Multi-colored pile fabric and process

Abstract

A novel textile fabric comprised of pile-like yarns in which individual component yarns, at least one of which is texturized, comprising individual pile-like yarns have different shrinkage characteristics, and a method for making and patterning such fabrics. Upon the application of a shrinkage agent (e.g., heated air streams), either uniformly or selectively to the pile surface, the individual component yarns shrink to different degrees. By shrinking the relatively high shrinkage component yarns more than the adjacent relatively low shrinkage component yarns, the visual exposure of the relatively low shrinkage yarns is increased, and the visual contribution of the aesthetic qualities (e.g., color, light reflectivity, etc.) of such low shrinkage yarns is enhanced.

1 . A process for generating patterns in a textile pile fabric comprising the steps of: 
 (a) creating a textile pile fabric having a plurality of individual pile-like yarns, each of said pile-like yarns being comprised of a first type of component yarn having a first set of aesthetic characteristics and a first shrinkage characteristic that causes said first type of component yarn, as a result of exposure to a shrinking agent, to exhibit relatively low shrinkage, and a second type of component yarn, lengthwise coupled with said first type of component yarn, having a second set of aesthetic characteristics and a second shrinkage characteristic that causes said second type of component yarn, as a result of similar exposure to said shrinking agent, to exhibit greater shrinkage than said first type of component yarn, wherein at least one of said component yarn types is texturized;    (b) applying a shrinkage agent to said pile fabric, thereby inducing shrinkage in said component yarns comprising said individual pile-like yarns, said shrinkage of said first type of component yarns within a given pile-like yarn being less than said shrinkage of said second type of component yarns within said given pile-like yarn as a result of exposure to said shrinkage agent, said shrinkage causing said second type of component yarns to shorten and recede in the direction of said fabric ground to a greater extent than said first type of component yarns and enhancing the visual contribution of the aesthetic characteristics of said first type of component yarns relative to the aesthetic characteristics of said second type of component yarn;    (c) subjecting said pile fabric to a dyeing step.    
   
   
       2 . The process of  claim 1  wherein said dyeing step occurs prior to the application of said shrinkage agent.  
   
   
       3 . The process of  claim 1  wherein said dyeing step involved the selective application of dye to said fabric in a pattern configuration.  
   
   
       4 . The process of  claim 2  wherein said dyeing step involved the selective application of dye to said fabric in a pattern configuration.  
   
   
       5 . The process of  claim 1  wherein said shrinkage agent is applied only in selected areas of said pile fabric in accordance with electronically defined pattern data.  
   
   
       6 . The process of  claim 5  wherein said shrinkage agent is applied in registry with a pre-determined pattern to be applied to said pile fabric.  
   
   
       7 . The process of  claim 5  wherein said shrinkage agent is applied in registry with a pre-existing pattern on said pile fabric.  
   
   
       8 . The process of  claim 5  wherein said shrinkage agent is heat.  
   
   
       9 . The process of  claim 5  wherein said shrinkage agent is comprised of a plurality of pressurized, heated gas streams directed at said pile fabric.  
   
   
       10 . The process of  claim 9  wherein said gas streams are selectively interrupted in accordance with pattern information in order to cause localized shrinkage of said second type of component yarns only in pile-like yarns within areas defined by said pattern.  
   
   
       11 . The process of  claim 9  wherein said gas streams are directed at the face of said pile fabric.  
   
   
       12 . The process of  claim 1  wherein the primary constituent of said first type of component yarns is selected from the group consisting of polyester, nylon, and cellulosic fibers.  
   
   
       13 . The process of  claim 1  wherein the primary constituent of said second type of component yarns is selected from the group consisting of polypropylene, polyester, and nylon.  
   
   
       14 . The process of  claim 1  wherein said second type of component yarns are comprised of solution dyed polypropylene.  
   
   
       15 . The process of  claim 1  wherein said first type of component yarns are commingled with said second type of component yarns.  
   
   
       16 . The process of  claim 1  wherein said first type of component yarns are selected from the group consisting of polyester, nylon, and rayon fibers and wherein said shrinkage agent is comprised of a plurality of pressurized, heated gas streams, said gas streams having been heated to a temperature within the range of about 300° F. to about 460° F. and directed onto the face of said pile fabric.  
   
   
       17 . The process of  claim 1  wherein said first type of component yarns are selected from the group consisting of polyester, nylon, and rayon fibers and wherein said shrinkage agent is comprised of a plurality of pressurized, heated gas streams, said gas streams having been heated to a temperature within the range of about 550° F. to about 590° F. and directed onto the back of said pile fabric.  
   
   
       18 . The process of  claim 16  wherein said gas streams have been heated to a temperature within the range of about 350° F. to about 460° F.  
   
   
       19 . The process of  claim 16  wherein gas streams, heated to a temperature within the range of about 550° F. to about 590° F., are also directed onto the back of said pile fabric.  
   
   
       20 . A process for forming a multicolored pile fabric comprising the steps of: 
 (a) creating a textile pile fabric having a plurality of individual pile-like yarns, each comprised of a first type of component yarn comprised of package dyed polyester having a first set of color and light reflectivity characteristics, said dyed polyester yarn having shrinkage characteristics that causes it to exhibit relatively low shrinkage as a result of exposure to heated air streams having a temperature between about 350° F. and about 460° F., and a second type of component yarn, physically associated with said first type of component yarn, comprised of solution dyed polypropylene having a second set of color and light reflectivity characteristics, said polypropylene yarn having shrinkage characteristics that causes it to exhibit greater shrinkage than said polyester component yarn as a result of similar exposure to heated air streams having a temperature between about 350° F. and about 460° F.    (b) applying a plurality of heated air streams having a temperature between about 350° F. and about 460° F. to the face of said pile fabric, thereby inducing shrinkage in said component yarns comprising said pile-like yarns, said shrinkage of said polyester component yarns being less than said shrinkage of said polypropylene component yarns as a result of exposure to said heated air streams, said shrinkage causing said polypropylene component yarns to shorten and recede in the direction of said fabric ground to a greater extent than said polyester component yarns and visually enhancing the relative contribution of the set of color and light reflectivity characteristics of said polyester component yarns relative to the overall appearance of the pile fabric.    
   
   
       21 . The process of  claim 20  wherein the relative contributions of the respective colors of said polyester and said polypropylene component yarns combine visually to form a third color in areas of the pile fabric.  
   
   
       22 . The process of  claim 20  wherein said polyester component yarns are comprised of textured polyester and wherein said polypropylene yarns are flat and unentangled with said textured polyester yarns, wherein the combination of the respective colors of said textured polyester and said polypropylene component yarns, and the relative light reflectivity of said polypropylene component yarns, combine visually to form iridescent areas on the pile fabric.  
   
   
       23 . A textile pile fabric having a plurality of individual pile-like yarns, at least some of which are comprised of a first type of component yarn having a first set of aesthetic characteristics and a first shrinkage characteristic that causes said first type of component yarn, as a result of exposure to a shrinking agent, to exhibit relatively low shrinkage, and a second type of component yarn, physically associated with said first type of component yarn, having a second set of aesthetic characteristics and a second shrinkage characteristic that causes said second type of component yarn, as a result of similar exposure to said shrinking agent, to exhibit greater shrinkage than said first type of component yarn, wherein at least one of said first type and said second type of component yarns is textured, and wherein said individual pile-like yarns of said fabric are comprised of component yarns of the first type that exhibit relatively low shrinkage and component yarns of the second type that exhibit greater shrinkage than said first type of component yarns.  
   
   
       24 . The fabric of  claim 23  wherein said linear shrinkage of said first type of component yarn is less than about 6%, and the linear shrinkage of said second type of component yarn is greater than about 20%.  
   
   
       25 . The fabric of  claim 23  wherein said melting point of said first type of component yarn is within the range of about 480° F. and about 500° F., and the melting point of said second type of component yarn is within the range of about 300° F. and about 320° F.  
   
   
       26 . The fabric of  claim 23  wherein said shrinkage of said first type of component yarn is less than about 3%, and the shrinkage of said second type of component yarn is greater than about 15%.  
   
   
       27 . The pile fabric of  claim 23  in which said pile-like yarns are comprised of at least two component yarns, one of which is solution-dyed polypropylene and the other of which is textured polyester.  
   
   
       28 . The fabric of  claim 23  wherein substantially all of said pile-like yarns comprising said pile fabric are comprised of component yarns that have been shrunken to some degree.  
   
   
       29 . The pile fabric of  claim 23  in which said pile-like yarns are comprised of at least three component yarns, one of which is flat solution-dyed polypropylene and the other of which is selected from the group consisting of piece-dyed and package-dyed polyester.  
   
   
       30 . The fabric of  claim 23  wherein said pile fabric contains first areas in which substantially all of said pile-like yarns comprising said pile fabric are comprised of component yarns that have been shrunken to some degree, and also contains second areas in which substantially all of said pile-like yarns are comprised of component yarns that remain substantially unshrunken.  
   
   
       31 . The pile fabric of  claim 30  in which said first areas are configured in accordance with a pre-determined pattern.  
   
   
       32 . The pile fabric of  claim 30  in which at least some of said first areas correspond to, and are substantially in registry with, areas in which component yarns have been dyed in accordance with a pre-determined pattern.  
   
   
       33 . A textile fabric having a pile face and an fabric back, said pile face being comprised of a plurality of individual pile-like yarns, each comprised of a first type of component yarn comprised of package dyed textured polyester having a first set of color and light reflectivity characteristics and a second type of component yarn, physically associated with said first type of component yarn, comprised of solution dyed polypropylene having a second set of color and light reflectivity characteristics, wherein said polypropylene component yarn has a lower melting point that causes it to exhibit greater shrinkage than said polyester component yarn, said lower melting point causing, upon exposure to heat in a plurality of individual pile-like yarns, said polypropylene component yarn to shorten and recede in the direction of said fabric back to a greater extent than said polyester component yarn and visually enhancing the relative contribution of the set of color and light reflectivity characteristics of said polyester component yarn in said plurality of pile-like yarns relative to the overall appearance of the pile fabric.