Classifications

• • D—TEXTILES; PAPER
  • D05—SEWING; EMBROIDERING; TUFTING
  • D05C—EMBROIDERING; TUFTING
  • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
  • D05C17/02—Tufted products
  • D05C17/026—Tufted products characterised by the tufted pile surface
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
  • D02G3/445—Yarns or threads for use in floor fabrics
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
  • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
  • D06N7/0065—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
  • D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/23907—Pile or nap type surface or component
  • Y10T428/23993—Composition of pile or adhesive

Definitions

• the invention relates to multicolor carpets formed from solution-dyed, BCF fibers.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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 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.
• a method of making a multicolor carpet 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.
• 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.
• 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.
• 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 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.
• F!G. 1 A and FIG. 1 B are images of multicolor carpets of the current invention.
• FIG. 2A, FIG. 2B and FIG. 2C are images of multicolor carpets of the current invention.
• FIG. 3A and FIG. 3B are images of multicolor carpets of the current invention.
• 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.
• 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.
• the inventors have found that multicolor carpets of the current invention can be produced with satisfactory aesthetics, wear performance and staining properties.
• 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.
• 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.
• 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.
• multicolor carpets are formed from solution dyed BCF yarns that are essentially free of severe interlace nodes
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• the multicolor carpet is comprised of a plurality of tufts, wherein each tuft is comprised of at least one tufted yarn.
• each tuft is comprised of tufted yarn of a single color.
• 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.
• the use of a single color yarn over large areas of the carpet should be minimized.
• an ABAB thread up can be used.
• an ABCABC thread up can be used.
• a four color carpet an AB CD two ends per needle thread up can be used.
• the majority of tufts are immediately adjacent to at least one other tuft comprised of tufted yarn of at least one different color.
• each tuft is immediately adjacent to at least one other tuft comprised of tufted yarn of at least one different color.
• the multicolor carpets of the present invention also exhibit excellent durability.
• the carpet has an appearance rating of at least 3 when subjected to a walk test according to ASTM
• the carpet has an appearance rating of at least 4.5 when subjected to a walk test according to ASTM D6119.
• 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
• 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.
• the solution-dyed bulked continuous filaments are formed from nylon 6,6 polymer.
• the solution-dyed bulked continuous filaments are formed from aliphatic carbon filaments, especially polypropylene.
• 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.
• the solution-dyed bulked continuous filaments of the multicolor carpet further comprise a cationic dye additive.
• 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.
• the cationic dye additive is 5- sulfoisophthalate.
• 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.
• 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.
• the plurality of tufted yarns used in the multicolor carpet further comprises at least one conductive filament.
• 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.
• 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.
• the present invention also provides for a method of manufacturing a multicolor carpet.
• 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.
• 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.
• 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
• 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.
• 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
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• the phrase "about 'x' to 'y' H includes "about 'x' to about y".

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Mechanical Engineering (AREA)
• Carpets (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Artificial Filaments (AREA)

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Publications (2)

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• 2015
  • 2015-04-08 CN CN201580018558.5A patent/CN106661827A/zh active Pending
  • 2015-04-08 US US15/302,428 patent/US20170016160A1/en not_active Abandoned
  • 2015-04-08 AU AU2015243916A patent/AU2015243916B2/en not_active Ceased
  • 2015-04-08 WO PCT/US2015/024862 patent/WO2015157380A1/en active Application Filing
  • 2015-04-08 EP EP15776948.0A patent/EP3129545A4/de not_active Withdrawn

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