# US 5,707,469 A · Method of producing dyed nylon walk-off mats having improved washfastness, and mats produced thereby

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 5,707,469 A
- Document ID: US5707469A
- Status: Granted
- Kind: A
- Application number: 08/613,281
- Filed: 1996-03-11
- Granted: 1998-01-13
- Earliest claimed: 1996-03-11
- Assignees: Robert R. Hixson
- Inventors: Robert R. Hixson; David R. Kelly; Hobert C. Sweatman
- Web page: https://patentgrep.com/patent/US5707469A

## CPC

- D06P 3/248: {using reactive dyes}
- D06N 7/0068: {characterised by the primary backing or the fibrous top layer}
- D06N 7/0071: {characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing}
- D06P 1/67366: {Phosphates or polyphosphates}
- D06P 5/02: After-treatment
- D06P 5/2077: {after dyeing}
- D06N 2201/0263: Polyamide fibres
- D06N 2203/02: Natural macromolecular compounds or derivatives thereof
- D06N 2209/0823: within the layer by addition of a colorant, e.g. pigments, dyes
- Y10S 8/924: Polyamide fiber
- Y10S 8/929: Carpet dyeing
- D06P: DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS

## Abstract

A method of making a dyed nylon walk-off mat having improved washfastness includes dyeing nylon yarn, or a tufted nylon mat, in a fiber reactive dye solution having a pH in the range of about 0.5 to about 2.5. The yarn is then heated, such as by steam, at a temperature above 200.degree. F., after which the yarn is treated with an alkaline solution followed by a heat treatment. A backing, such as of rubber or vinyl, is applied to the mat at an elevated temperature. The application of the backing at elevated temperature, and the heat treatment subsequent to application of the alkaline solution, may be performed simultaneously.

## Claims

### Claim 1

A method of making a dyed nylon walk-off mat having improved washfastness comprising the steps of:
(a) providing a fiber reactive dye solution having a pH in the range of about 0.5 to about 2.5,
(b) applying the dye to nylon yarn to color the latter,
(c) heating the yarn to a temperature above 200.degree. F.,
(d) contacting the yarn with an alkaline solution,
(e) tufting the yarn into a walk-off mat either before of after performing steps (b)-(d),
(f) applying a heat-responsive, rubber-like backing to the mat, and
(g) subjecting the mat and backing to an elevated dry heat temperature, said temperature being high enough to cause the backing to adhere to the mat and also to cause fixation of the fiber reactive dye to the nylon yarn of the mat.

### Claim 2 (depends on 1)

A method as defined in claim 1 including the step of washing the yarn after the heating step (c).

### Claim 3 (depends on 1)

A method as defined in claim 1 including the step of drying the yarn after contacting the yarn with an alkaline solution.

### Claim 4 (depends on 1)

A method as defined in claim 1 wherein the dry heat temperature of step (g) is in the range of 260.degree. F. to 350.degree. F.

### Claim 5 (depends on 1)

A method as defined in claim 1 wherein dye fixation is produced by formation of covalent bonds between the fiber reactive dye and the nylon yarn.

### Claim 6 (depends on 1)

A method as defined in claim 1 wherein the heating step (c) is accomplished by steaming the yarn.