Carpet dyeing systems and methods
AssigneeMohawk Carpet Distribution, Inc.
InventorsMick Allen, Ronnie Cargle, Randy Hixon, Keith Bray, Ron Paynter
Life of this patent
Estimating the term…
Abstract
Embodiments of the present invention provide systems and methods for “dye-to-order” carpet manufacturing that address deficiencies in the carpet manufacturing industry, some of which are discussed above. In one embodiment, an improved manufacturing system is provided that allows manufacturers to change colors “on the fly” (e.g., within a single roll) with minimal waste. In another embodiment, a dye-to-order processing system is provided that maps multiple orders to undyed carpet rolls such that usage of the undyed carpet rolls is optimized.
Claims7
A method of dyeing carpet to satisfy a plurality of customer orders comprising the steps of:
- receiving a plurality of customer orders wherein each order identifies a color and a length;
- identifying which colors cannot be dyed in sequence based on a visual effect of blending of sequential dyes at a transition between colors in sequence;
- determining a dyeing sequence for at least a portion of the plurality of customer orders, based on the colors identified by the respective orders and the identification of colors that cannot be dyed in sequence, to reduce the visual effect of blending of sequential dyes at a transition between colors in the sequence;
- assigning the plurality of customer orders to one or more greige rolls of carpet based at least in part on the determined dyeing sequence wherein at least one greige roll of carpet has at least one transition from one color to another color;
- and
- dyeing the one or more greige rolls of carpet;
- wherein the step of dyeing the one or more greige rolls of carpet comprises:
- feeding said one or more greige rolls through a dye application head which switches from one color to another color according to a respective customer order.
Dependencies are inferred from the claim text.