Method for delivering proper amounts of bleach and mill dye to discolored regions of a carpet using a roller-ball applicator

Abstract

A new method of delivering more precise amounts of carpet mill dye to regions of discoloration using a roller-ball applicator enables precisely metered delivery of the three primary dye colors to discolored carpet fibers. The method eliminates the need for a water extraction, enables the restoration of a more uniform color pattern, and eliminates dye overspray outside of the treated region that is inherent with the use of a spray bottle. The applicator is held with a loose grip and the roller ball is alternately moved in clockwise and counter-clockwise directions while in contact with the carpet fibers to be dyed. This ensures that dye is delivered to all sides of the fiber. To ensure even dye penetration and improved motion of the roller ball, an emulsifier is added to the dye solution. After each application, a microfilament cloth is wiped across the treated region.

Claims

1. A method for delivering precise amounts of liquid selected from the group consisting of carpet mill dye, a carpet fiber bleaching agent, and a bleach neutralizer, to a discolored region of a carpet, said method comprising the following sequence of steps: providing a plurality of roller-ball applicators, one of which contains red carpet mill dye, another of which contains yellow carpet mill dye, yet another of which contains blue carpet mill dye, still another of which contains the carpet fiber bleaching agent, and finally another of which contains a bleach neutralizer; if the discolored region has been stained, then, using the roller-ball applicator filled with the carpet fiber bleaching agent, gradually remove the stain by alternately moving the roller ball in clockwise and counter-clockwise directions, with the roller-ball of the applicator in contact with the carpet fibers that have been stained, thereby delivering the enclosed carpet fiber bleaching agent to all sides of the carpet fibers in said stained, discolored region; wiping a microfilament cloth across the fibers to which the carpet fiber bleaching agent has been applied using the selected applicator; if the discolored region of the carpet has been bleached, either accidentally or in order to remove the stain, then the bleach neutralizer is applied to the bleached region with the roller-ball applicator containing the bleach neutralizer by alternately moving the roller ball in clockwise and counter-clockwise directions, with the roller-ball of the applicator in contact with the carpet fibers that have been bleached, thereby delivering the bleach neutralizer to all sides of the carpet fibers in said discolored region; wiping a microfilament cloth across the fibers to which the bleach neutralizer has been applied; selecting a roller-ball applicator containing an appropriate first carpet mill dye color to begin a process for adding a proper combination of primary dyes to the carpet fibers in the discolored region, the addition of said first carpet mill dye color accomplished by alternately moving the roller ball in clockwise and counter-clockwise directions, with the roller-ball of the applicator in contact with the carpet fibers that have been stained, thereby delivering the first carpet mill dye color to all sides of the carpet fibers in said stained, discolored region; wiping a microfilament cloth across the fibers to which the first carpet mill dye color was applied; selecting a roller-ball applicator containing an appropriate second carpet mill dye color to begin a process for adding a proper combination of primary dyes to the carpet fibers in the discolored region, the addition of said second carpet mill dye color accomplished by alternately moving the roller ball in clockwise and counter-clockwise directions, with the roller-ball of the applicator in contact with the carpet fibers that have been stained, thereby delivering the second carpet mill dye color to all sides of the carpet fibers in said discolored region; wiping a microfilament cloth across the fibers to which the second carpet mill dye color was applied; if required, select a roller-ball application ontaining an appropriate third mill dye color and apply to the discolored regions as heretofore described, followed by a wiping of a microfilament cloth across the fibers to which the third carpet mill dye color was applied.

2. The method of claim 1, wherein an emulsifier is added to each dye solution and to the bleaching agent, which promotes even penetration of the liquid and improved motion of the roller ball of the selected applicator.

3. The method of claim 2, wherein said emulsifier is a cross-linked polyacrylate polymer known as carbomer.

4. The method of claim 1, wherein said bleaching agent is an aqueous solution of sodium hypochlorite.

5. The method of claim 1, wherein the bleach neutralizer is a sodium thiosulfate solution.

6. The method of claim 5, wherein guar gum powder is added to the sodium thiosulfate solution.

7. A method for delivering precise amounts of liquid selected from the group consisting of carpet mill dye, a carpet fiber bleaching agent, and a bleach neutralizer, to a discolored region of a carpet, said method comprising the steps of: providing a plurality of roller-ball applicators, one of which contains red carpet mill dye, another of which contains yellow carpet mill dye, yet another of which contains blue carpet mill dye, still another of which contains the carpet fiber bleaching agent, and finally another of which contains the bleach neutralizer; if the discolored region has been stained, then, using the roller-ball applicator filled with the carpet fiber bleaching agent, gradually remove the stain by alternately moving the roller ball in clockwise and counter-clockwise directions, with the roller-ball of the applicator in contact with the carpet fibers that have been stained, thereby delivering the enclosed carpet fiber bleaching agent to all sides of the carpet fibers in said stained, discolored region; if the discolored region of the carpet has been bleached, either accidentally or in order to remove the stain, then the bleach neutralizer is applied to the bleached region with the roller-ball applicator containing the bleach neutralizer by alternately moving the roller ball in clockwise and counter-clockwise directions, with the roller-ball of the applicator in contact with the carpet fibers that have been bleached, thereby delivering the bleach neutralizer to all sides of the carpet fibers in said discolored region; selecting a roller-ball applicator containing an appropriate first carpet mill dye color to begin a process for adding a proper combination of primary dyes to the carpet fibers in the discolored region, the addition of said first carpet mill dye color accomplished by alternately moving the roller ball in clockwise and counter-clockwise directions, with the roller-ball of the applicator in contact with the carpet fibers that have been stained, thereby delivering the first carpet mill dye color to all sides of the carpet fibers in said stained, discolored region; selecting a roller-ball applicator containing an appropriate second carpet mill dye color to begin a process for adding a proper combination of primary dyes to the carpet fibers in the discolored region, the addition of said second carpet mill dye color accomplished by alternately moving the roller ball in clockwise and counter-clockwise directions, with the roller-ball of the applicator in contact with the carpet fibers that have been stained, thereby delivering the second carpet mill dye color to all sides of the carpet fibers in said discolored region; if required, select a roller-ball application ontaining an appropriate third mill dye color and apply to the discolored regions as heretofore described; and wiping a microfilament cloth across the carpet fibers of the discolored regions each time liquid is applied to those fibers using a roller-ball applicator.

8. The method of claim 7, wherein an emulsifier is added to each dye solution and to the bleaching agent, which promotes even penetration of the liquid and improved motion of the roller ball of the selected applicator.

9. The method of claim 8, wherein said emulsifier is a cross-linked polyacrylate polymer known as carbomer.

10. The method of claim 7, wherein said bleaching agent is an aqueous solution of sodium hypochlorite.

11. The method of claim 7, wherein the bleach neutralizer is a sodium thiosulfate solution.

12. The method of claim 11, wherein guar gum powder is added to the sodium thiosulfate solution.

13. A method for delivering precise amounts of aqueous solutions of mill dye, a carpet fiber bleaching agent, and a bleach neutralizing agent, to a discolored region of a carpet during a multi-step color restoration procedure, said method comprising the steps of: employing a plurality of roller-ball applicators to dispense said precise amounts, and wherein an applicator tip of the instrument is alternately moved in clockwise and counter-clockwise directions, with the tip in contact with the carpet fibers in the discolored region, thereby delivering the aqueous solutions to all sides of the carpet fibers in said region; and wiping a microfilament cloth across the carpet fibers of the discolored regions each time an aqueous solution is applied to those fibers.

14. The method of claim 13, wherein an emulsifier is added to each dye solution and to the bleaching agent, which promotes even penetration of the liquid and improved motion of the roller ball of the selected applicator.

15. The method of claim 14, wherein said emulsifier is a cross-linked polyacrylate polymer known as carbomer.

16. The method of claim 13, wherein said bleaching agent is an aqueous solution of sodium hypochlorite.

17. The method of claim 13, wherein the bleach neutralizer is a sodium thiosulfate solution.

18. The method of claim 17, wherein guar gum powder is added to the sodium thiosulfate solution.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a roller-ball applicator having a glass storage vessel;

(2) FIG. 2 is a roller-ball applicator having a deformable storage tube; and

(3) FIG. 3 is dome applicator having a deformable storage tube.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(4) As heretofore explained, traditional methods of restoring proper color to bleached regions of carpet utilize dilute primary color carpet mill dyes, which are applied by a spray bottle. The excess water is then removed by an extraction machine and the discoloration is monitored. Achieving an exact color match involves replacing only the missing primary colors in the correct ratio. This is accomplished by adding primary colors in a controlled amount. As dye is applied, the discoloration is carefully monitored for a color shift. A determination is made in continuing with the same dye color or applying a different primary color. Using a roller ball, the same amount of dye is delivered without the excess water. Both methods utilize the same principle in deriving at a correct color match. That is to say, the color of the bleached area at any given time determines the primary color used. When any change of color is noted, then the primary color used is always determined by that discoloration. For example the appearance of blue or green would indicate red dye is to be applied. For the appearance of lavender, yellow dye is applied. Blue dye is applied when a yellow, orange, or salmon colored is noted.

(5) Referring now to FIG. 1, a first roller-ball applicator 100 includes a glass bottle 101 having a capacity of about 10 ml and a cap 102 preferably made of high-density polyethylene. The cap 102 has a truncated cylindrical socket 103 into which has been snapped a roller ball 104, which has a diameter of about 1 cm. The first roller-ball applicator 100 is a preferred applicator for bleached spots greater than about 25 mm in diameter.

(6) Referring now to FIG. 2, a second roller-ball applicator 200 includes a squeezable supply tube 201 preferably made of low-density polyethylene. The squeezable supply tube has a capacity of about 2 ml. A cap 202, which is preferably made of high-density polyethylene, has a truncated spherical socket 203 into which is snapped a stainless steel roller ball 204 having a diameter of about 3 mm. The second roller-ball applicator 200 is a preferred applicator for bleached spots having a diameter less than about 25 mm.

(7) Referring now to FIG. 3, a dome applicator 300 includes a squeezable supply tube 301 preferably made of low-density polyethylene. The squeezable supply tube has a capacity of about 2 ml. A cap 302, which is preferably made of high-density polyethylene, has a dome tip 303 which has a diameter of about 3 mm. The dome applicator 300 is an alternative to the second roller-ball applicator 200 and is useful for recoloring bleached spots having a diameter less than about 25 mm. The dome tip 303 is equipped with a central aperture 304 that leads directly to the liquid supply within the squeezable supply tube 301. Thus, release of dilute liquid dye from the dome tip the dome applicator 300 is more difficult to control because it is not modulated by rotation of a roller-ball, as is the case with the first and second roller-ball applicators 100 and 200, respectively.

(8) The advantages of using a roller-ball application method over using spray bottles are numerous and impressive. For one, the required three roller-ball applicators becomes the storage containers for the three primary dye color mixtures. There is no need for spray bottles or for a water extraction machine. With less water on the work area, the color loss area is easier to see. This minimizes the chances of going too dark or getting a non-uniform color. An over-spray pattern is also avoided.

(9) An eye dropper, also known as a Pasteur pipette, or dropper, is a device used to transfer small quantities of liquids. They are used in the laboratory and also to dispense small amounts of liquid medicines. Pasteur pipettes can deliver small amounts of aqueous solutions to carpet fibers during the recoloring process and can substitute for the dome applicator 300. After dispensing a desired amount of aqueous solution in the discolored region, the tube of the dropper can be held between the thumb and index finger and the tip of the dropper can be moved in alternately clockwise and counterclockwise directions to fully wet all sides of the carpet fibers being treated.

(10) Using the roller-ball and dome applications, as well as the Pasteur pipette, the carpet recoloring process is simpler, with fewer steps involved, making the process is less intimidating and easier to understand. Because of uncertainty, many individuals choose methods that do not produce excellent results. One such method involves the use of crayons. These actually create more problems. The reduction of uncertainty makes the use of a roller ball applicator the better choice.

(11) Wool carpeting can be challenging when restoring color as over wetting will result in the fibers going brown. This can be avoided by using the roller ball method. Wool and nylon carpeting will also dry much quicker. From a marketing standpoint, a recoloring kit based on the new method is easier to manufacture, package and sell.

(12) Permanent stains on a carpet can be bleached using the roll-on applicator. This allows for controlled bleaching. Just as proper color can be gradually restored to a carpet, colors that make up a stain can be gradually removed. This results in the stain being removed with minimal color loss to the actual carpet. Over applying a bleaching agent with a spray bottle will remove more color than what is desired. It will also increase the size of the color loss area. The use of anti-bleaching agents are reduced when less chemicals are used to remove stains.

(13) Before removing a stain by a bleaching process, all efforts should be made in removing the stain first by a carpet shampoo spotter. In most cases individuals by habit would use more shampoo than is required. Removing the shampoo completely takes time and is often left in the carpet. In this case, less is better. Over months this spotter will chemically alter the carpet. When the carpet is cleaned, a region of discoloration appears. This can be prevented by using only the amount of carpet shampoo spotter needed. We therefore would use the roll-on applicator as a carpet spotter for removing stains. This could be used in removing stains from upholstery or even clothing.

(14) It should also be noted that the use of roller-ball applicators can also be used in conjunction with any method using carpet mill dyes.

(15) The recoloration method using roller-ball applicators excels in removing partial bleach spots. These require very little dye for restoration of the original color. The process is very accurate and quick. Repair of the bleached spot is permanent, and the repaired spot will not change color when cleaned. The look and feel is the same as the original carpet. There is no need to mix dyes, set up spray bottles with an extractor machine. The instructions are simple.

(16) The process involves the use of the three primary colors of dye. Carpet mill dyes are converted into a stable liquid dye solution by adding equal parts of H.sub.2O and 91% Isopropyl Alcohol. The alcohol prevents gradual clumping that occurs when acid dyes are dissolved in water. Each solution is then placed in a 10 or 15 ml bottle equipped with a roller-ball applicator. The roller balls are preferably made of stainless steel or glass. When applying carpet mill dye, the bottle with the roller-ball applicator is held with a loose grip. The roller ball of the applicator, while in contact with the carpet fibers to be dyed, is alternately moved in clockwise and counterclockwise directions. This ensures that dye is delivered to all sides of the fiber. To ensure even dye penetration and improved motion of the metal or glass roller ball in its socket, an emulsifier is added to the dye solution. Carbomer, a cross-linked polyacrylate polymer, is presently the preferred emulsifier. It is an easy to use water soluble polymer that is widely used as an emulsifying, stabilizing, suspending, thickening and gelling agent in myriad applications because it is both versatile and safe. Carbopol® 940 is a trademarked brand of carbomer. Carbomer is added to the dye-water-alcohol mixture within a range of 0.25 grams/liter to 5 grams/liter. In order to effect proper mixing of the carbomer with the mixture, a high-speed blender is a virtual necessity. The BlendTec® Total Classic Blender, which is equipped with a motor rated at 3.0 peak horsepower, is highly effective for this purpose.

(17) Emulsifiers are used to maintain a uniform dispersion of one liquid in another, such as oil in water. The basic structure of an emulsifying agent includes a hydrophobic portion, which is usually a long-chain fatty acid, and a hydrophilic portion that may be either charged or uncharged. The hydrophobic portion of the emulsifier dissolves in the oil phase, and the hydrophilic portion dissolves in the aqueous phase, forming a dispersion of small oil droplets. Emulsifiers thus form and stabilize oil-in-water emulsions. The emulsifier allows non-polar acid dyes to be suspended in an alcohol-containing aqueous solution. The emulsifier also slows the bonding of acid dyes to the nylon or wool fibers. This ensures a more uniform dye application once a damp microfilament cloth is wiped across the area. The microfilament cloth minimizes carpet fiber distortion. When a damp microfilament cloth is gently rubbed on the nylon fibers, The hydrophobic tail of the emulsifier transfers to the microfilament cloth, thereby enabling the acid dye to more freely bond to the nylon or wool fibers.

(18) Different chemicals involved in restoring carpet color may also be applied with the roll-on applicator bottles with better results. Pet urine, as it is converted to ammonia, will raise the PH of the stain and remove color. Citric acid is used to lower pH and stabilize the color in areas where pets have urinated. The citric acid can be applied using a roller-ball applicator. Excess citric acid is not needed. Because carbomer can be used as a gelling agents for solutions which are pH neutral (i.e., pH=7), different gelling agents must be used for citric acid solutions. Guar gum powder is one such gelling agent that is compatible with citric acid solutions. Guar gum, also called guaran, is a galactomannan polysaccharide extracted from guar beans that has thickening and stabilizing properties useful in the food, feed and industrial applications. The guar seeds are mechanically dehusked, hydrated, milled and screened according to desired application.

(19) Sodium thiosulfate is used to neutralize sodium hypochlorite (the active ingredient in chlorine bleach). This is sold as a bleach neutralizer and is used to prevent or minimize color loss when sodium hypochlorite has been spilled on a carpet. Sodium thiosulfate is also used when correcting a spot of discoloration. Standard practice has typically been to saturate a bleached spot with a sodium thiosulfate solution. However, because the chemical neutralization reaction occurs within the carpet fibers themselves, there is no need to apply excess bleach neutralizer to the carpet. Use of a roller-ball applicator containing a solution of sodium thiosulfate enables a much more measured and controlled application sodium thiosulfate solution to the spot, thereby eliminating the need to apply excess bleach neutralizer. Like citric acid, sodium thiosulfate cannot be gelled using carbomer. However, guar gum powder is an effective gelling agent for sodium thiosulfate solutions.

(20) The inventor serendipitously discovered that when sodium thiosulfate is combined with guar gum powder, the effectiveness of sodium thiosulfate is greatly increased. The ability of sodium thiosulfate to remain in a solution is enhanced, thus higher concentrations of sodium thiosulfate can be made. Using the roller ball applicator or even an eye dropper to neutralize chlorine is far more effective than when the guar gum is added to an aqueous solution of sodium thiosulfate, as more sodium thiosulfate is in direct contact with the carpet fibers.

(21) Although only three types of applicators for use in restoration of stained and bleached carpet are shown and described, it will be obvious to those having ordinary skill in the art that changes and modifications may be made thereto without departing from the scope and the spirit of the invention as hereinafter claimed.