System and method for space-dyeing yarn

Abstract

A process for manufacturing spaced dyed yarn for use with tufted or pile carpet including applying one or more colors of dye to one or more yarns in a predetermined spaced relation to form a colorized yarn having a predetermined color pattern.

We claim: 
     
         1 . A process for manufacturing a space-dyed yarn for use with tufted or pile carpet comprising:
 extruding a plurality of filaments of polymeric material;   combining the filaments to form a plurality of polymeric strands;   drawing the plurality of polymeric strands;   texturizing the plurality of polymeric strands into one or more yarn plugs; and   selectively applying one or more colors of dye to each yarn plug at timed intervals in a spaced relation to form a colorized yarn plug having a predetermined color pattern.   
     
     
         2 . The process of  claim 1 , further comprising cooling and pulling the colorized yarn plug to form a colorized yarn. 
     
     
         3 . The process of  claim 1 , further comprising winding the textured and colorized yarn onto a creel. 
     
     
         4 . The process of  claim 2 , further comprising, prior to winding, tacking the individual colorized yarn. 
     
     
         5 . The process of  claim 1 , wherein the polymeric material is selected from the group consisting of polyesters, polyamides and polyolefins. 
     
     
         6 . The process of  claim 5 , wherein the polyesters are selected from the group consisting of poly(ethylene terephthalate), poly(butylene terephthalate) and copolymers and mixtures thereof. 
     
     
         7 . The process of  claim 5 , wherein the polyamides are selected from the group consisting of nylon 6, nylon 6/6, nylon 6/9, nylon 6/10, nylon 6/12, nylon 11, nylon 12 and copolymers and mixtures thereof.