown in Figure 4 may be employed with the enclosure structures of Figures 2 and 3. In all of the above discussed embodiments of Figures 1-4, the temperature of the vapor spray 6 has been controlled so as to achieve substantially instantaneous fixation of the dye on the carpet 2. In Figure 5 there is shown a carpet 200 moved continuously in the direction indicated by the arrow by conventional moving structure. The carpet is moved past an Åappli- cation position or station indicated generally by 40. At station 40 there is sprayed onto the carpet a liquid dye formu-lation heated to a temperature below the boiling point of the liquid. Thus, the heated dye formulation is introduced through a supply conduit 60. The formulation supplied to conduit 60 may be preheated, or the exterior of the conduit may be heated, thereby to heat the dye formulation. The dye formulation is discharged from conduit 60, for example through nozzle BOin the form of a spray 100 toward the carpet 200 at the application position 40. A nozzle 80as such is not necessarily required, and the spray 100 may be discharged from conduit 60 simply through an opening therein, or conduit 60 simply may be in the form of a tube having an open lower end. In accordance with a novel feature of the present invention, the temperature of the dye spray 100 is controlled such that the dye contacts the carpet 200 at a temperature sufficient to achieve substantially instantaneous fixation. Temperature control specifically is achieved by enclosing the spray 100 by an enclosure 120. Enclosure 120 is of relatively small volume and maintains a temperature control to prevent the temperature of the dye spray MDO from substantially decreasing prior to contact with the carpet 200. The specific size of enclosure 120 is not particularly important, as long as it is small enough to achieve the above results. In actual practice, the length of enclosure 120 in the direction of movement of the carpet has been approximately 66 cm. The application of the heated dye spray achieves two functions. Firstly, the spray of the dye essentially transports the dye into the carpet. Secondly, the heated liquid contains sufficient energy to achieve substantially instantaneous fixation of the dye to the carpet. The spacing of the nozzle 80 from the carpet, the temperature of the liquid, and the pressure of the spray supplied from nozzle 80 will vary substantially from installation to installation, depending upon the dye employed, the carpet employed, the speed of the carpet, etc. It is believed that one of ordinary skill in the art, upon considering the present disclosure, would understand how to vary these parameters while achieving performance of the present invention. It generally is believed that the spacing from the nozzle 80 to the carpet 200, according to this embodiment of the invention, may vary from 2,5 to 18 cm, more preferably from approximately 6,3 to 12,7 cm. This however is considered to be exemplary only and not in any way limiting to the scope of the present invention. Such spacing obviously must be not so great so as to prevent the dye spray from being driven into the carpet. Furthermore, the pressure of the dye spray must be sufficient to achieve such driving force. Additionally, the particular temperature of the dye formulation supplied to conduit 60 and also the temperature of the dye spray as it contacts the carpet will vary from situation to situation, depending on a number of parameters, for example the dye employed and the carpet employed. It is believed that those skilled in the art would understand how to achieve the substantially instantaneously fixation of the present invention for a particular dye and a particular carpet. The above discussion has been with regard to the application of a dye to a carpet. The present invention particularly is suitable for the application of an acid dye to a polyamide carpet, for example a natural polyamide such as wool, or a synthetic polyamide such as nylon. It is believed that the heat of the dye spray 100 opens up cavities, and that this diffusion is enhanced by the polar attraction of the acid dye to the polyamide material. It is believed that the process and apparatus of the present invention could be employable with dispersed dyes and/or polyester substrate materials, but this probably would required additional steaming, Certain dyes which are of particular interest in carrying out the present invention are: azo dyes of the formula EMI15.1 wherein A is hydrogen, unsubstituted or substituted alkyl, -CONR2, -S02NR2, -SO2R, wherein R is alkyl, cycloalkyl, aryl and aryloxy, and B is hydrogen, halogen, alkanoylamino, alkoxycarbonylamino, alkylsulfonyiamino or arylsulfonylamino; anthraquinone dyes of the formula EMI15.2 wherein one Y is hydrogen or alkyl and the other is alkanoylamino or hydroxyalkylsulfamoyl and Z is hydrogen or alkyl; ; azo dyes of the formulae EMI16.1 wherein B1, B2 and E1 are hydrogen, cl-c4-alkyl or C1-C4-alkoxy, and X is straight-chain or branched-chain C1-C4 alkyl, or straight-chain or branched-chain C2-C4-hydroxyalkyl, and each of Z1, 22 and 23 independently of the other is hydrogen, halogen, C1-C4 alkyl or C1-C4 alkoxy; 1: :2 cobalt complex dyes of the formula EMI16.2 in which (R1)0-2 represents 0 to 2 substituents R1 which, independently of each other, can be C1-4-alkyl, C1-4- alkoxy, halogen, nitro, sulfo, sulfamoyl, N-C1-4-alkyl- sulfamoyl, N-C1-2-alkoxy-C1-2-alkylsulfamoy, phenylaminosulfonyl, carboxyphenylaminosulfonyl, C1-4-alkylsulfonyl or acetylamino; 1:2 chromium complex or 1:2 cobalt complex dyes of the formula EMI17.1 in which R2 is defined in the same way as R1 in the previous formula, and (R3)02 represents 0 to 2 substituents R3 which, independently of each other, can be halogen or sulfamoylt 1:2 cobalt complex or 1: :2 chromium complex dyes of the formula EMI17.2 in which R4 is defined in the same way as R1 in the prior formula and R5 is hydrogen, acetylamino, methoxycarbonylamino or methylsulfonylamino; 1:2 cobalt or 1:2 chromium complex dyes of the formula EMI18.1 in which (R6)1-2 represents 1 to 2 substitutents R6 which, independently of each other, can be sulfo or nitro; 1:2 chromium complex dyes of the formula EMI18.2 in which R7 is defined in the same way as R1 in the prior formula, and (R8)l-2 represents 1 to 2 substituents R8 which, independently of each other, can be halogen, methyl or sulfo, or in which 2 adjacent substituents R8 can form a closed bridge member -S02-CH2-0-; 1:2 cobalt or 1: :2 chromium complex dyes of the formula EMI18.3 in which R9 is defined in the same way as R6 in a prior formula, and RlO is hydrogen or hydroxyl; dyes of the formula EMI19.1 in which X is oxygen or sulfur, Ril is hydrogen or C1-4- alkyl, Y is a substituted or unsubstituted aryl radical, and n is 1, 2 or 3, the benzene ring A can be substituted by halogen, and the benzene rings B and D, independently of each other, can be substituted by halogen, C1-4-alkyl, C1-4-alkoxy or a radical of the formula -(0-CH2CH2-)- -R12 in which R12 is hydrogen, methyl or ethyl; dyes of the formula EMI19.2 in which Z is -O-SO2-, -NH-S02-, -NH-CO- and the phenyl rings A, B and D can be substituted as given in the previous formula; 1: :2 cobalt complex dyes of the formula EMI20.1 in which R13 is defined in the same way as R1 in the first formula, and R14 is hydrogen or phenylt 1:2 chromium complex dyes of the formula EMI20.2 in which (R15)0-2 represents O to 2 substituents R15 which, independently of each other, can be C1-4-alkyl, C1-4-alkoxy, halogen, carboxyl or sulfo; and 1:2 chromium mixed complex dyes of the formula EMI21.1 <tb> <SEP> OLH <SEP> RO <tb> <SEP> II <SEP> I <SEP> \ <SEP> / <tb> <SEP> :--NPIILNN- <SEP> <tb> <SEP> Ir <SEP> 1 <tb> <SEP> (R17S1-2 <SEP> k <tb> <SEP> OH <SEP> HO <SEP> VH <SEP> HO\ <tb> + <SEP> t <SEP> N <SEP> N+ <SEP> \ <SEP> + <tb> O <SEP> a <SEP> \a/ <SEP> I. <SEP> <tb> V <SEP> a <SEP> + <SEP> I <SEP> \. <tb> V <tb> <SEP> R18 <SEP> V <SEP> \. <tb> <SEP> (i;6;1-2 <SEP> R18 <SEP> < <tb> <SEP> OH <SEP> HO, <tb> 1:1 <SEP> chromium <SEP> complex <SEP> ig <SEP> .I <SEP> -N-N-/. <tb> <SEP> I. <SEP> ';-NIN-- <SEP> / <tb> <SEP> R <SEP> V <SEP> <tb> <SEP> R19 <SEP> 20 <SEP> \\ <SEP> // <tb> in which (R16)l-2 represents 1 to 2 substitutents R16 which, independently of each other, can be sulfo or nitro, (R17)-1-2 represents 1 to 2 substitutents R17 which, independently of each other, can be nitro, halogen, methyl or acetylamino, R18 is defined in the same way as R17 and independently of the latter, Rlg is defined in the same way as R17 and independently of the latter, and R20 is acetylamino, methoxycarbonylamino, ethoxycarbonylamino, methylsulfonylamino or N,N-dimethylaminosulfonyl. Specific examples of dyes which are preferred for use according to the instant invention are the red azo dyes of the formulae EMI22.1 EMI23.1 a mixture of 20 parts of the red dye EMI23.2 and 80 parts of the red dye EMI23.3 a mixture of 20 parts or the red dye EMI24.1 and 80 parts of the red dye EMI24.2 a mixture of 50 parts of the red dye EMI24.3 and 50 parts of the red dye EMI25.1 a mixture of 50 parts of the red dye EMI25.2 and 50 parts of the red dye EMI25.3 a mixture of 30 parts of the red dye EMI26.1 and 70 parts of the red dye EMI26.2 the orange dye of the formula EMI26.3 the yellow dyes of the formulae EMI26.4 EMI27.1 blue anthroquinone dyes of the formulae EMI27.2 EMI28.1 or mixtures of anthraquinone dyes of formulae (I) and (III), (I) and (V), (II) and (III) and (II) and (V) wherein the ratio is 20:80 to 80:20, especially 40:60 to 60:40; especially mixtures of anthraquinone dyes of formulae (I) and (III) wherein the ratio is 48:52 or mixtures of anthraquinone dyes of formulae (I) and (V) wherein the ratio is 52:48; and metal complex dyes such as the yellow 1:2 cobalt complex of EMI28.2 the bordeaux 1:2 cobalt complex of EMI29.1 and the black dye obtained on mixing EMI29.2 <tb> <SEP> .st <tb> HO <SEP> S,I <SEP> S <SEP> . <SEP> <tb> <SEP> 3 <SEP> / <SEP> \\'/ <SEP> \/ <SEP> \ <tb> <SEP> It <SEP> I <tb> <SEP> 0 <SEP> 0 <SEP> a <tb> <SEP> s <SEP> 1 <tb> <SEP> $ <SEP> vf <SEP> Z <SEP> N-N: <SEP> 8 <tb> <SEP> 0-0 <tb> <SEP> dt <tb> <SEP> 0 <tb> <SEP> 0a0 <tb> <SEP> 0 <SEP> 1:1 <SEP> 0 <tb> <SEP> - <SEP> N-. <SEP> 2 <tb> <SEP> I <SEP> II <tb> <SEP> 0 <SEP> II <tb> <SEP> ; <SEP> 1:2 <SEP> cobalt <SEP> complex <tb> <SEP> t <SEP> / <tb> <SEP> .f <SEP> ,oCB3 <tb> <SEP> 0 <tb> <SEP> IIi <tb> <SEP> 0 <tb> It is to be understood however that the present invention is not limited to the application of a dye to a carpet, but may be employed for application of a dye to another type of textile substrate or for the application of another chemical to a carpet or other textile substrate. Specifically, it is intended that other chemicals which may be applied in accordance with the present invention are softeners, anti-static chemicals, anti-soiling chemicals, waterproofing chemicals, anti-microbial chemicals, etc. Furthermore,it is contemplated that the present invention add any of the above chemicals, or other chemicals, along with a dye. It is to be understood that the carpet 200 has a substantial dimension in a direction into the plane of the figure. Accordingly,the apparatus of the present invention also will have a corresponding dimension in such direction. This may be by providing several conduits spaced in such dimension, i.e. across the width of the carpet. Alternatively, the apparatus shown in Figure 5 could extend entirely across the width of the carpet. Figure 6 illustrates a modification of the embodiment of Figure 5. Thus, whereas in Figure 5 the carpet 200 passes through the enclosure 120, in the embodiment of figure 6 the carpet passes around a portion of the periphery of an enclosure 120b which has therethrough, in the area of the application station, a single large opening 160. The carpet 200is caused to move over the exterior of enclosure 120b and across opening 160 to form a seal of the opening. Thus, the spray 100 passes through opening 160 to dye the carpet 200 moving therepast, and the carpet seals opening 160 to avoid any loss of temperature control within enclosure 120b. Figure 7 illustrates a further embodiment of the present invention, and specifically a modification of the embodiment of Figure 6. Thus, in accordance with this embodiment of the present invention, the enclosure may be in the form of a confined channel leading from the conduit 60 orthe nozzle 80 and having a discharge end180. The substrate 200 is caused to move across the discharge end 180, whereby the dye formulation. is sprayed onto the substrate. Figure 7 illustrates the arrangment as being somewhat of a modification of the structure shown in Figure 6, but this merely is to indicate the provision of a curved surface across which the substrate moves. Any other configuration may be employed, as will be apparent to those skilled in the art. One possible advantage of the use of the structure shown in Figure 7 is that the interior of the casing surrounding channel 120c may be supplied with steam to maintain the desired temperature of the dye spray. In the present invention the dye pick-up is especially within the range of 300 to 6008 and more especially within the range of 400 to 500%. Example 1: A dye liquor is heated to 96-980C and sprayed at 3 atm through a row of nozzles onto a nylon 66 carpet as the carpet moves continuously through an enclosure of the type shown in Figure 5. The residence time of the carpet within the enclosure is of the order of 5 seconds and is adjusted as needed to obtain a 500% pick-up of the dye formulation. The following dye formulations were employed: Formulation 1: 0,480 g/l of the 1:2-cobalt complex of the dye of formula EMI32.1 0,046 g/l of the mixed 1:2-cobalt complex of the dyes of formula EMI32.2 0,176 g/l of the mixture of the 1:2-chromium complexes of the formulae EMI33.1 <SEP> /OH <SEP> HO <SEP> OH <SEP> HO\0 <SEP> -. <tb> o <SEP> // <SEP> z <SEP> o <SEP> o <SEP> N-. <SEP> 11 <SEP> \ <SEP> 0,15 <SEP> b & l <tb> <SEP> tn <SEP> o <SEP> o <tb> <SEP> /7 <SEP> OH <tb> <SEP> o <SEP> O2N\ <SEP> o <SEP> o <tb> <SEP> N-./' <SEP> \\ <tb> <SEP> 1.1 <SEP> Cr-complex <SEP> r <SEP> !N <SEP> = <SEP> .=. <SEP> 0,60 <SEP> ol <SEP> (3) <tb> <SEP> ./ <SEP> II <tb> <SEP> o <SEP> Mcl <SEP> NO2 <tb> <SEP> m <SEP> 1 <SEP> 2 <SEP> a <tb> <SEP> z <SEP> z <SEP> z <SEP> m <tb> <SEP> z <SEP> z <SEP> z <SEP> n <tb> <SEP> * <SEP> N <SEP> V <tb> p: <SEP> // <SEP> \ <SEP> m <SEP> // <SEP> + <SEP> o <SEP> > : <SEP> // <SEP> + <SEP> o <tb> o <SEP> e\ <SEP> = <SEP> o <SEP> N-.1 <SEP> \\ <tb> <SEP> II <SEP> I <tb> <SEP> Z <SEP> 0 <SEP> ;=e <SEP> = <tb> <SEP> cV <SEP> V <tb> <SEP> x <tb> <SEP> NO2 <SEP> I <tb> <SEP> CH <SEP> \ <SEP> / <SEP> w <SEP> x <tb> <SEP> 3 <tb> <SEP> 20 <SEP> &verbar; <SEP> O <SEP> :E: <tb> <SEP> b <tb> <SEP> Z <SEP> H <SEP> a <tb> <SEP> w <SEP> <tb> <SEP> :U <SEP> l <SEP> < <SEP> o <tb> <SEP> o <SEP> < <tb> <SEP> A <tb> <SEP> ll <SEP> l <tb> <SEP> N <tb> <SEP> o <tb> <SEP> 7 <tb> <SEP> o <tb> 2,000 g/l of the ammonium sulfate ester of ethoxylated nonylphenol 0,50 g/l of ethoxylated nonylphenol. Formic acid as needed to adjust pH to 4.0 Good dye fixation is obtained. Formulation 2: 0,150 g/l of the dye of formula EMI34.1 0,1 g/l of the dye of formula EMI34.2 0,125 g/l of the dye of formula EMI34.3 2,0 g/l of the ammonium sulfate ester of ethoxylated nonylphenol 0,5 g/l of ethoxylated nonylphenol Formic acid as needed to adjust pH to 4.0. Formulation 3: 0,35 g/l of the dye of formula (4) 0,35 g/l of the dye of formula (5) 0,10 g/l of the dye of formula (6) 2,00 g/l of the ammonium sulfate ester of ethoxylated nonylphenol 0,50 g/l of ethoxylated nonylphenol Formic acid as needed to adjust pH to 4.0 Formulation 4: 0,30 g/l of the dye of formula (4) 0,20 g/l of the dye of formula (5) 0,25 g/l of the dye of formula (6) 2,00 g/l of the ammonium sulfate ester of ethoxylated nonylphenol 0,50 g/l of ethoxylated nonylphenol Formic acid as needed to adjust pH to 4.0. There is obtained with each formulation good dye fixation. By adjusting the pH to 8-10 with trisodium phosphate instead of to 4.0, similar good results can be obtained on nylon 6 carpets with the above formulations 2 to 4. Example 2: Using formulation 2 of Example 1 and the conditions of that example, but with the pH adjusted to 3.0 with formic acid, a wool carpet was similarly sprayed with dye solution. Again good dye fixation was obtained. Example 3: The dye liquor is heated to 1000C, pumped at 2,7 atm to the spray nozzle and mixed with steam 1,6 atm. The hot liquor is sprayed onto the carpet in a steam filled enclosure 16 (Figun 1) with resultant 448% dye pick-up. The following dye formulations were run at 448% pick-up on various substrates. Formulation 1: 0,234 g/l of the dye of formula EMI36.1 0,276 g/l of the dye of formula (5) of Example 1 0,276 g/l of the dye of formula (6) of Example 1 1,000 g/l of sodium dioctylsulfosuccinate 0,75 g/l of acetic acid to pH 4. Formulation 2: 0,48 gCllof the 1:2-cobalt complex of the dye of formula (1) 0,046 g/l of the mixed 1:2-cobalt complex of the dyes of formulae (2) 0,176 g/l of the mixture of the 1:2-chromium complex of the formula (3) 1,000 g/l of sodium dioctylsulfosuccinate 0,75 g/l acetic acid to pH 4. Formulation 3: 0,335 g/l of the dye of formula (4) 0,223 g/l of the dye of formula (5) 0,276 g/l of the dye of formula (6) 1,000 g/l of sodium dioctylsulfosuccinate 0,75 g/l acetic acid to pH 4. Carpet Substrates: Polyamide 66 Polyamide 6 superba setX Polyamide 6 (fluorocarbon) suessen and superba sett The shade difference between substrates was less than the difference obtained by cold spray method (Otting). Fiber cross sections show dye penetration of 50-75% versus 100% obtained by exhaust methods (dyed in back). Fastness testing (Xenon, waterbleed, crocking, ozone) show results comparable to exhaust methods. Although the present invention has been described and illustrated with respect to preferred embodiments thereof, it is to be understood that various modifications and changes may be made to the specifically described and illustrated features without departing from the scope of the present invention.

Claims: WHAT IS CLAIMED: 1. A process for applying and simultaneously fixing a chemical to a textile substrate, said process comprising: continuously moving said substrate past an application position; and at said application position spraying said chemical in vapor form, in the presence of steam as a carrier, or spraying a liquid formulation containing said chemical heated to a temperature just below the boiling point thereof, toward said substrate thus transporting said chemical or said heated formulation into said substrate at a temperature sufficient to achieve substantially instantaneous fixation of said chemical. 2. A process as claimed in claim 1, wherein said process comprising: continuously moving said substrate past an application position; and at said application position spraying said chemical in vapor--frm, in the presence of steam as a carrier, toward said substrate and thereby transporting said chemical into said substrate at a temperature sufficient to achieve substantially instantaneous fixation of said chemical. 3. A process as claimed in claim 1, wherein said process comprising: heating a liquid formulation containing said chemical to a temperature just below the boiling point thereof; continuously moving said substrate past an application position; and at said application position spraying said heated formulation toward said substrate thus transporting said heated formulation into said substrate at a temperature sufficient to achieve substantially instantaneous fixation of said chemical. 4. A process as claimed in claim 1, wherein said chemical comprises a dye. 5. A process as claimed in claim 4, wherein said dye comprises an acid dye. 6. A process as claimed in claim 4, wherein said dye comprises a metal complex acid dye. 7. A process as claimed in claim 1, wherein said textile substrate comprises a natural or synthetic polyamide substrate. 8. A process as claimed in claim 1, wherein said textile substrate comprises natural or synthetic polyamide carpet. 9. A process as claimed in claim 7, wherein said textile substrate comprises a wool carpet. 10. A process as claimed in claim 7 wherein said textile substrate comprises a nylon carpet. 11. A process as claimed in claim 1, wherein said chemical is a dye, and further comprising controlling the temperature of said vapor or heated dye formulation such that said dye contacts said substrate at a temperature to achieve substantially instantaneous fixation. 12. A process as claimed in claim 11, wherein said temperature controlling means comprises enclosing said vapor or dye spray, and thereby preventing substantial cooling of said dye and steam or said dye spray before contact thereof with said substrate. 13. A process as claimed in claim 2, wherein said spraying comprises supplying said chemical and said steam to a blending chamber, and discharging said vapor from said chamber toward said substrate. 14. A process as claimed in claim 2, wherein said spraying comprises heating said chemical in liquid form to steam, thereby forming said vapor, and directing said vapor toward said substrate. 15. An apparatus for applying a chemical to a textile substrate, said apparatus comprising: means for continuously moving a textile substrate past an application position; and means, at said application position, for spraying a chemical in vapor form, in the presence of steam as a carrier, or for spraying a liquid formulation containing said chemical, heated to a temperature below the boiling point thereof, toward the substrate and for transporting the chemical in vapor form or the heated formulation containing said chemical into the substrate at a temperature sufficient to achieve substantially instantaneous fixation of said chemical. 16. An apparatus as claimed in claim 15, wherein said apparatus comprising: means for continuously moving a textile substrate past an application position; and means, at said application position, for spraying a chemical in vapor form, in the presence of steam as a carrier, toward the substrate and for transporting the chemical into the substrate at a temperature sufficient to achieve substantially instantaneous fixation of said chemical. 17. An apparatus as claimed in claim 15, wherein said apparatus comprising: means for continuously moving a textile substrate past an application position; and means, at said application position, for spraying a liquid formulation containing said chemical, heated to a temperature below the boiling point thereof, toward the substrate and for transporting the heated formulation containing said chemical into the substrate at a temperature sufficient to achieve substantially instantaneous fixation of said chemical. 18. An apparatus as claimed in claim 15, wherein the chemical is a dye, and further comprising means for controlling the temperature of said vapor or said dye spray such that the dye contacts the substrate at a temperature sufficient to achieve substantially instantaneous fixation. 19. An apparatus as claimed in claim 18, wherein said controlling means comprises an enclosure housing said vapor or said dye spray and preventing a substantial decrease in the temperature thereof. 20. An apparatus as claimed in claim 19, wherein said enclosure also houses that portion of the substrate at said application position. 21. An apparatus as claimed in claim 19, wherein said enclosure has therethrough, in the area of said application position, an opening through which passes the dye, and said moving means causes the substrate to move in contact with the exterior of said enclosure and pass over said opening while forming a seal of said opening. 22. An apparatus as claimed in claim 19, wherein said enclosure comprises a confined channel having a discharge end, and said moving means causes the substrate to move across said discharge end of said channel. 23. An apparatus as claimed in claim 19, wherein said enclosure has therein, in the area of said application position, a plurality of holes enabling passage of the vapor containing the dye therethrough, and said moving means causes the substrate to move in contact with the exterior of said enclosure across said holes. 24. An apparatus as claimed in claim 16, wherein said spraying means comprises a blending chamber, means for supplying said chemical to said chamber, means for supply ing steam to said chamber, and means for discharging said vapor from said chamber toward the substrate. 25. An apparatus as claimed in claim 16, wherein said spraying means comprises means for heating the chemical in liquid form to steam, and then for directing said vapor toward the substrate.

Inventors: CHAPPELL, JOSEPH SHEDD
Applicants: CIBA-GEIGY AG
Application year: 1984
Main classification: D06B1
IPC codes: D06B19, D06B1