EP3129545A1

EP3129545A1 - Multicolor carpet and method of making same

Info

Publication number: EP3129545A1
Application number: EP15776948.0A
Authority: EP
Inventors: Wai-Hai Tung; Elizabeth MCFARLAND
Original assignee: Invista North America LLC
Current assignee: Invista Textiles UK Ltd
Priority date: 2014-04-10
Filing date: 2015-04-08
Publication date: 2017-02-15
Also published as: CN106661827A; US20170016160A1; EP3129545A4; AU2015243916A1; WO2015157380A1; AU2015243916B2

Abstract

A multicolor carpet comprising a plurality of tufted yarns, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein at least one of the yarns is of a different color than any of the other yarns, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

Description

MULTICOLOR CARPET AND METHOD OF MAKING SAME

FIELD OF THE INVENTION

[0001] The invention relates to multicolor carpets formed from solution-dyed, BCF fibers.

BACKGROUND OF THE INVENTION

[0002] Polymers have long been the most prevalent material used for forming yarns for use in the carpet industry. Therefore, there is a continuing interest to develop less costly and more environmentally friendly methods of carpet production.

[0003] Multicolor carpets are widely used to provide consumers with various design options for flooring designs. These carpets are typically formed from direct tufted, white acid dyeable staple fibers. Colors are printed on theses carpets after the carpet fibers are tufted. Printed carpets do not have sharp color registration, acceptable stain resistance and good color fastness. Some direct tufted nylon carpets are sold as floor coverings in automotive interiors, mainly in solid colors. However, due to bonding issues, antistatic fiber cannot be used in automotive carpeting. For these reasons, direct tuft carpets have not found broad acceptance for residential or commercial markets.

[0004] Carpets that are suitable for use for residential purposes typically require additional process steps to meet the necessary quality standards. Residential carpet processing consists of many steps including cable twisting, heatsetting, dyeing and applying low pH stain block chemicals. These steps are costly and unfriendly to the environment due to extensive consumption of energy, water, steam and low pH chemicals. Cable twisting and heatsetting are required to make aesthetically attractive carpets with good tip definition. However, the tip definition of cable twisted carpets deteriorates with traffic due to twist unrevealing that results in worn out look.

[0005] Therefore, there is a need for multicolor carpets with improved stain resistance and color fastness that also meet the quality standards necessary for residential and commercial markets. SUMMARY OF THE INVENTION

[0006] The present invention relates to a multicolor carpet that is direct tufted and meets the quality standards needed for use in residential and commercial markets. The multicolor carpets of the current invention eliminate costly and environmentally unfriendly steps typically necessary for carpets that are sold into the residential and commercial flooring markets. These eliminated steps can include, twisting, heatsetting, dyeing and downstream wet processing.

[0007] In one nonlimiting aspect of the present invention, a multicolor carpet is disclosed comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

[0008] in another nonlimiting aspect of the present invention, a multicolor carpet is disclosed comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein the solution- dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali metal salt thereof, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

[0009] In another nonlimiting aspect of the present invention, a multicolor carpet is disclosed comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein the solution- dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali metai salt thereof, wherein the plurality of tufted yarns further comprises at least one conductive filament , wherein the yarns have not been twisted, wherein the yarns have not been heatset.

[00010] in another embodiment aspect of the present invention, a method of making a multicolor carpet is disclosed, wherein the method comprises the step of tufting a plurality of yarns of at least two different colors to form a carpet, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein the yarns have not been twisted, and wherein the yarns have not been heatset. [00011] In another noniimiting aspect of the present invention, an article of manufacture is disclosed, at least a portion of which comprises a multicolor carpet comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

[00012] In another noniimiting aspect of the present invention, an article of

manufacture is disclosed, at least a portion of which comprises, a multicolor carpet comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein the solution-dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali metal salt thereof, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

[00013] In another noniimiting aspect of the present invention, an article of

manufacture is disclosed, at least a portion of which comprises, a multicolor carpet comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein the solution-dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali metal salt thereof, wherein the plurality of tufted yarns further comprises at least one conductive filament , wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

BRIEF DESCRIPTION OF THE DRAWINGS

[00014] F!G. 1 A and FIG. 1 B are images of multicolor carpets of the current invention.

[00015] FIG. 2A, FIG. 2B and FIG. 2C are images of multicolor carpets of the current invention.

[00016] FIG. 3A and FIG. 3B are images of multicolor carpets of the current invention.

DETAILED DESCRIPTION OF THE INVENTION [00017] Provided by the present invention are muiticoior carpets comprising a plurality of tufted yarns of at least two different colors, wherein the yarns have not been twisted, and wherein the yarns have not been heatset. Also provided is a method for production of carpets and articles of manufacture, at least a portion of which comprise the multicolor carpets disclosed herein.

[00018] It is common for carpet that is used for residential or commercial purposes to be twisted, heatset and be subjected to downstream wet processing to achieve desirable properties. The multicolor carpets of the current invention are not subjected to a twisting step, such as ply twisting or cable twisting, or a heatsetting step which give a tufted carpet tip definition. Downstream wet processing steps can include dyeing, and the application of stain resist or soil resist chemistries. Contrary to what would be expected, the inventors have found that multicolor carpets of the current invention can be produced with satisfactory aesthetics, wear performance and staining properties. Furthermore, the multicolor carpets of the current invention simulate the appearance of twisted and heatset yarns in tufted fabrics, without being subjected to twisting, heatsetting or any downstream wet processing after tufting.

[00019] Without being bound by any particular theory, it is believed that in order to achieve a multicolor carpet with satisfactory aesthetics the yarn used must be smooth and have good interlace without containing a large number of interlace nodes. Interlace nodes with a diameter less than 30% of the main yarn body are considered to be severe tight interlace nodes, interlace nodes with a diameter less than 50% of the main yarn body are considered to be moderate interlace nodes. In one nonlimiting embodiment of the current invention, the multicolor carpets are formed from solution dyed BCF yarns that contain less than 5 severe interlace nodes per meter and less than 30 moderate interlace nodes per meter. In another nonlimiting embodiment of the current invention, multicolor carpets are formed from solution dyed BCF yarns that are essentially free of severe interlace nodes, in another nonlimiting embodiment of the current invention, the multicolor carpets are formed from solution dyed BCF yarns that contain less than 20 moderate interlace nodes per meter. The number of moderate and severe interlace nodes are determined by visual inspection according to the Node Evaluation Procedure, defined below. [00020] The multicolor carpets of the current invention can be formed in various carpet constructions that are known in the industry. In one non!imiting embodiment of the current invention, the multicolor carpets have a pile height of 0.5 inches or less. In another nonlimiting embodiment of the current invention, the multicolor carpets have a pile height of 0.375 inches or less. In one nonlimiting embodiment of the current invention, the multicolor carpets have a face weight in the range of about 12 to about 50 ounces per yard. In another nonlimiting embodiment of the current invention, the multicolor carpets have face weight in the range of about 18 to about 40 ounces per yard.

[00021] The multicolor carpets of the current invention can be formed from yarns of denier and filament count that that are known for use in carpet manufacturing. In nonlimiting embodiments of the current invention, the yarns comprise solution-dyed bulked continuous filaments (BCF) yarns, in one nonlimiting embodiment of the current invention, the yarns have a denier in the range from about 500 denier to about 3000 denier. In another nonlimiting embodiment of the current invention, the yarns have a denier in the range from about 1 00 denier to about 1800 denier.

[00022] The multicolor carpets of the current invention can be formed from yarns from a plurality of colors, in one nonlimiting embodiment of the current invention, the multicolor carpets comprise between 2 to 8 different color yarns. In nonlimiting embodiments, yarns may comprise filaments of at least 2 different colors.

[00023] in one nonlimiting embodiment of the current invention, the multicolor carpet is comprised of a plurality of tufts, wherein each tuft is comprised of at least one tufted yarn. In another nonlimiting embodiment each tuft is comprised of tufted yarn of a single color.

[00024] Without being bound any particular theory, it is believed that the patterns formed from the use of different color yarns create the color definition necessary for the multicolor carpets to have an acceptable aesthetic look that is comparable to carpets formed from yarns that have been subjected to several additional texturing steps. To maximize the color definition in the multicolor carpet, the use of a single color yarn over large areas of the carpet should be minimized. For a two color carpet an ABAB thread up can be used. For a three color carpet an ABCABC thread up can be used. For a four color carpet an AB, CD two ends per needle thread up can be used.

[00025] in one nonlimiting embodiment of the current invention, the majority of tufts are immediately adjacent to at least one other tuft comprised of tufted yarn of at least one different color. In another nonlimiting aspect, each tuft is immediately adjacent to at least one other tuft comprised of tufted yarn of at least one different color. In another nonlimiting embodiment of the current invention, there is no 12 square inch area of the carpet covered by yarns of only a single color. In another nonlimiting embodiment, there is no 4 square inch area of the carpet covered by yarns of only a single color. In yet another nonlimiting embodiment of the current invention, there is no single square inch area of the carpet that is covered by yarns of only a single color.

[00026] The multicolor carpets of the present invention also exhibit excellent durability. In one nonlimiting embodiment of the current invention, the carpet has an appearance rating of at least 3 when subjected to a walk test according to ASTM

D6119. In another nonlimiting embodiment of the current invention, the carpet has an appearance rating of at least 4.5 when subjected to a walk test according to ASTM D6119.

[00027] in a nonlimiting embodiment of the current invention, the multicolor carpet of the current invention may be comprised of bulked continuous filaments formed from solution-dyed polyamide polymer. Suitable polyamides include fiber forming

polyamides known in the art to be suitable for the formation of bulked continuous filament fibers, having sufficient viscosity, tenacity, chemical stability and crystaiinity to be at least moderately durable in such application. The at least one polyamide resin may be selected from the group consisting of nylon 5,6; nylon 6/6; nylon 6; nylon 7; nylon 1 1 ; nylon 12; nylon 6/10;, nylon 6/12; nylon DT; nylon 6T; nylon 61; and blends or copolymers thereof. In one embodiment, the solution-dyed bulked continuous filaments are formed from nylon 6,6 polymer.

[00028] in another nonlimiting embodiment, the solution-dyed bulked continuous filaments are formed from aliphatic carbon filaments, especially polypropylene.

[00029] Suitable polyesters include fiber forming polyesters known in the art. The at least one polyester resin may be selected from the group consisting of polyethylene terephthalate, polytrimethyiene terephthalate, polybutylene terephthalate, polyethylene naphthalate, poiylactic acid (PLA) and blends or copolymers thereof.

[00030] In embodiments of the current invention, the solution-dyed bulked continuous filaments of the multicolor carpet further comprise a cationic dye additive. The use of cationic dye additives in thermopiastics has been discussed in US Patent No. 5,108,684 to Anton, herein incorporated by reference. The use of cationic dye additives impart stain resistant properties to the yarns used in the current invention. Suitable cationic dye additives which may be used include those aromatic sulfonates and their alkali metal salts which are capable of copolymerizing with the polymeric raw materials used to form the solution dyed bulk continuous filaments of the current invention. In one noniimiting embodiment of the current invention, the cationic dye additive is 5- sulfoisophthalate. In another noniimiting embodiment, the 5-sulfoisophthalate in the solution-dyed bulked continuous filaments is in the range of about 1 to about 8 percent by weight. In another noniimiting embodiment, the 5-sulfoisophthalate in the solution- dyed bulked continuous filaments is in the range of about 1 to about 4 percent by weight. In one noniimiting embodiment of the current invention, the multicolor carpet has a stain rating of at least 5. In another noniimiting embodiment of the current invention, the carpet has a stain rating of about 10.

[00031] in one noniimiting embodiment of the current invention, the plurality of tufted yarns used in the multicolor carpet further comprises at least one conductive filament. In another noniimiting embodiment, the amount of conductive filaments is sufficient to form an antistatic carpet. Examples of conductive filaments that can be used to impart antistatic properties to a carpet were disclosed in US Patent Nos. 4,900,495 and 4,997.712, herein incorporated by reference. In one noniimiting embodiment of the current invention, the conductive filaments is spin orientated and has a nonconductive polymeric component coextensive with a component of electrically conductive carbon dispersed in a polymeric matrix wherein the nonconductive polymeric component of the spin-oriented, conductive filaments is a melt-blend containing a major amount of a nonconductive, fiber-forming polymeric material.

[00032] The present invention also provides for a method of manufacturing a multicolor carpet. In this method, a plurality of yarns of at least two different colors are tufted to form a carpet, wherein the yarns comprise so!ution-dyed, bulked continuous filaments, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

[00033] Also provided by the present invention are articles of manufacture, at least a portion of which comprises a multicolor carpet comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise soiution-dyed bulked continuous filaments, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

[00034] Also provided by the present invention are articles of manufacture, at least a portion of which comprises, a multicolor carpet comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise solution-dyed bulked

continuous filaments, wherein the solution-dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali metal salt thereof, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

[00035] Also provided by the present invention are articles of manufacture, at least a portion of which comprises, a multicoior carpet comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise solution-dyed bulked

continuous filaments, wherein the solution-dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali metal salt thereof, wherein the plurality of tufted yarns further comprises at least one conductive filament , wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

Definitions

[00036] BCF - Bulked Continuous Filament

[00037] SIPA - sulfonated isophthalic acid

Test Methods

[00038] Walk Test: The durability of the carpet was measured by the walk test under ASTM D6119 for creating surface appearance changes in pile yarn floor covering form foot traffic. [00039] Stain Resistance Test: Acid dye stain resistance is evaluated using a procedure modified from the American Association of Textiie Chemists and Co!orists (AATCC) Method 175-2003, "Stain Resistance: Pile Fioor Coverings." 9 wt% of aqueous staining solution is prepared, according to the manufacturer's directions, by mixing cherry-flavored KOOL-AID® powder (Kraft/General Foods, White Plains, N.Y., a powdered drink mix containing, inter alia, FD&C Red No. 40). A carpet sample (4x6- inch) is placed on a flat non-absorbent surface. A hollow plastic 2-inch (5.1 cm) diameter cup is placed tightly over the carpet sample. Twenty mL of the KOOL-AID® staining solution is poured into the cup and the solution is allowed to absorb completely into the carpet sample. The cup is removed and the stained carpet sample is allowed to sit undisturbed for 24 hours. Following incubation, the stained sample is rinsed thoroughly under cold tap water, excess water is removed by centrifugation, and the sample is dried in air. The carpet sample was visually inspected and rated for staining according to the FD&C Red No. 40 Stain Scale described in AATCC Method 175-2003. Stain resistance is measured using a 1- 0 scale. An undetectable test staining is accorded a value of 10. Ratings are determined by visual examination by a panel of evaluators.

[00040] Node Evaluation Procedure: The frequency of nodes formed by the process, and the tightness of the discrete nodes formed, were determined by visual observation. Typically, a length of yarn as provided by the process is hung vertically, with no tension applied. The length of yarn is 2.5 - 3 meters. Then, the number of moderate and severe interlace nodes, in the form of entangled or compacted regions, are counted along the length of the yarn. A moderate interlace node is adjudged to have a yarn diameter of less than 50% of the main yarn body. A severe interlace node is adjudged to have a diameter of less than 30% of the main yarn body. The routine is repeated for 4-5 more yarn segments representative a given sample, and the values determined used to provide an average number of moderate and severe interlace nodes for a given sample of yarn.

[00041] The SDN BCF yarns used to make the multicolor carpets of the current invention contain less than 5 severe interlace nodes per meter and typically, no severe interlace nodes are observed. SDN BCF yarns made by this process used in the current invention comprise less than 30 moderate interlace nodes. In other aspects of the current invention, the SDN BCF yarns comprise less than 20 moderate interlace per meter.

Examples

[00042] The following Examples demonstrate the present invention and its capability for use. The invention is capable of other and different embodiments, and its several details are capable of modifications in various apparent respects, without departing from the scope and spirit of the present invention. Accordingly, the Examples are to be regarded as illustrative in nature and non-limiting.

Example 1 (comparative)

[00043] Two ends of 1500 denier, 6.5 dpf solution dyed BCF yarn were ply twisted together (3.25 turns per inch) on a Voikman twisting machine. Both BCF used in this example were earth tone color yarns with slightly different shade (code as western sand and sand dune). The cable twisted yarn was heatset on Superba at 265 F and

converted into 0.5 inch pile height, 18 oz/yd. cut pile carpet on a 5/32 gauge tufting machine, a typical construction for low weight residential carpet.

[00044] The finished carpets was stained with Kool-aid for 24 hours, rinsed with water and judged by a panel of experts to have a stain rating of 6 in a 1 to 10 scale.

This sample failed the STAIN MASTER® stain protection requirement.

[00045] This carpet sample was also tested for newness retention in a Vetterman drum. After 5000 cycles, this sample had a severe worn out pattern and was rated by a panel of experts to be unacceptable as branded STAIN MASTER® carpet.

Example 2 (comparative) [00046] A 1500 denier, 6.5 dpf medium earth tone co!or solution dyed BCF yarn was tufted into a 18 oz/yd. 1/4" pile height cut pile carpet on a 1/12 gauge M-tufting machine. The finished solid color carpet had no tip definition and rated by a panel of experts to be aesthetically unacceptable for residential carpet.

Example 3 (current invention)

[00047] Three 1500 denier 6.5 dpf light, medium and dark earth tone solution dyed BCF yarns, after having passed the Node Evaluation Procedure, were alternately tufted into a 18 oz/yd. multicolor 1/4" pile height cut pile carpet on a 1/12 gauge M-tufting machine. The finished carpet had a different colored yarn tuft separating it in each direction from any other yarn tuft of the same color, and none of the yarns of the carpet were either twisted or heat set. Overall the carpet gave an attractive appearance. The mixture of colors in adjacent tufts gives a pseudo tip definition that was similar to the tip definition created by cable twist and heatset carpets.

[00048] The finished carpets was stained with Kool-aid for 24 hours, rinsed with water and judged by a panel of experts to have a stain rating of 10 in a 1 to10 scale. This sample passed the STAIN MASTER® stain protection requirement.

[00049] This carpet sample was also tested for newness retention in a Vetterman drum. After 5000 cycles, this sample had no worn out or crushed pattern. The tested carpet had the exact same look as the untested carpet.

Example 4 (current invention)

[00050] Three 1500 denier 6.5 dpf light, medium and dark earth tone solution dyed BCF yarn, after having passed the Node Evaluation Procedure, were alternately tufted into a 22 oz/yd. multicolor 1/4" pile height loop pile carpet on a 5/64 gauge M-tufting machine. The finished carpet had an attractive appearance.

[00051] The finished carpets was stained with Kool-aid for 24 hours, rinsed with water and judged by a panel of experts to have a stain rating of 10 in a 1 to 10 scale. This sample passed the STAINMASTER® stain protection requirement. [00052] This carpet sampie was also tested for newness retention in a Vetterman drum. After 5000 cycles, this sample had no worn out pattern. The tested carpet had the exact same look as the untested carpet.

Example 5 (current invention)

[00053] 1500 denier, 13 dpf solution dyed BCF yarn made from cationic dyeable polymer and, after having passed the Node Evaluation Procedure, were tufted on a 1/10 gauge tufting machine (color point by Card-Monroe Corporation). Two color light weight carpets (19 oz/yds. 10/32 inch pile height, 10 stitches per inch) with various patterns and color combinations were successfully produced without any processing issue. The finished carpets had an attractive appearance. The multicolor carpets formed from these yarns are depicted in FIGs. 1A and 1 B.

[00054] The finished carpets were stained with Kool-aid for 24 hours, rinsed with water and judged by a panel of experts to have a stain rating of 10 in a 1 to 10 scale. These samples passed the STAI MASTER® stain protection requirement.

[00055] These carpet samples were also tested for newness retention in a Vetterman drum. After 5000 cycles, this sample had no visible worn out pattern.

Example 6 (current invention)

[00056] 1500 denier, 13 dpf solution dyed BCF yarns made from cationic dyeable polymer and having passed the Node Evaluation Procedure were tufted on a 1/10 gauge tufting machine (color point by Card-Monroe Corporation). Three color light weight carpets (19 oz/yds. 10/32 inch pile height, 10 stitches per inch) with various patterns and color combinations were successfully produced without any processing issue. The finished carpets had an attractive appearance. The multicolor carpets formed from these yarns are depicted in FIGs. 2A, 2B and 2C.

[00057] The finished carpets were stained with Kool-aid for 24 hours, rinsed with water and judged by a panel of experts to have a stain rating of 10 in a 1 to 10 scale. These samples passed the STAINMASTER® stain protection requirement. [00058] These carpet samples were also tested for newness retention in a Vetterman drum. After 5000 cycles, this sample had no visible worn out pattern.

Example 7 (current invention)

[00059] 997 denier, 9 dpf solution dyed Nylon 66 BCF yarns made from cationic polymer and having passed the Node Evaluation Procedure were used for this example. In one case, two earth tone color yarns (western sand, color A, antique white, color B) were used in odd number needles and other two earth tone color yarns (Indian pottery color C, sand dune color D) were used in even number needles on a 1/10 gauge CMC color point tufting machine. Medium weight carpets (26 oz, 3/8" pile height, 10 stitched per inch) were successfully produced without any tufting issue. This sample was subject to 20,000 cycle walk test (ASTM D6119) at Professional test lab in Dalton Georgia. The rating was 3.5. it was considered as a good performing carpet. The multicolor carpet formed from these yarns is depicted in FIG 3A.

[00060] In another case, two grayish color yarns (Woodsmock, Burmese gray) were used in odd number needles and another two grayish color yarns (mineshaft, pearl) were used in even number needles on a 1/ 0 gauge CMC color point tufting machine. Medium weight carpet (32 oz, 3/8" pile height, 10 stitches per inch) were successfully produced without any processing issues. The multicolor carpet formed from these yarns is depicted in FIG 3B.

[00061] This sample was subjected to 20,000 cycle walk test at Professional Testing Laboratory, Inc. (Dalton, Georgia). The rating was 4.5, which rates the sample as a superior performing carpet.

Example 8 (current invention)

[00062] A 1800 denier 90 filament tri-color Nylon 6 BCF yarn was made on

Neumag S+ spinning machine. This yarn as spun, had 30 filaments each of black, gray and white color filaments. This yarn was tufted on a 1/8 gauge cut pile tufting machine to form a 18 oz/yd. 10/32 inch pile height, 10 stitch per inch cut pile carpet. It had an appearance of near solid color carpet but with interesting light, medium and dark toner effect.

Example 9 (current invention)

[00063] A 1800 denier 102 filament tri-coior polyester BCF yarn was made on Neumag S+ spinning machine. This yarn as spun, had 34 filaments each of black, dark brown and white color filaments. This yarn was tufted on a 1/8 gauge cut pile tufting machine to form a 18 oz/yd. 10/32 inch pile height, 0 stitch per inch cut pile carpet. It had an appearance of near solid color carpet but with interesting light, medium and dark toner effect.

[00064] It should be noted that ratios, concentrations, amounts, and other numerical data may be expressed herein in a range format, it is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. To illustrate, a concentration range of "about 0.1 % to about 5%" should be interpreted to include not only the explicitly recited concentration of about 0.1 wt% to about 5 wt%, but also the individual concentrations (e.g., 1 %, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.5%, 1.1 %, 2.2%, 3.3%, and 4.4%) within the indicated range. The term "about" can include ±1%, ±2%, ±3%, ±4%, ±5%, ±8%, or ±10%, of the numerical value(s) being modified. In addition, the phrase "about 'x' to 'y'^H includes "about 'x' to about y".

[00065] While the illustrative embodiments of the invention have been described with particularity, it will be understood that the invention is capable of other and different embodiments and that various other modifications will be apparent to and may be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims hereof be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing ail the features of patentable novelty which reside in the present disclosure, including all features which would be treated as equivalents thereof by those skilled in the art to which the invention pertains.

Claims

1. A multicolor carpet comprising a plurality of tufted yarns of at least two different colors, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

2. The multicolor carpet of claim 1 wherein the carpet has an appearance rating of at least 3 when subjected to a walk test according to ASTM D6119.

3. The multicolor carpet of claim 1 wherein the carpet has not been subjected to any downstream wet processing after tufting.

4. The multicolor carpet of claim 1 wherein yarns contain less than 30 moderate interlace nodes per meter.

5. The multicolor carpet of claim 1 wherein yarns contain less than 20 moderate interlace nodes per meter.

6. The multicolor carpet of claim 1 wherein yarns contain less than 5 severe

interlace nodes per meter.

7. The multicolor carpet of claim 1 wherein the carpet has a pile height of 0.5 inches or less.

8. The multicolor carpet of claim 1 wherein the carpet has a pile height of 0.375 inches or less.

9. The multicolor carpet of claim 1 wherein the carpet has a face weight in range of about 12 to about 50 ounces per yard.

10. The multicolor carpet of claim 1 wherein the carpet has a face weight in range of about 18 to about 40 ounces per yard.

11.The multicolor carpet of claim 1 wherein the carpet comprises between 2 to 8 different color yarns.

12. The multicolor carpet of claim 1 wherein the yarns are comprised of a plurality of filaments, and wherein at least a portion of the yarns are comprised of filaments of at least two different colors.

13. The multicolor carpet of claim 1 wherein the carpet is comprised of a plurality of tufts, wherein each tuft is comprised of at least one tufted yarn.

14. The multicoior carpet of claim 13 wherein the majority of tufts are immediately adjacent to at least one other tuft comprised of tufted yarn of at least one different co!or.

15. The multicoior carpet of claim 13 wherein each tuft is immediately adjacent to at ieast one other tuft comprised of tufted yarn of at least one different color.

16. The multicoior carpet of claim 1 wherein there is no 12 square inch area of the carpet covered by yarns of only a single co!or.

17. The multicolor carpet of claim 1 wherein there is no 4 square inch area of the carpet covered by yarns of only a singie color.

18. The multicolor carpet of claim 1 wherein there is no single square inch area of the carpet covered by yarns of only a single color.

19. The multicolor carpet of claim 1 wherein the solution-dyed bulked continuous filaments are formed from filaments selected from the group consisting of polyamides, polypropyienes, polyesters and copolymers and blends thereof.

20. The multicolor carpet of claim 1 wherein the solution-dyed bulked continuous filaments are formed from nylon 6,6 filaments.

21. The multicolor carpet of claim 1 wherein the solution-dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali metal salt thereof.

22. The multicoior carpet of claim 21 wherein the carpet has a stain rating of at ieast 5.

23. The multicolor carpet of claim 21 wherein the carpet has a stain rating of about 10.

24. The multicolor carpet of claim 21 wherein the aromatic sulfonate is 5- sulfoisophthalate.

25. The multicolor carpet of claim 1 wherein the plurality of tufted yarns further

comprises at ieast one conductive filament.

26. The multicolor carpet of claim 25 wherein the amount of conductive filaments is sufficient to form an antistatic carpet.

27. A multicolor carpet comprising a plurality of tufted yarns, wherein the yarns

comprise solution-dyed bulked continuous filaments, wherein the solution-dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali meta! salt thereof, wherein at least one of the yarns is of a different color than any of the other yarns, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

28. A multicolor carpet comprising a plurality of tufted yarns, wherein the yarns

comprise solution-dyed bulked continuous filaments, wherein the solution-dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali metal salt thereof, wherein at least one of the yarns is of a different color than any of the other yarns, wherein the plurality of tufted yarns further comprises at least one conductive filament , wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

29. The method of making a multicolor carpet comprising the step of tufting a

plurality of yarns to form a carpet, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein at least one of the yarns is of a different color than any of the other yarns, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

30. The method of claim 29 wherein the carpet has an appearance rating of at least 3 when subjected to a walk test according to ASTM D6119.

31. The method of claim 29 wherein the carpet has not been subjected to any

downstream wet processing after tufting.

32. The method of claim 29 wherein yarns contain less than 30 moderate interlace nodes per meter.

33. The method of claim 29 wherein yarns contain less than 5 severe interlace nodes per meter.

34. The method of claim 29 wherein the carpet has a pile height of 0.5 inches or less.

35. The method of claim 29 wherein the carpet has a face weight in range of about 12 to about 50 ounces per yard.

36. The method of claim 29 wherein the carpet comprises between 2 to 8 different color yarns.

37. The method of claim 29 wherein the yarns are comprised of a plurality of

filaments, and wherein at least a portion of the yarns are comprised of filaments of at least two different colors.

38. The method of claim 29 wherein the carpet is comprised of a plurality of tufts, wherein each tuft is comprised of at least one tufted yarn.

39. The method of claim 38 wherein the majority of tufts are immediately adjacent to at least one other tuft comprised of tufted yarn of at least one different color.

40. The method of claim 38 wherein each tuft is immediately adjacent to at least one other tuft comprised of tufted yarn of at least one different color.

41. The method of claim 29 wherein there is no 12 square inch area of the carpet covered by yarns of only a single color.

42. The method of claim 29 wherein there is no 4 square inch area of the carpet covered by yarns of only a single color.

43. The method of claim 29 wherein there is no single square inch area of the carpet covered by yarns of only a single color.

44. The method of claim 29 wherein the solution-dyed bulked continuous filaments are formed from filaments selected from the group consisting of polyamides, poiypropyienes, polyesters and copolymers and blends thereof.

45. The method of claim 29 wherein the soiution-dyed bulked continuous filaments are formed from nylon 6,6 filaments.

46. The method of claim 29 wherein the solution-dyed bulked continuous filaments further comprises an aromatic sulfonate or an alkali metal salt thereof.

47. The method of claim 46 wherein the carpet has a stain rating of at least 5.

48. The method of claim 46 wherein the aromatic sulfonate is 5-suifoisophthalic acid.

49. The method of claim 29 wherein the plurality of tufted yarns further comprises at least one conductive filament.

50. The method of claim 49 wherein the amount of conductive filaments is sufficient to form an antistatic carpet.

51. An article of manufacture, at least a portion of which comprises the multicolor carpet of any of claims 1 through 50.