CN116568879A

CN116568879A - Multicolor polyester fabric and method for producing the same

Info

Publication number: CN116568879A
Application number: CN202180081194.0A
Authority: CN
Inventors: 詹姆斯·L·威廉斯; 蒂莫西·G·萨默斯; 斯科特·格雷顿·索罗; 菲利普·杰里·布罗克
Original assignee: Aladdin Manufacturing Corp
Current assignee: Aladdin Manufacturing Corp
Priority date: 2020-12-02
Filing date: 2021-11-29
Publication date: 2023-08-08
Also published as: CA3196657A1; EP4256119A2; WO2022119770A2; WO2022119770A3; US20240026604A1; MX2023006137A

Abstract

The present invention relates to a carpet comprising: fancy yarns of cationically dyeable polyester are dyed with basic dyes; and background polyester or polyamide yarns, not dyed with basic dyes, and wherein the carpet is over-dyed with disperse dyes or acid dyes. The invention also relates to a method for producing such a top-dyed carpet.

Description

Multicolor polyester fabric and method for producing the same

Citation of related applications

The present application claims priority and benefit from U.S. patent application Ser. No. 63/120,534, filed on month 12/2020, the entire contents of which are incorporated herein by reference for all purposes.

Technical Field

The present invention relates to a fabric, in particular a carpet, comprising: a cationically dyeable polyester effect yarn dyed with a basic dye; and background polyamide or polyester yarns that are not dyed with basic dyes, and wherein the fabric has been over-dyed with disperse dyes or acid dyes. The invention also relates to a method of making such a top-dyed fabric and articles, such as carpets and mats, comprising such a fabric.

Background

Some carpets are made from two types of yarns. The first type of yarn is called effect yarn (effect yarn) and polyester is usually dyed (usually space dyed) with a disperse dye prior to flocking. The second yarn is called the "background yarn" and is usually undyed, but can be dyed with a different dye. After flocking the two yarns, the carpet is then over-dyed with different dyes (typically disperse dyes).

Since the color of the effect yarn is saturated, the over-dyeing process has little or no effect on the coloring of the effect yarn as a whole. However, during the top dyeing, some dye from the fancy yarn will penetrate into the background yarn. This penetration results in a loss of color development and contrast in the finished product.

Accordingly, there is a need for a carpet that includes a fancy yarn and a background yarn flocked together and that enhances the color fastness in the fancy yarn during the subsequent over-dyeing process, thereby enhancing the color development and contrast of the finished carpet. There is also a need for improved methods of making such carpets.

Disclosure of Invention

One embodiment of the invention is a carpet comprising a pile comprising a first yarn and a second yarn, the pile being flocked into a primary backing;

wherein the first yarn has a cationically dyeable polyester yarn; and is also provided with

Wherein the second yarn comprises polyester or polyamide.

One embodiment of the present invention is a carpet comprising a woven face fabric comprising first yarns and second yarns, the first yarns interwoven with the second yarns;

Wherein the second yarn comprises polyester or polyamide.

One embodiment of the present invention is a method of making a carpet, the method comprising over-dyeing a carpet tile with a disperse dye or an acid dye:

wherein the carpet facer comprises a first yarn, a second yarn, and a backing;

wherein the first yarn has a cationically dyeable polyester yarn and is dyed with a basic dye;

wherein the second yarn comprises a polyester or a polyamide and is dyed or undyed with a second dye; and is also provided with

Wherein a pile comprising the first yarn and the second yarn is flocked into the backing.

One embodiment of the present invention is a woven fabric comprising first yarns interwoven with second yarns;

wherein the first yarn has a cationically dyeable polyester yarn, the first yarn being dyed with a basic dye prior to interweaving with the second yarn; and is also provided with

Wherein the second yarn comprises polyester or polyamide and is undyed or dyed with a different dye prior to interweaving with the first yarn.

One embodiment of the present invention is a carpet comprising any of the woven fabrics described above.

Drawings

Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

fig. 1A is a cross-sectional view of a portion of a flocked carpet in accordance with one embodiment of the present invention.

FIG. 1B is a cross-sectional view of a portion of a woven carpet according to one embodiment of the invention.

FIG. 2 is a block diagram of an exemplary process for making an embodiment of the carpet of the present invention.

Detailed Description

The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. In the following description, various components may be identified as having particular values or parameters, however, these items are provided as exemplary embodiments. Indeed, the exemplary embodiments are not limiting of the various aspects and concepts of the invention as many comparable parameters, dimensions, ranges and/or values may be implemented. The terms "first," "second," and the like, "primary," "exemplary," "secondary," and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Furthermore, the terms "a," "an," and "the" do not denote a limitation of quantity, but rather denote the presence of "at least one" of the referenced item.

Each of the embodiments disclosed herein is considered to be applicable to each of the other disclosed embodiments. All combinations and subcombinations of the various elements described herein are within the scope of the invention. Furthermore, the inventive content schematically disclosed herein may be suitably practiced in the absence of any element not specifically disclosed herein.

It should be understood that where a range of parameters is provided, all integers and ranges within the range, as well as the tenth and percentile thereof, are also provided by the embodiment. For example, "5% to 10%" includes 5%, 6%, 7%, 8%, 9% and 10%;5.0%, 5.1%, 5.2%,. 9.8%, 9.9%, and 10.0%; and 5.00%, 5.01%, 5.02%. 9.98%, 9.99% and 10.00%, and for example, 6% to 8%, 7% to 9%, 5.1% to 9.9% and 5.01% to 9.99%.

In the case of a numerical value or range, "about" as used herein refers to ±1%, ±5% or ±10% of the numerical value or range as recited or claimed.

"cationically dyeable polyester" or "cationically dyeable polymer" as used herein refers to a polymer that has been modified to allow cationic molecules (such as cationic dyes) to adhere thereto. The cationically dyeable polymer is anionic.

As used herein, a "basic dye" is a dye that is known/made to dye fibers having anions. These will be readily apparent to those skilled in the art.

As used herein, "facial fabric" or "carpet" refers to yarns or fibers in combination with a primary backing.

As used herein, "securing" two objects together refers to securing or attaching the objects to one another by means such as an adhesive or other means.

Wherein the second yarn comprises polyester or polyamide.

One embodiment of the present invention is a carpet comprising a woven face fabric (facemask) comprising first yarns and second yarns, the first yarns interwoven with the second yarns;

Wherein the second yarn comprises polyester or polyamide.

In one embodiment, the second yarn comprises polyester.

In one embodiment, the second yarn comprises polyamide.

In one embodiment, the first yarn has been dyed with a basic dye; and wherein the second yarn has been dyed with a second dye or undyed.

In one embodiment, the carpet has been over-dyed with a disperse dye.

In one embodiment, the first yarn comprises polyethylene terephthalate (PET) or polytrimethylene terephthalate (PTT).

In one embodiment, the first yarn comprises a sulfonated entity. In another embodiment, the first yarn comprises sulfur in a concentration of at least 1000ppm by weight.

In one embodiment, at least one of the first yarn and the second yarn comprises a continuous filament. In another embodiment, the continuous filaments are bulked continuous filaments.

In one embodiment, the carpet has at least one additional cationically dyeable polyester yarn.

In one embodiment, the carpet has at least one additional polyester or polyamide yarn.

In one embodiment, the second yarn comprises polyamide and the carpet has been overcoated with an acid dye.

In one embodiment, the first yarn has been space dyed.

In one embodiment, the first yarn comprises a cationically dyeable polyethylene terephthalate (PET) or a cationically dyeable polypropylene terephthalate (PTT).

wherein the carpet facer comprises a first yarn, a second yarn, and a backing;

wherein the first yarn has a cationically dyeable polyester yarn and has been dyed with a basic dye;

wherein the second yarn comprises a polyester or a polyamide and has been dyed with a second dye or undyed; and is also provided with

Wherein a pile comprising the first yarn and the second yarn has been flocked into the backing.

In one embodiment, the second yarn comprises polyester and the carpet is overcoated with a disperse dye.

In one embodiment, the second yarn comprises polyamide.

In one embodiment, the carpet tile further comprises at least one additional yarn comprising polyester or polyamide that has been dyed or undyed with a second dye or a third dye.

wherein the first yarn has a cationically dyeable polyester yarn that has been dyed with a basic dye prior to interweaving with the second yarn; and is also provided with

In one embodiment, the second yarn comprises polyester and the fabric has been overcoated with a disperse dye.

In one embodiment, the second yarn comprises polyamide and the fabric has been overcoated with a disperse dye or an acid dye.

Fig. 1A schematically illustrates one possible carpet construction. The carpet is generally indicated by reference numeral 100. Carpet 100 includes face yarns (or pile yarns) 110 that are flocked to a web, weave, or spunbond fabric, referred to as primary backing 120, to form a face fabric 125. In the illustrated embodiment, the primary backing 120 is woven. Face yarn 110 includes both fancy yarn 112 and background yarn 114. Primary backing 120 has face yarn 110 extending outwardly through the primary backing from one flocked face, primary back coating or precoat 130 on the opposite face, and optionally at least one secondary back coating or primary coating (commonly referred to as a fast transfer coating) 140. Other layers may also be associated with the carpet 100.

Fig. 1B schematically illustrates an alternative construction that includes a woven fabric 125 instead of a flocked fabric. In this embodiment, face yarn 110, including fancy yarn 112 and background yarn 114, interweaves to form a woven face fabric 125. On the underside of the facecloth 125 there is a primary back coating or pre-coating 130 on the opposite side, and optionally at least one secondary back coating or main coating (commonly referred to as a fast transfer coating (skip coat)) 140. Other layers may also be associated with the carpet 100.

The primary back coating or pre-coating 130 (if present) generally comprises carboxylated latex (e.g., styrene-butadiene based latex), PVC (polyvinyl chloride), EVA (ethylene vinyl acetate), or other polymer based materials, and the secondary back coating 140 may also comprise these same polymers. The primary and/or secondary backcoating may be a foamed polymer. One or both of the primary and secondary backcoatings 130, 140 may include a filler material. The most common filler is a mineral filler (such as calcium carbonate), although other fillers such as alumina trihydrate, bauxite, magnesium hydroxide, and the like may be used. In some cases, calcium carbonate may be used with other common materials (such as metal salts). Carpet 100 may be produced with a filler in one or both of primary back coating 130 and secondary back coating 140, where the primary back coating and secondary back coating comprise waste carpet as all or part of the filler. As an alternative, only one single back coating may be provided instead of the primary and secondary back coatings. Similar to the primary backcoating in the first alternative, the single backcoating also anchors the pile yarns in the primary backing. The single back coating may be composed of the same materials as used for the primary back coating and the secondary back coating.

In making the carpet 100, generally, for the embodiment depicted in fig. 1A, the fiber clusters are flocked by a woven or nonwoven fabric as the primary backing 120. The portion of the pile surface on the exposed surface of the carpet includes facial fibers or facial yarns 110. The back coating 130 is applied to the back of the flocked structure to lock in the flocking. Next, a woven or nonwoven secondary backing 140 is laminated to the back of the primary backing 120 to increase the dimensional stability of the carpet.

Primary backing 120 is a supportive scrim through which tufts are flocked and typically comprises a polyolefin (such as polyethylene or polypropylene); however, other materials may be used, such as polyesters (including, for example, PET). For example, a slit tape made of PET may be used. The secondary backing 140 is a fabric that is adhered to the primary backing with the flocked back sandwiched in them with the back coating 130. Secondary backing 140 is typically made of polypropylene; however, other backing types may be used, such as jute, PVC (polyvinyl chloride), polyurethane, and PET. Secondary backing 140 may be a nonwoven fabric including, but not limited to, spunbond, wet, meltblown, and air entangled.

Filler material (such as calcium carbonate) and binder material may be applied to the back side of the flocked carpet backing as a slurry of various concentrations. In a preferred embodiment, there is more filler than binder material. For example, a representative filler to binder ratio may comprise about 80% ("wt%" or "%") calcium carbonate to about 20wt% binder by weight. While calcium carbonate is one of the most commonly used filler materials, those skilled in the art to which this disclosure pertains will recognize that carpets containing other filler materials may be used in the processes described herein.

The adhesive material functions to adhere the flocking to the backing. The binder material may include latex such as carboxy-styrene-butadiene rubber, styrene-butadiene rubber (SBR), natural rubber latex, vinyl acetate ethylene copolymer (VAE or EVA), other natural or synthetic rubber, polyurethane, or polymer (such as PET). While latex is one of the most common adhesive materials used to hold tufts to carpet backing, one skilled in the art to which this disclosure pertains will recognize that carpets containing other adhesives may be used in the process described herein.

A variety of different cationically dyeable (i.e., having anions) polymers may be used in fancy yarn 112. The cationically dyeable polymers or yarns are often referred to in the art as "cationic polymers" or "cationic yarns" despite the fact that they are anionic so that cations can bind to the polymer or yarn. Thus, those skilled in the art will appreciate that elements traditionally referred to as cationic (such as polymers or yarns) are in fact cationically dyeable. The cationically dyeable polymer may be produced by any method suitable for producing a polymer capable of being dyed with a cationic (basic) dye. For example, the sulfonated monomer may be copolymerized with a polymer subunit to produce a sulfonated polymer. In one embodiment, the sulfonated monomer is sulfoisophthalic acid. In one embodiment, the sulfonated monomer is polymerized with the polymer subunits in a higher percentage than would be used in the finished product to produce a highly sulfonated copolymer; the highly sulfonated copolymer is then mixed with a polymer and spun to produce a cationically dyeable polymer fiber.

Suitable methods for preparing cationically dyeable polymers are found, for example, in U.S. Pat. nos. 3,542,743, 3,846,507, 3,898,200, 5,108,684, 5,445,653, 5,889,138, 6,117,550, 6,133,382, and 9,745,415, the entire contents of which are incorporated herein by reference.

In one embodiment, the cationically dyeable polymer comprises sulfur in an amount of at least, up to or about 1,000ppm, 2,000ppm, 3,000ppm, 4,000ppm, 5,000ppm, 6,000ppm, 7,000ppm, 8,000ppm, 9,000ppm, 10,000ppm, 15,000ppm, 20,000ppm, 25,000ppm, 30,000ppm, 35,000ppm, 40,000ppm, 45,000ppm, 50,000ppm, 60,000ppm, 70,000ppm, 80,000ppm, 90,000ppm, or 100,000ppm, as compared to the total mass of the polymer.

In one embodiment, the cationically-dyeable polymer is a cationically-dyeable polyester. For example, the polyester may comprise a cationically dyeable PET or a cationically dyeable PTT.

Fancy yarn 112 is dyed with basic dye prior to flocking. In one embodiment, fancy yarn 112 is space dyed prior to flocking. The basic dye may be any basic dye known in the art. In one embodiment, the fibers of fancy yarn 112 are dyed before being twisted into two forms. In one embodiment, undyed fibers are spun into a yarn and then the yarn is dyed. This can be done with spun yarn or BCF yarn. In one embodiment, the staining method is selected from the group consisting of: direct dyeing, loose fiber dyeing, wool top dyeing, and yarn dyeing. In one embodiment, the yarn is dyed with a basic dye at a concentration of 1g/l to 50 g/l.

A variety of different polymers may be used to make the background yarn 114. In one embodiment, the polymer is a polyamide. In one embodiment, the polyamide is nylon 6 (polycaprolactam) or nylon 66 (poly (hexamethylene adipamide)). In one embodiment, the polymer is a polyester. In one embodiment, the polyester is PET, PTT, or a blend thereof.

In one embodiment, the background yarn 114 is not dyed (i.e., undyed) at all prior to flocking. In one embodiment, background yarn 114 is dyed prior to flocking with a different dye than that used to dye fancy yarn 112 prior to flocking. In one embodiment, the background yarn 114 is dyed with a disperse dye prior to flocking.

Unless otherwise indicated, the polymers used in any of the yarns of embodiments of the present invention may be virgin, recycled, or blends thereof.

For both fancy yarn 112 and background yarn 114, the fibers may be formed from their respective polymers by any method known in the art to produce fibers from a single polymer or from a blend. The polymer may be extruded to have any shape or size suitable for the polymer carpet fibers. In addition, the carpet fibers may undergo any post-spinning process that is generally considered to be used to prepare polymeric carpet fibers. The fibers may be as spun or heat set. "fiber" refers to what is known in the art as a fiber, such as continuous filaments, monofilaments, staple fibers, and the like. The fibers may be round or have other shapes such as octalobal, triangular, sunburst (also known as sun), sector oval, trilobal, four-channel (also known as quad), sector ribbon, star, and the like. These fibers may also be solid, hollow or porous. The fibers are formed into yarns and the fibers or yarns can be used to make a variety of materials, particularly carpets, rugs, mats, and the like.

The yarns or fibers of the present invention may also comprise other components such as, but not limited to, treating agents, matting agents, tackifiers, optical brighteners, gloss reducing agents (e.g., titanium oxide), heat stabilizers (e.g., phosphorus compounds), antioxidants (e.g., hindered phenols), antistatic agents, pigments, ultraviolet blockers, and combinations thereof.

Thus, each yarn may be independently prepared according to any method for preparing yarns that is deemed useful in the art. For example, each yarn of the present invention may be a partially oriented yarn, a spun drawn yarn, a textured yarn, a friction false twist yarn, and a bulked continuous filament ("BCF") yarn. Preferred steps for preparing BCF yarns include spinning (e.g., extruding, cooling, and coating filaments), single-stage or multi-stage stretching at limited temperatures and draw ratios (such as with heated rolls, heated pins, or hot fluid assistance), annealing, expanding, winding, optionally relaxing, and winding the filaments on packages for subsequent use.

The yarns may be flocked in any pattern or arrangement known in the art. In one embodiment, the fancy yarn and the background yarn are each distributed to create a design effect.

In another embodiment, there are discrete areas of the face fabric that include only fancy yarns and discrete areas of the face fabric that include only background yarns. In one embodiment, the facecloth will include these discrete areas adjacent to each other, creating a clear boundary and a more pronounced visual effect due to the absence of bleeding during the overprinting.

In another embodiment, the facer includes discrete regions, but also includes intermediate regions that form gradients between 100% fancy yarn regions and 100% background yarn regions. Because of the clearer contrast between the effect yarn and the background yarn, the gradient in these intermediate regions will also be easier to control because of the lack of bleeding during the top dyeing.

In one embodiment, one or more of the fancy yarn and the background yarn is a multi-strand yarn. In various embodiments, the multi-ply yarn is a two, three, four, or five ply yarn. One or more of the yarns is cationically dyeable, while the other yarns are not. Further, the other strands may be the same as the background yarn or may be different from the background yarn. The cationically dyeable yarn may be dyed prior to assembly of the multi-ply yarn, or the yarn may be assembled prior to application of the cationic dye. Such differently configured two-ply yarns are commonly referred to as barber pole yarns. These barbershop yarns are known to those skilled in the art. In one embodiment, all of the yarns in the multi-strand yarn are the same.

These yarns may be present in the flocked fabric at any density suitable for carpeting. Carpet Density (CD) is known to be calculated in ounces per cubic yard via the following equation:

CD＝(FW*36)/PH

where FW is the facial weight (carpet weight in ounces per square yard of carpet) and PH is the pile height of the carpet in inches. In one embodiment, the carpet density is at least, up to, or about 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, 5,000, 5,500, 6,000, 6,500, 7,000, 7,500, or 8,000 ounces per cubic yard.

In one embodiment, the fancy yarn of the carpet comprises at least, up to or about 1,000, 1,500, 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, 5,000, 5,500, 6,000, 6,500, 7,000, 7,500 or 8,000 piles per square meter. In one embodiment, the background yarn of the carpet comprises at least, up to, or about 1,000, 1,500, 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, 5,000, 5,500, 6,000, 6,500, 7,000, 7,500, or 8,000 piles per square meter.

In one embodiment, the fancy yarn comprises 1% to 99% of the total pile of the carpet. In one embodiment, the fancy yarn comprises at least, up to, or about 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% of the total pile of the carpet.

In one embodiment, the background yarn comprises 1% to 99% of the total pile surface of the carpet. In one embodiment, the background yarn comprises at least, up to, or about 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% of the total pile surface of the carpet.

After flocking, the face fabric 125 or the carpet 100 is over-dyed with a dye. In one embodiment, the dye is a disperse dye. In an alternative embodiment, the dye is an acid dye.

In one embodiment, the fancy yarn will be dyed along its entire length as a result of the manufacturing process. In one embodiment, the fancy yarn is formed into a barber pole with the background yarn, and then flocked or woven with the background yarn, and then overcoated.

In one embodiment, a pH of 2.0 to 3.0 is used. In one embodiment, useful dyes are yellow GL, red GRL, and blue GRL liquid dyes. In one embodiment, buffers, wetting agents and defoamers are used. In one embodiment, the individual yarns are dyed set at 275°f. In one embodiment, the two yarns are heat set at 290°f.

Discussion and examples

As discussed above, there is a need for a over-dyed carpet that includes dyed fancy yarns and background yarns with improved color development and contrast between the different yarns.

The inventors have found that by using a cationically dyeable polymer in the fancy yarn, dyeing the fancy yarn with a basic dye prior to flocking, and using a polyester or polyamide background yarn, no basic dye penetrates onto the background dye during the over-dyeing process. Thus, better color development and contrast is achieved in the finished carpet product. This also applies to embodiments in which the background yarn is dyed prior to the over-dyeing process using a dye that is different from the basic dye used to dye the fancy yarn.

While embodiments have been illustrated and described in detail above, such illustration and description are to be considered illustrative or exemplary and not restrictive. The same applies to the following steps, which are non-limiting illustrations of the manner in which the invention may be practiced. It is to be understood that changes and modifications may be made by those skilled in the art within the scope and spirit of the following claims. In particular, embodiments within the scope of the present invention include any combination of features from the different embodiments described above and below.

Step 1: obtaining fancy yarn

As described hereinabove, the fibers may be obtained via any process known in the art for preparing fibers from polymers. The cationically dyeable fancy yarn comprising a polymer is dyed with a basic dye prior to flocking (fig. 2, block 201). In one embodiment, the dye in the effect yarn is fully saturated so that the effect yarn is not dyed or is dyed negligible during the subsequent over-dyeing process. Fancy yarns may also contain other components listed above.

Step 2: obtaining background yarn

As noted, the background yarn is a polyester or polyamide yarn and may be undyed or dyed or pigmented with dyes other than those used to dye fancy yarns. The background yarn may also contain other components listed above. Fancy yarns may also be colored.

Step 3: face fabric for making flocking

In this embodiment, the fancy yarn and the background yarn are each flocked to the primary backing to form a "face fabric" (fig. 2, block 202). The facial fabric may also have a primary and/or secondary back coating adhered thereto either before or after the overprinting. In a preferred embodiment, the facial fabric is dyed over a continuous dye range prior to any back coating being applied.

Step 4: set dyeing

Carpets with or without the primary and/or secondary backcoating are then overcoated with a disperse dye or an acid dye (fig. 2, block 203). In one embodiment, the carpet is counterstained via a method selected from the group consisting of: rope dyeing, jet rope dyeing, printing and kuste (continuous) dyeing.

Alternative embodiments

The carpets described herein may be prepared with more than one different type of fancy yarn and/or more than one background yarn. For example, two different polymers may be used to make the first fancy yarn and the second fancy yarn, wherein the first fancy yarn and the second fancy yarn may be dyed with the same basic dye or with different basic dyes. Alternatively, the same polymer may be used to form a first portion of fancy yarn and a second portion of fancy yarn, wherein the first portion is dyed with a different basic dye than the second portion.

Similarly, two different polyesters or polyamides may be used to make the first background yarn and the second background yarn. Both may be undyed prior to the step of overprinting; in other embodiments, both may be dyed or colored with the same dye prior to flocking, or with different dyes or colors prior to flocking, or one may be dyed while the other may be undyed. Alternatively, the same polymer may be used to form a first portion of fancy yarn and a second portion of fancy yarn, wherein the first portion is dyed with a different basic dye than the second portion. In another embodiment, the same polyester or polyamide may be used to form the first portion of the background yarn and the second portion of the background yarn, wherein the first portion is dyed with a different dye than the second portion prior to flocking, or wherein one portion is dyed and the other portion is undyed prior to flocking.

Furthermore, while the above description relates primarily to fabrics made by flocking fancy yarns and background yarns into a primary backing, an alternative embodiment uses a woven fabric with the same advantages rather than a flocked fabric. In particular, fancy yarn as described above is interwoven with background yarn as described above. After the two yarns are interwoven, they are over-dyed with a disperse dye. The yarns may be single-stranded or multi-stranded, and may be of any shape known in the art. The yarns may be woven using any technique known in the art. After the woven fabrics are formed, they can be used to prepare carpets in the same manner as the flocked fabrics described above, including via application of a primary and/or secondary back coating.

Conclusion(s)

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the present disclosure. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A carpet comprising a pile comprising a first yarn and a second yarn, the pile being flocked into a primary backing;

Wherein the second yarn comprises polyester or polyamide.

2. A carpet comprising a woven face fabric comprising first yarns and second yarns, the first yarns interwoven with the second yarns;

Wherein the second yarn comprises polyester or polyamide.

3. Carpet according to claim 1 or 2 wherein the second yarn comprises polyester.

4. Carpet according to claim 1 or 2 wherein the second yarn comprises polyamide.

5. The carpet of any of claims 1-4, wherein the first yarn is dyed with a basic dye; and wherein the second yarn is dyed or undyed with a second dye.

6. The carpet of claim 5, wherein the carpet is over-dyed with a disperse dye.

7. The carpet of claim 5 or 6, wherein the first yarn is space dyed.

8. The carpet of any of claims 1-7, wherein the first yarn comprises a cationically dyeable polyethylene terephthalate (PET) or a cationically dyeable polypropylene terephthalate (PTT).

9. The carpet of any of claims 1-8, wherein the first yarn comprises a sulfonated entity.

10. The carpet of claim 9, wherein the first yarn comprises sulfur in a concentration of at least 1000ppm by weight.

11. The carpet of any of claims 1-10, wherein at least one of the first yarn and the second yarn comprises continuous filaments.

12. The carpet of claim 11, wherein the continuous filaments are bulked continuous filaments.

13. The carpet of any of claims 1 to 12 having at least one additional cationically dyeable polyester yarn.

14. Carpet according to any of claims 1 to 13 having at least one additional polyester or polyamide yarn.

15. The carpet of claim 5, wherein the second yarn comprises polyamide, and wherein the carpet is over-dyed with an acid dye.

16. The carpet of claim 15, wherein the first yarn is space dyed.

17. The carpet of any of claims 15 to 16, wherein the first yarn comprises a cationically dyeable polyethylene terephthalate (PET) or a cationically dyeable polypropylene terephthalate (PTT).

18. The carpet of any of claims 15 to 17, wherein the first yarn comprises a sulfonated entity.

19. The carpet of claim 18, wherein the first yarn comprises sulfur in a concentration of at least 1000ppm by weight.

20. The carpet of any of claims 15-19, wherein at least one of the first yarn and the second yarn comprises continuous filaments.

21. The carpet of claim 21, wherein the continuous filaments are bulked continuous filaments.

22. The carpet of any of claims 15-21 having at least one additional cationically dyeable polyester yarn.

23. The carpet of any of claims 15 to 22 having at least one additional polyamide yarn.

24. A method of making a carpet, the method comprising over-dyeing a carpet facer with a disperse dye or an acid dye;

wherein the carpet facer comprises a first yarn, a second yarn, and a backing;

25. The method of claim 24, wherein the second yarn comprises polyester and the carpet is over-dyed with a disperse dye.

26. The method of claim 25, wherein the second yarn comprises polyamide.

27. The method of any of claims 24 to 26, wherein the carpet tile further comprises at least one additional yarn comprising polyester or polyamide dyed or undyed with a second or third dye.

28. A woven fabric comprising a first yarn interwoven with a second yarn;

29. The woven fabric of claim 28, wherein the second yarn comprises polyester and the fabric is over-dyed with a disperse dye.

30. The woven fabric of claim 28, wherein the second yarn comprises polyamide and the fabric is over-dyed with a disperse dye or an acid dye.

31. A carpet comprising the woven fabric of any one of claims 28 to 30.