Bleach Safe, Stain Free, Quick Drying Drylon Rugs

Abstract

A process for making a Drylon rug is disclosed, wherein the said process comprises use of dope dyed, micro-denier filament, cabled and heat set polyester yarn or micro denier filament, cabled heat set dyed with antimicrobial treatment for tufting of rugs, thereby eliminating the process of batch dyeing after the formation of rugs and further ensuring that the rugs are bleach safe, quick drying, anti microbial and stain resistant. The present invention also discloses Drylon rugs as manufactured using yarns of invention. Further, the present invention discloses the process for manufacture of Drylon yarns.

1 . A process for making a Drylon rug comprising use of, dope dyed or yarn dyed, micro-denier per filament, cabled and heat set polyester yarn for tufting of rugs, thereby eliminating the process of batch dyeing after the formation of rugs, further ensuring that the rugs are bleach safe, quick drying and stain resistant wherein, said process comprises:
 (a) tufting of micro-denier per filament, dope dyed, cabled and heat-set polyester filament or tufting of micro denier per filament, cabled, heat set yarn dyed with anti-microbial treatment on cheeses is creeled on tufting machine to form tufted fabric roll;   (b) loading the tufted rolls of step (a) on latexing machine followed by application of latex to form a coated rug fabric;   (c) cutting the rug fabric of step (b) on a infra-red guided cutting machine as per pre-determined specification to form rugs;   (d) stitching of rugs of step (c) on four sides by stitching machine;   (e) washing, checking, mending and folding and packing the stitched rugs of step (d), in poly bags, and;   (f) packing the poly bag packed rugs of step (e) in cartons.   
     
     
         2 . A process for making Drylon rug as claimed in  claim 1 , wherein the dope dyed or yarn dyed, micro denier per filament, is in range of 1.0 to 5.0 DPF and with yarns of 600×2, 1200×2, 1800 and 2400 filaments, up on cabling, wherein range is from 150 to 3600 filaments or 75×2 to 1800×2. 
     
     
         3 . The process for making Drylon rug as claimed in  claim 2 , wherein the Drylon filament is dope dyed during the process of filament extrusion by adding color master batch during extrusion of spinning process. 
     
     
         4 . The process of making Drylon rug as claimed in  claim 2 , wherein the Drylon filament is dyed after cabling and heat setting in pressure vessels with antimicrobial treatment. 
     
     
         5 . The process for making Drylon rug as claimed in  claim 3 , wherein dope dyeing imparts bleach safe property and good color fastness to the said filament. 
     
     
         6 . The process of making Drylon rug as claimed in  claim 4 , wherein yarn dyeing imparts bleach safe and anti microbial properties. 
     
     
         7 . The process for making Drylon rug as claimed in  claim 1 , wherein cabling results in soft and bulky tufts. 
     
     
         8 . The process for making Drylon rug as claimed in  claim 1 , wherein tufting is carried out on table-tufting or machine tufting. 
     
     
         9 . The process for making Drylon rug as claimed in  claim 8 , wherein the tufting loop height is in range of 3 mm to 34 mm. 
     
     
         10 . The process for making Drylon rug as claimed in  claim 8 , wherein the tufting has a loop density in the range of 18 to 96 per square inch. 
     
     
         11 . The process for making Drylon rug as claimed in  claim 8 , wherein machine tufting also includes jacquard patterning. 
     
     
         12 . The process for making Drylon rug as claimed in  claim 1 , wherein the rug is coated with latex on remote side to impart anti-skid property and to hold tufts intact. 
     
     
         13 . The process for making Drylon rug as claimed in  claim 12 , wherein latexing on the remote side of the rug fabric is carried out on a continuous latexing machine. 
     
     
         14 . The process for making Drylon rug as claimed in  claim 12 , wherein the latexing mixture comprises of synthetic or natural latex, accelerator and gel. 
     
     
         15 . The process for making Drylon rug as claimed in  claim 12 , wherein the said rug, is made on table-tufting which has latex spray coated or brush applied on remote side. 
     
     
         16 . The Drylon rug as manufactured according to the process as claimed in  claim 1 , comprising use of dope dyed, micro denier per filament, cabled and heat set polyester yarn or microfilament cabled, heat set and yarn dyed with anti microbial treated yarn for tufting of the Drylon rug, thereby eliminating the process of batch dyeing after formation of rugs, further ensuring that the Drylon rugs are bleach safe, quick drying and stain resistant. 
     
     
         17 . The Drylon rug as claimed in  claim 16 , wherein the dope dyed or yarn dyed, micro denier per filament ranges from 1.0 to 5.0 DPF and with filaments of 600×2, 1200×2, 1800 and 2400 filaments, wherein the range is from 150 to 3600 filaments or 75×2 to 1800×2. 
     
     
         18 . The Drylon rug as claimed in  claim 17 , wherein the Drylon filament is dope dyed during the spinning and extrusion process by adding color master batch during extrusion of spinning process or yarn dyed with anti microbial treatment, in pressure vessels after extrusion, cabling and heat setting. 
     
     
         19 . The Drylon rug as claimed in  claim 18 , whereby dope dyeing or yarn dyeing of microfilaments imparts bleach safe property and good color fastness to the said filament. 
     
     
         20 . The Drylon rug as claimed in  claim 17 , wherein cabling results in soft and bulky tufts. 
     
     
         21 . The Drylon rug as claimed in  claim 16 , wherein tufting is on table-tufting or machine tufting. 
     
     
         22 . The Drylon rug as claimed in  claim 21 , wherein tufting loop height is in the range of 3 mm to 34 mm. 
     
     
         23 . The Drylon rug as claimed in  claim 21 , wherein tufting loop density is in range of 18 to 96 per square inch. 
     
     
         24 . The Drylon rug as claimed in  claim 21 , wherein machine tufting is in jacquard pattern. 
     
     
         25 . The Drylon rug as claimed in  claim 16  wherein the said rug is coated with latex on remote side to impart anti-skid property and to hold tufts intact. 
     
     
         26 . The Drylon rug as claimed in  claim 25 , wherein latexing is carried out on a continuous latexing machine. 
     
     
         27 . The Drylon rug as claimed in  claim 25 , wherein the latexing mixture comprises of synthetic or natural latex, accelerator and gel. 
     
     
         28 . The Drylon rug as claimed in  claim 25 , wherein the said rug is made on table tufting which has the latex spray coat or brush applied on remote side.