STAIN RESISTANT MULTICOLOR TEXTURED CUT PILE CARPET

Abstract: Multicolored stain-resistant nylon carpet is prepared by tufting a space dyed cationic-dyeable carpet nylon, dyed with an acid or premetallized dye intermixed and tufted with an acid dyeable nylon and overdyed with an acid dye to selectively dye the acid dyeable fibers but not the already space dyed yarns.

Description: STAIN RESISTANT MULTICOLOR TEXTURED CUT PILE CARPET This invention relates to textured, heathered, multicolored carpet having improved stain resistance, lightfastness and ozone resistance of nylon, especially nylon carpet. Background of the Invention Stain resistant nylon carpets enjoy significant market acceptance. Stain resistance is typically imparted to nylon by treating the fiber as a solid filament or in a carpet form by the topical application of a chemical finish as described in the following U.S. patents to Monsanto: U.S. 4,501,591; 4,592,940; and 4,839,212. The low acid pH necessary to fix this stain resistant finish has the adverse property of greatly altering the shade of the cationic dye which is normally used on this cationic dyeable fiber, precluding its use as a styling factor to obtain multicolor effects in subsequent carpet. However, by using cationic dyeable nylon, which has been previously dyed with acid dyes, in either a solid shade or, preferably, space printed to give multiple short spacings of color, this complication is overcome. Nylon carpet fiber is generally classified as to type, depending upon its receptivity to acid dyes and basic or cationic dyes. Cationic dyeable nylons contain sufficient SO,H groups or COOH groups within the polymer structure, which groups are receptive to cationic or basic dyes to render the fiber dyeable to a cationic dye. Acid dyeable nylons are essentially conventional nylons, such as polyhexamethylene adipamide and polyeaprolactarn. Acid dyeable nylons vary as to type and are characterized as being weakly dyed with acid dyes, average dyed with acid dyes, or deeply dyed with acid dyes. Cationic dyeable nylons generally exhibit inherent stain resistant properties, especially to acid- ype stains, as compared to other nylon types used for carpet. Cationic dyeable nylons are dyeable with selected cationic dyes, but suffer from poorer lightfastness, especially in light shades, than do comparable shades dyed on acid dyeable nylon using monosulfonated or premetalized acid dyes. This has resulted in the under-utilization of cationic dyeable nylon as a carpet fiber. The fiber's inherently useful properties which otherwise make it attractive as a carpet fiber previously have not been fully realized. Initial dyeing is accomplished using the space dyeing or intermittent dyeing technique in which the yarn within a given area or space is dyed a particular color, the color and spaces varying throughout the length of the yarn according to random or predetermined orders. Dyeing carpet yarn is described in U.S. 4,206,735 which relates to a carpet prepared by space dyeing a polyester or polypropylene yarn then tufting the space dyed yarn with another yarn, undyed and having a susceptibility to a dye to which the polyester or polypropylene space dyeing yarn is not susceptible, followed by dyeing the undyed yarn taking care that the selective dyeability of the undyed yarn does not interfere with the previously space dyed yarn. Tak dyeing is used to provide coloration for the nylon tufts and Tak dyeing is explained in U.S. 4,146,362. Another type of space dyeing is described in U.S. 4,033,717 to Whitaker in which a continuous filament yarn is knit into a prefabric such as a tube or a sock, selectively dyed in a predetermined pattern using various colors, then deknitted, wound onto cones and heated to develop the color. This is also known as a knit/deknit process. When tufted into a carpet, the tufts of the space dyed yarn are arranged randomly or preferably in predetermined blocks or areas. Research Disclosure 17913 (March 1979) uses the space dyed yarns of the Whitaker patent, combines them with undyed yarns, then overdyes to a different color to provide a carpet having different color combinations. Space dyed yarns may also be prepared using "resist" techniques to treat the fabric to "resist" the type of dye employed, as described in Jilla, U.S. 3,989,453. Piece dyeing carpets using carpet pile made from two or more different classes of .yarns, one yarn being susceptible to one type of dyeing and the other class of yarns susceptible to a different type of dye, is described in U.S. 3,439,999 DETAILED DESCRIPTION OF THE INVENTION This invention provides a procedure for preparing stain resistant carpet having an attractive multicolored appearance. A multicolored carpet is created according to this invention using cationic dyeable nylon yarn, which has been space dyed or printed to multiple colors with premetalized or acid dyes. This multicolored yarn is combined with acid dyeable nylon yarn, tufted into a carpet, then overdyed with an acid dye. The acid dye fixes to the acid dyeable nylon but not the cationic dyeable nylon leaving the multicolored spaced dyed yarn clear and distinct against a contrasting field of solid color yarns. Variations in the colors of the multicolored cationic dyeable nylon yarn, the shade of the background acid dyeable nylon yarn, the relative amounts and positioning of the two types of yarn, their construction into a carpet and other factors all provide styling variations. The preferred techniques for dyeing the cationic dyeable nylon yarns include exhaust dyeing, pad/steam dyeing, continuous carpet dyeing and the like. Illustrative examples for dyeing procedures thought to be suited to the process of this invention are: Pad/Steam - A dye bath is prepared as follows: guar gum (Celcagum V-60) 0.3 antifoam (Sedgekill AO) 0.15 wetting/penetrating agent (Dyebath SS-75) 0.7 premetalized acid dyestuff % (pH adjusted to 6.0 with monosodiu phosphate) and applied to the cationic dyeable nylon at wet pickup of 90 to 140% based on the weight of the -yarn. For proper fixation, the yarn is steamed for 6 to 12 minutes then washed, extracted, treated with a fluorchemical soil repellant and dried. Exhaust Dyeing - an aqueous dyebath is prepared containing the required amount of premetalized acid dyestuff, the pH adjusted to 6.0 with monosodium phosphate and, optionally, up to 0.5% Irgasol SW, a weakly cationic complexing agent which retards the strike of the acid dye by complexing with the dye and then slowly releasing the dye to the fiber as the temperature rises, is added. The dyebath temperature, initially at 80°F, is increased at a rate of 2°F per minute to 140°F and held there for 15 minutes, then raised again at 2°F per minute to 208-212°F. Cationic dyeable nylon is then exhaust dyed for 30 to 60 minutes or longer as needed to achieve the desired depth of shade. Illustrative cationic dyeable nylons include: Filament: DuPont Monsanto Allied BASF "Antron" Type 924 "Ultron" 2360-68-JEJ "Antron" Type 494 "Anso" Type 7L422 "Antron" Type 754 "Anso" Type 753 "Antron" Type 854 "Antron" Type P695 "Antron Luraena" Type P-807A Nylon Staple: "Antron" P-676A "Ultron"-750-JES "Anso" Type 591 "Zeftron" W118S "Antron" P-683A "Antron" 543A "Antron" 547A An affinity for cationic dyes is usually imparted by the incorporation of a monomer containing sulfonic acid groups. Thus one such modification of a polyamide fiber is obtained by adding a certain amount of sulphoisophthaiic acid prior to polymerization. Premetalized and acid dyes considered suited to the process are selected from the following list: Trade Name Haniifaeture: Color Tηr!«»y N?.τn_. K'_ι_r.b Irganol Brilliant Yellow Ciba-Geigy Acid Yellow 127 3GLS Iεolan Black RL, Liq Mobay Acid Black 139 Bordeaux R 220% Acid Red 182 Brown S-RL Acid Brown 413 Grey KP- BL 200 Navy Blue S-RL Acid Blue 335 Red S-RL- Acid Red 414 Yellow K-FRL 200% Acid Yellow 137 Yellow NW 250% Acid Yellow 151 139 Yellow S-GL Acid Yellow 232 Lanaperl Blue GN 200 Blue GN 621 Fast Navy Blue R 200 Turquoise Blue GL Lanaεyn Black BGL 200% Black BRL 200% Black S-DL, Liq . Black S-GL, Liq Black S-RL, Liq Bordeaux GRL Bordeaux RL Brown 2GL Carbon BL Dark Brown S-BL Dark Brown S-GL Grey BL Grey BLR 1816 Navy S-BL, Liq Navy S-DNL Olive Green S-4GL Olive S-2GL Orange S-RL Red 2GLN Red S-G, Liq Rubine S-5BL Yellow NW 1390 Yellow 2RL Yellow S-2GL, Liq Levalan Brown I-BRL Cold Mobay Acid Brown 330 SOL Dark Brown I-TL Acid Brown 331 T ade Name Mar fart.nrer Color Tndex Name Num Neutral Yellow EKL ORC Acid Yellow 121 Ex Cone Neutral Yellow 2GL Acid Yellow 129 Ex Neutral Yellow GLSN Acid Yellow 114 Neutral Yellow WN Acid Yellow 151 250% The following level dyeing acid dyes are thought to wor particularly in the light depths but do not build very well as strength iε increased: Nylanthrene Black GLRT C& Black GLWC Blue B-AR 67% Liq Blue B-AR 200% Blue B-GA Blue B-NB Blue GLF Blue LGGL Brilliant Blue 3BLF Brilliant Blue 2RFF Brilliant Yellow Acid Yellow 49 4NGL Brilliant Yellow B-NGL Brilliant Yellow Acid Yellow 219:1 B-4RK Brilliant Yellow CGL p.a.f. Brown RSM Navy LFWG Orange B-GN Orange 3G Acid Orange 156 Orange SLF Cone Acid Orange 116 Pink BLRF (pat) Red B-2B Red B-2BSA Acid Red 266 Red B-CLN Cone Red 2RDF Red 4RL (pat) Rubine 5BLF Acid Red 299 Scarlet B-YKS Scarlet GYL Ex (pat) Scarlet YDL p.a.f. Yellow FLW Acid Yellow 159 Yellow BAR Liq Acid Yellow 152 Yellow SL 200% Acid Yellow 198 Yellow SL Liq Acid Yellow 198 Tτ-ade Name Manufacturer Nylotaine Black D-2R ICI Blue A-G Cone Grains Blue A-2R Blue B-3G Blue C-B Blue C-2G Blue C-3R Bordeaux C-B Bordeaux C-3B Green C-G Green C-3G Navy C-2R Red A-B Red A-2B 100% Red B-3B Red C-2B Red C-BA Red C-G Violet C-B Yellow A-G Yellow A-G 33% Pεt Yellow A-2GA 200% Yellow A-4R 150 Nylosan Blue 2AL/C-2AL Sandoz Acid Blue 25 6205 Blue E/C-BGL 200% Blue E/C-BRL Acid Blue 288 Blue E/C-GL Acid Blue 72 Blue F-GBL Acid Blue 127 Blue F-L Acid Blue 80 6158 Blue F-RL Sandoz Acid Blue 247 Blue N-BLN Blue N-5GL 200% Blue PRL Bordeaux E-2BL Bordeaux N-BL Brilliant Blue N-FL Brilliant Green F-6GL Brown N-2R Green F-BL, 200% Navy N-RBL Cone Orange C-GNS/E-GNS Pat Orange E-2GL Orange N-RL Red E-BM Red F-5B Red F-BR Red F-2R/C-2R Red F-RL Red F-RS, Cone Trade Name Hsnn ^t,n- r Fast Red GN Mobay Fast Rubine A5BL 167 Fast Rubine A-5BLW Faβt Violet A-BB Fast Yellow A-3GL Faβt Yellow A-3RL Faβt Yellow 4GL 175 Red 2BL 200 Red 2BL Liq 33 Red 2BL Disp 67 Red BR-CL Diep 83 Red BR-CL 250 Red CD-R Red FL 200 Red FL Liq 33 Red FL Disp 67 Yellow FGL 200 Yellow FGL Liq 66 Yellow K-RNL 200 Yellow Brown 3GL Page numbers reference AATCC* Buyer's Guideline for the Textile Wet Processing Industry ♦American Association of Textile Chemists and Colorists EXAMPLE 1 Cationic dyeable yarn (Antron type 854) knit into a tube was continuously dyed in a laboratory lima pad/steam unit with 100% wet pickup with the indicated premetalized dyes depending upon the shade desired, then steamed for approximately 8 minutes to provide the desired base shade. The base shade-dyed tube was then overprinted using a silk screen process: Pad baths for the background shade were: Gray: Irgalan Bordeaux EL -015% Irgalan Yellow 3RL .015% Irgalan Blue 3RL .1487% Light Gold: Irgalan Yellow 3RL Celcagum V-60 Dyebath SS-75 Each pad bath also included Celcagum V-60 (.3%) and Dyebath SS-75 (.7%) and was adjusted to pH 6 with MSP. Print pastes in 4 shades were prepared from a base of thickener (Lyngum CP-3) 2.35%, penetrant (Tergitol) 1%, an antifoaming agent (Antifoam CK-2) 0.15% and adjusted to pH 6.0 with MSP. Dyes used for the 4 shades were: dark gold: Irgalan Yellow 3RL 1% bright blue: Irgalan Brilliant Blue 7GS 0.25% burgandy: Irgalan Bordeaux EL 200% 1% green: Irgalan Brilliant Blue 7GS 0.25% Irgalan Yellow 3RL 0.25% The printed samples were fixed with steam, washed and dried. The print design was satisfactorily fixed to the nylon tube with good crockfastness. This dyed and space printed product offers a styling versatility advantage over solution dyed nylon, in which pigment is extruded with the polymer, by allowing multiple colors on one yarn while maintaining the antistaining advantage inherent in cationically dyed nylon yarns. Additionally a skein of "Antron Lumena" P-807A solution pigmented yarn (colored pigment is incorporated into the polymer prior to extrusion into filament form) which also exhibits cationic dyeable properties, was printed with the same dark gold, bright blue and burgundy formulation above. This was followed by fifteen minutes atmospheric steaming at 210°F, washing and drying. The resulting overprint with the premetalized acid dye was judged to have acceptable crock fastness and performance as a product styling tool. EXAMPLE 2 Three different space dyed ("Duracolor") single yarns (premetalized acid dyes on -cationic Dupont type 494A Antron) prepared in the manner of Example 1 were plied with a natural regular acid dyeable type 1608 Monsanto nylon singles yarn. All three yarns were then Superba Frieze heat set to lock in the twist. The three different heatset yarns were then tufted into carpet in an A,B,C needle thread up. The resulting carpet was then overdyed on the laboratory Kuster dye range using two different methods: (A) Wet out with water followed by Kuster flood application of a solid shade acid dye formula. (B) A thin gum layer of 1000-2000 cps viscosity was applied to the tips of the carpet followed by a Kuster flood shade similar to A above. Dye Formulation: (A) Wet Out: Water pH 4.Q Flood shade: .17% "Progacyl" D49 DW* .30% Z-Wet wetting agent .40% Dyebath ACB .20% Monosodium Phosphate Monosulfonated acid dyes pH 4.0; 400% wet pickup (B) Gum Layer: .85% "Progacyl" D-49 DW* .25% Antifoam CK-2 .20% MSP (monosodium phosphate) 2.0% Penetrant SDP-2 Kuster Flood: .20% "Progacyl" D-49 DW* 2.0% Formic acid .30% Penetrant KB .10% Antifoam CK-2 Monosulfonated acid dyes * a derivatized guar gum thickener of Rhone-Poulenc Similar carpets were tufted using different yarns all containing a cationic dyeable nylon space dyed with premetalized acid or acid dyestuffs plied with a greige regular acid dyeable nylon.

Claims: WHAT IS CLAIMED IS: 1. A process of preparing a stain resistant multicolored carpet comprising the successive steps of: (a) space dyeing a cationic-dyeable nylon yarn with an acid dye or a premetalized dye at a pH of less than 7.0 and fixing the dye to the fibers, the cationic dyeable nylon yarn dyed into predetermined colors, a predetermined pattern, or both, to intermittently dye the yarn different colors along the length thereof; (b) tufting the space dyed yarns of step (a) and an acid dyeable nylon yarn into a carpet; and (c) dyeing the carpet prepared in step (b) with an acid dye to selectively dye the acid dyeable nylon fibers and not the space dyed cationic dyeable nylon fibers, to produce a multicolored stain resistant carpet. 2. The process of claim 1, in which the cationic dyeable fibers are dyed at a pH from about 4.0 to 6.5. 3. The process of claim 1, in which a premetalized dye is used in step (a). 4. The process of claim 1, in which an acid dye is used in step (a) . 5. The process of claim 1, including the additional step of (d) applying a fluorocarbon soil repellant to the carpet. 6. A multicolored nylon textured cut pile carpet having improved stain resistance composed of space dyed cationic dyeable nylon yarn dyed to two or more different shades with an acid or premetalized dye intermixed and tufted with an acid dyeable nylon dyed to a background shade with an acid dye.

Inventors: GUESS ROY E, JENKINS WILLIAM G, GUESS, ROY, E., JENKINS, WILLIAM, G.
Applicants: BURLINGTON INDUSTRIES INC, BURLINGTON INDUSTRIES, INC.
Application year: 1992
Main classification: D06P3
IPC codes: D05C17, D06M13, D06M101, D06P1, D06P3, D06P5, D06P7