Deep sublimation dyeing of fibrous composites

A method for dyeing a textile composite, the method comprising:

• coating at least a portion of a first surface of a sublayer with a solid sublimation dye;
• incorporating the sublayer containing the solid sublimation dye into the textile composite, the textile composite comprising at least a first layer adjacent the first surface of the sublayer;
• and
• activating the solid sublimation dye to a gas sublimation dye that permeates the first layer from the first surface of the sublayer and solidifies within the first layer,
• wherein the sublayer comprises a primary backing, and
• wherein incorporating the sublayer comprises tufting yarn through the sublayer to form tufted yarn loops adjacent the first surface and tufted yarn back-laps adjacent a second surface of the sublayer opposite the first surface, the tufted yarn loops comprising the first layer of the textile composite and the tufted yarn back-laps comprising a second layer of the textile composite.

A method for dyeing a textile composite, the method comprising:

• coating at least a portion of a first surface of a sublayer with a solid sublimation dye;
• incorporating the sublayer containing the solid sublimation dye into the textile composite, the textile composite comprising at least a first layer adjacent the first surface of the sublayer, wherein incorporating the sublayer into the textile composite comprises
• placing a plurality of fibers adjacent the first surface of the sublayer to form the first layer;
• and
• needle-punching fibers from the plurality of fibers through the first surface of the sublayer to form a needle-punched textile composite;
• activating the solid sublimation dye to a gas sublimation dye that permeates the first layer from the first surface of the sublayer and solidifies within the first layer.

A method for dyeing a textile composite, the method comprising:

• coating at least a portion of a first surface of a sublayer with a solid sublimation dye;
• incorporating the sublayer containing the solid sublimation dye into the textile composite, the textile composite comprising at least a first layer adjacent the first surface of the sublayer;
• and
• activating the solid sublimation dye to a gas sublimation dye that permeates the first layer from the first surface of the sublayer and solidifies within the first layer,
• wherein incorporating the sublayer into the textile composite comprises laminating the first layer to the first surface of the sublayer, the solid sublimation dye disposed between the first layer and the face layer, and
• wherein activating the sublimation dye further comprises simultaneously laminating the first layer to the first surface and activating the solid sublimation dye.

A method for dyeing a textile composite, the method comprising:

• coating at least a portion of a first surface of a sublayer with a solid sublimation dye;
• incorporating the sublayer containing the solid sublimation dye into the textile composite, the textile composite comprising at least a first layer adjacent the first surface of the sublayer;
• and
• activating the solid sublimation dye to a gas sublimation dye that permeates the first layer from the first surface of the sublayer and solidifies within the first layer,
• wherein incorporating the sublayer into the textile composite comprises laminating the first layer to the first surface of the sublayer, the solid sublimation dye disposed between the first layer and the face layer, and
• wherein laminating the first layer to the first surface comprises pattern bonding the first layer to the first surface to create depressed surface areas and elevated surface areas in the laminate, solid sublimation dye activated during lamination proceeds into the elevated surface areas.

A method for forming a textile composite, the method comprising:

• coating at least a portion of a first surface of a sublayer with a first solid sublimation dye and at least a portion of a second surface of the sublayer with a second solid sublimation dye, the second surface opposite the first surface;
• laminating a first layer to the first surface and a second layer to the second surface;
• and
• activating the first solid sublimation dye to a first gas sublimation dye that permeates the first layer from the first surface of the sublayer and solidifies within the first layer and the second solid sublimation dye to a second gas sublimation dye that permeates the second layer from the second surface of the sublayer and solidifies within the second layer.