Method of producing dyed nylon walk-off mats having improved washfastness, and mats produced thereby

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° 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.

We 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 .Iadd.light, regular or deep dyeable .Iaddend.nylon yarn to color the latter,   (c) heating the yarn to a temperature above 200° F.,   (d) contacting the yarn with an alkaline solution,   (e) tufting the yarn into a walk-off mat either before .[.of.]. .Iadd.or .Iaddend.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.   
     
     
       2. A method as defined in claim 1 including the step of washing the yarn after the heating step (c). 
     
     
       3. A method as defined in claim 1 including the step of drying the yarn after contacting the yarn with an alkaline solution. 
     
     
       4. A method as defined in claim 1 wherein the dry heat temperature of step (g) is in the range of 260° F. to 350° F. 
     
     
       5. 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. 
     
     
       6. A method as defined in claim 1 wherein the heating step (c) is accomplished by steaming the yarn.