EP3653787A1 - Gepolsterte teppiche mit polyestergarn und verfahren zu deren herstellung - Google Patents

Gepolsterte teppiche mit polyestergarn und verfahren zu deren herstellung Download PDF

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Publication number
EP3653787A1
EP3653787A1 EP18208540.7A EP18208540A EP3653787A1 EP 3653787 A1 EP3653787 A1 EP 3653787A1 EP 18208540 A EP18208540 A EP 18208540A EP 3653787 A1 EP3653787 A1 EP 3653787A1
Authority
EP
European Patent Office
Prior art keywords
polyester
rug
filaments
fibers
modifier
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP18208540.7A
Other languages
English (en)
French (fr)
Inventor
Mack BRINDLE
Jacqueline KILLINGS
Melissa North
Maria HOOKER
Alfred SCROGGINS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aladdin Manufacturing Corp
Original Assignee
Aladdin Manufacturing Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aladdin Manufacturing Corp filed Critical Aladdin Manufacturing Corp
Priority to CA3118551A priority Critical patent/CA3118551A1/en
Priority to CN201980074694.4A priority patent/CN113015466A/zh
Priority to PCT/US2019/060414 priority patent/WO2020102013A1/en
Priority to EP19884686.7A priority patent/EP3880038A4/de
Priority to MX2021005544A priority patent/MX2021005544A/es
Priority to AU2019379532A priority patent/AU2019379532A1/en
Publication of EP3653787A1 publication Critical patent/EP3653787A1/de
Priority to US17/811,783 priority patent/US20220341089A1/en
Pending legal-status Critical Current

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Classifications

    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N7/00Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063Floor 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
    • D06N7/0065Floor 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
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47GHOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00Floor fabrics; Fastenings therefor
    • A47G27/02Carpets; Stair runners; Bedside rugs; Foot mats
    • A47G27/0212Carpets; Stair runners; Bedside rugs; Foot mats to support or cushion
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/88Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds
    • D01F6/92Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polycondensation products as major constituent with other polymers or low-molecular-weight compounds of polyesters
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0036Polyester fibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06PDYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/34Material containing ester groups
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06PDYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/34Material containing ester groups
    • D06P3/52Polyesters
    • D06P3/54Polyesters using dispersed dyestuffs
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06PDYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/02After-treatment
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, 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
    • D06N2201/00Chemical constitution of the fibres, threads or yarns
    • D06N2201/02Synthetic macromolecular fibres
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06PDYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P1/00General processes of dyeing or printing textiles, or general processes of dyeing leather, furs, or solid macromolecular substances in any form, classified according to the dyes, pigments, or auxiliary substances employed
    • D06P1/0004General aspects of dyeing
    • D06P1/0008Dyeing processes in which the dye is not specific (waste liquors)
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2503/00Domestic or personal
    • D10B2503/04Floor or wall coverings; Carpets

Definitions

  • the invention relates to washable rugs comprising polyester yarn, particularly polyethylene terephthalate (PET) yarn, having a sufficiently low degree of crystallinity so as to improve dye pickup and enable a rinsing or scouring process to remove excess dye molecules following the dyeing cycle.
  • PET polyethylene terephthalate
  • the invention further relates to methods of preparing such washable rugs.
  • beck dyeing in which the rugs and carpet are submerged in a vat comprising dye and water.
  • PET Polyethylene terephthalate
  • PET carpets and rugs are dyed with dispersed dyes.
  • the dye used for PET acts more like a stain that is adhered to the PET fiber. This dye also stains most other materials in the backings of carpet and rugs.
  • carpet manufacturing the finished backing is applied after the dyeing process to avoid staining. For beck dyed rugs, the backing is applied before dyeing. Therefore the backing is exposed to staining from the dispersed dyes.
  • a thickness of foam and/or adhesive is attached to the underside of a section of a tufted primary backing.
  • the foam and/or adhesive may provide cushioning and support.
  • rugs of this type are preferably washable by the consumer.
  • PET rugs have primarily been produced using solution dyeing or yarn dyeing for the tufts.
  • beck dyeing which is also referred to as piece-dyeing in this context. Smaller batches of rugs produced in multiple colors could be manufactured more efficiently.
  • foam and/or adhesive backing or "backing"
  • a person of skill in the art would not have thought it possible to use beck dyeing for PET rugs.
  • the entire rug, including the tufted primary backing and the rug backing would be submerged and saturated in the dye vat.
  • the amount of dye required to properly dye the PET fibers would be thought to have one or more several undesirable features, such dyeing or staining of the backing, the inability for a consumer to wash the rugs, and crocking and transfer of dye, in which some of the dye is rubbed off of the rug and onto adjacent surfaces, such as the floor. This would be thought to be especially problematic with regards to darker colors, which require the absorption of more dye; this often results in more excess dye remaining in the rug backing when the rug is in the possession of the consumer, which in turn increases the risk and severity of crocking and transfer of dye.
  • the process for removing excess dye following beck-dyeing is called "scouring,” and typically involves submerging the dyed carpet or rug in caustic chemicals. This is not always completely effective, especially when an excess of dye is used, due to the low dyeability of PET fibers and/or to the need to prepare darker-colored fibers.
  • a rug comprising
  • the rug may coprise a textile face fabric comprising a polyester yarn, said polyester yarn comprising polyester fibers or filaments, said fibers or filaments having an average percent crystallinity of less than about 30%, and said fibers or filaments comprising a crystallinity-reducing modifier; and a backing layer secured to the textile face fabric.
  • the polyester fibers or filaments may comprise polyethylene terephthalate (PET).
  • PET polyethylene terephthalate
  • the backing layer may comprise foam, the foam having a density ranging from about 2 oz per square yard to about 50 oz per square yard.
  • the backing layer may comprise a polyurethane foam.
  • the backing layer may comprise an adhesive.
  • the adhesive may be a foamed adhesive.
  • the polyester fiber or filament may comprise the modifier in an amount from about 0.5% to about 16% by weight.
  • the modifier may be a branched polyester.
  • the modifier may be polybutylene adipate terephthalate (PBAT).
  • the polyester yarn may comprise continuous filaments.
  • the filaments may be bulked continuous filaments.
  • the polyester yarn may exhibit increased dyeability compared to a polyester yarn comprising polyester fibers or filaments that have the same degree of crystallinity, but lack the modifier.
  • the increase in dyeability may be at least about 1% to at least about 300%, e.g. at least 1% to at least 25%.
  • the polyester fibers or filaments may comprise recycled polyester.
  • the recycled polyester may be recycled PET.
  • the recycled PET may have been recovered from carpet waste or plastic bottles.
  • the polyester fibers or filaments may comprise recycled PET and virgin PET, and wherein the ratio of recycled PET to virgin PET is from about 99:1 to about 1:99.
  • the rug may further comprise at least one component selected from the group consisting of finishing agents, delusterants, viscosity modifiers, optical brighteners, matting agents, thermal stabilizing agents, anti-oxidative agents, anti-static agents, pigments, and ultra-violet stabilizing agents.
  • a method of manufacturing a cushioned rug comprising:
  • the caustic liquid may comprise a dispersant.
  • the dispersant may be naphthalene sulfonate.
  • the polyester fibers or filaments may be fibers or filaments comprising polyethylene terephthalate (PET) yarn.
  • PET polyethylene terephthalate
  • the backing layer may comprise foam, said foam having a density ranging from about 2 oz per square yard to about 50 oz per square yard.
  • the backing layer may comprise a polyurethane foam.
  • the backing layer may comprise adhesive.
  • the adhesive may be a foamed adhesive.
  • the polyester fibers or filaments may comprise the modifier in an amount from about 1% to about 16% by weight.
  • the modifier may be a branched polyester.
  • the modifier may be polybutylene adipate terephthalate (PBAT).
  • the polyester yarn may comprise continuous filaments.
  • the continuous filaments may be bulked continuous filaments.
  • the method further may comprise the step of providing said polyester yarn, wherein said polyester fibers or filaments are extruded fibers or filaments obtained by melt extrusion of a molten polymer, said polymer comprising said crystallinity-reducing modifier, and drawing said extruded filaments so as to obtain a crystallinity of less than 30%.
  • the polyester yarn may exhibit increased dyeability compared to a polyester yarn comprising polyester fibers or filaments that have the same degree of crystallinity, but lack a modifier.
  • the increase in dyeability may be at least about 1% to at least about 300%, such as at least 1% to at least 25%.
  • the polyester fibers or filaments may comprise recycled polyester.
  • the recycled polyester may be recycled PET.
  • the recycled PET has been recovered from carpet waste or plastic bottles.
  • the polyester fibers or filaments may comprise recycled PET and virgin PET, and wherein the range of recycled PET to virgin PET ranges from about 99:1 to about 1:99.
  • the methods according to this second aspect of the inventing may provide rugs according to the first aspect of the invention.
  • a method to provide a rug comprises
  • 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. Further, 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.
  • recycled refers to any material that is post-consumer or post-industrial material.
  • a "backing” refers to a foam and/or adhesive layer. This is distinct from the primary or secondary backings found in carpet.
  • face fabric refers to yarns or fibers in combination with a primary backing, and optionally a secondary backing.
  • a "crystallinity-reducing modifier” is a modifier which reduces the crystallinity of a fiber or filament, compared to the crystallinity of a fiber or filament lacking the modifier, when added to the polymer from which the fiber or filament is made
  • a "greige” fabric is a fabric that is unfinished in some way, such as not being dyed.
  • to "secure” two objects together means to fix or attach the objects to each other, by means such as an adhesive or otherwise.
  • the term in terms of an effect, refers to the case where the interaction or presence of two elements produces a greater effect than would be expected based on the effect created by each of those elements individually.
  • the term may refer to a case where a fiber, F1, comprising a modifier and having decreased crystallinity compared to another fiber, F2, which lacks said modifier and has higher crystallinity, exhibits a greater improvement in dyeability, or some other property or metric of performance, compared to F2, than would be expected based on the improvements exhibited by two other fibers, the first of which contains the modifier but has the same degree of crystallinity as F2, and the second of which lacks the modifier but has the same degree of crystallinity as F1.
  • An embodiment of the invention is a rug, comprising
  • said rug consists essentially of said textile face fabric and said backing layer. In an embodiment, said rug consists of said textile face fabric and said backing layer.
  • the average percent crystallinity is less than about 29%, 28%, 27%, 26%, 25%, 24%, 23%, 22%, 21%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2% or 1%.
  • polyester fibers or filaments comprise polyethylene terephthalate (PET).
  • said backing layer comprises foam, said foam having a density ranging from about 2 oz per square yard to about 50 oz per square yard.
  • said backing layer comprises a polyurethane foam.
  • said backing layer comprises a viscoelastic foam material.
  • said backing layer comprises adhesive.
  • said adhesive is a foamed adhesive.
  • the polyester fiber or filament comprises the modifier in an amount from about 0.5% to about 16% by weight. In embodiments, the polyester fiber or filament comprises the modifier in an amount of less than, greater than, or equal to about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, or 16% by weight. In embodiments, the polyester fiber or filament comprises the modifier in an amount from about 1% to about 15%, about 3% to about 14%, about 5% to about 12%, or about 8% to about 10% by weight. Preferably, the polyester fiber or filament comprises the modifier in an amount from about 8% to about 10%. In an embodiment, the modifier is a branched polyester. In an embodiment, the modifier is polybutylene adipate terephthalate (PBAT).
  • PBAT polybutylene adipate terephthalate
  • the polyester yarn comprises continuous filaments.
  • the continuous filaments are bulked continuous filaments.
  • the polyester yarn exhibits increased dyeability compared to a polyester yarn comprising polyester fibers or filaments that have the same degree of crystallinity, but lack the modifier.
  • the increase in dyeability is at least about 1% to at least about 300%. In a further embodiment, the increase is at least 1% to at least 25%.
  • the polyester fibers or filaments comprise recycled polyester.
  • the recycled polyester is recycled PET.
  • the recycled PET has been recovered from carpet waste or plastic bottles.
  • the polyester fibers or filaments comprise recycled PET and virgin PET, and wherein the ratio of recycled PET to virgin PET is from about 99:1 to about 1:99.
  • the rug further comprises at least one component selected from the group consisting of finishing agents, delusterants, viscosity modifiers, optical brighteners, matting agents, thermal stabilizing agents, anti-oxidative agents, anti-static agents, pigments, and ultra-violet stabilizing agents.
  • An embodiment of the invention is a method of manufacturing a cushioned rug, said method comprising:
  • the average percent crystallinity is less than about 29%, 28%, 27%, 26%, 25%, 24%, 23%, 22%, 21%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2% or 1%.
  • the griege fabric is obtained by tufting.
  • the yarn is obtained by melt spinning or by extrusion spinning.
  • said caustic liquid comprises a dispersant.
  • said dispersant is naphthalene sulfonate.
  • said polyester fibers or filaments are fibers or filaments comprising polyethylene terephthalate (PET) yarn.
  • PET polyethylene terephthalate
  • said backing layer comprises foam, said foam having a density ranging from about 2 oz per square yard to about 50 oz per square yard.
  • said backing layer comprises a polyurethane foam.
  • said backing layer comprises a viscoelastic foam material.
  • said backing layer comprises adhesive.
  • said adhesive is a foamed adhesive.
  • the polyester fiber or filament comprises the modifier in an amount from about 0.5% to about 16% by weight. In embodiments, the polyester fiber or filament comprises the modifier in an amount of less than, greater than, or equal to about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, or 16% by weight. In embodiments, the polyester fiber or filament comprises the modifier in an amount from about 1% to about 15%, about 3% to about 14%, about 5% to about 12%, or about 8% to about 10% by weight. Preferably, the polyester fiber or filament comprises the modifier in an amount from about 8% to about 10%. In an embodiment, the modifier is a branched polyester. In an embodiment, the modifier is polybutylene adipate terephthalate (PBAT).
  • PBAT polybutylene adipate terephthalate
  • the polyester yarn comprises continuous filaments.
  • the continuous filaments are bulked continuous filaments.
  • the method further comprises the step of providing said polyester yarn, wherein said polyester fibers or filaments are extruded fibers or filaments obtained by melt extrusion of a molten polymer, said polymer comprising said crystallinity-reducing modifier, and drawing said extruded filaments so as to obtain a crystallinity of less than 30%.
  • the polyester yarn exhibits increased dyeability compared to a polyester yarn comprising polyester fibers or filaments that have the same degree of crystallinity, but lack the modifier.
  • the increase in dyeability is at least about 1% to at least about 300%. In a further embodiment, the increase is at least 1% to at least 25%.
  • the polyester fibers or filaments comprise recycled polyester.
  • the recycled polyester is recycled PET.
  • the recycled PET has been recovered from carpet waste or plastic bottles.
  • the polyester fibers or filaments comprise recycled PET and virgin PET, and wherein the ratio of recycled PET to virgin PET is from about 99:1 to about 1:99.
  • Fig. 1 shows a schematic cross-sectional view of a cushioned rug 2 according to one embodiment of the present invention.
  • the cushioned rug 2 is a layered structure comprising a top layer of face fabric 4 , and a backing layer 6 .
  • the backing layer 6 comprises a single layer of foam.
  • the backing layer 6 may be a composite of multiple foam layers with an optional fabric layer on the bottom.
  • backings of various densities and/or thicknesses may be secured together to produce various cushioning effects.
  • These foams may also be embossed to create a pattern in the backing.
  • the density of the foam may be 2 oz per square yard to 50 oz per square yard.
  • the foam may have a thickness of up to 1".
  • the foam is in the form of a non-skid layer.
  • the foam is viscoelastic foam or polyurethane foam. The foam can also be produced out of natural and synthetic latex rubber.
  • the backing layer 6 may be a foamed adhesive, which is secured to the face fabric 4 by its own adhesive properties.
  • the foam may be a layer of foam material which has been laminated to the face fabric 4 .
  • Fig. 2 illustrates schematically one potential carpet construction of the face fabric 4, or carpet, portion of Fig. 1 . It is generally designated by reference numeral 21 .
  • the carpet 21 includes face yarn 22 , which is tufted into a mesh, woven, or spunbonded fabric known as a primary backing 25 .
  • the primary backing 25 has pile yarns 22 tufted therethrough extending outwardly from one face, a primary backcoating or precoat 23 on the opposite face, and at least one secondary backcoating or main coat (frequently called a skip coat) 24 .
  • Other layers may also be associated with the carpet 1 .
  • the primary backcoating or precoat 23 generally comprises carboxylated latex (e.g ., a styrene-butadiene-based latex), PVC (polyvinylchloride), EVA (ethylenevinyl acetate), or other polymer-based material, and the secondary backcoating 24 may also include these same polymers.
  • This primary and/or secondary backcoating may be foamed polymer.
  • One or both of the primary backcoatings 23 and secondary backcoating(s) 24 can 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, or the like, may be utilized.
  • the carpet 1 may be produced with the filler in one or both of the primary backcoating 23 and secondary backcoating(s) 24 comprising waste carpeting as all or part of the filler.
  • only one single backcoating may be provided instead of a primary and secondary backcoating. Like the primary backcoating in the first alternative, this single backcoating will also anchor the pile yarns in the primary backing .
  • This single backcoating may be composed of the same material as set out for the primary and secondary bckcoating.
  • the fiber tufts are tufted through a woven or non-woven fabric, which is the primary backing 25 .
  • the part of the tufts on the exposed surface of the carpet comprises the face fiber or face yarn 2 .
  • a back-coating 23 is applied to the back of the tufted structure to lock in the tufts.
  • a woven or non-woven secondary backing 24 is laminated to the back of the primary backing 25 to give the carpet added dimensional stability.
  • the primary backing is a supportive scrim through which the tufts are tufted, and frequently is polyolefin, such as polyethylene or polypropylene; however, other materials such as polyester (including, for example, PET) can be used.
  • polyolefin such as polyethylene or polypropylene
  • other materials such as polyester (including, for example, PET) can be used.
  • slit tapes made from PET may be used.
  • the secondary backing is a fabric that is adhered behind the primary backing, sandwiching therein the back of the tufts with the adhesive material.
  • the secondary backing is frequently made of polypropylene; however other backing types, such as jute, PVC (polyvinyl chloride), polyurethane, and PET, can be used.
  • the secondary backing may be a non-woven fabric, including, but not limited to, spun-bond, wet-laid, melt-blown, and air-entangled.
  • a filler material such as calcium carbonate
  • an adhesive material are generally applied to the backside of the tufted carpet backing as a slurry in various concentrations.
  • a representative filler-to-adhesive ratio can comprise about 80 percent by weight (“wt %" or "%") calcium carbonate to about 20 wt % adhesive. While calcium carbonate is one of the most commonly employed filler materials, it should be recognized by those skilled in the art to which this disclosure pertains that carpets containing other filler materials can be used in the processes described herein.
  • the adhesive material functions to bind the tufts with the backing.
  • the adhesive material can include a latex, such as a carboxylic-styrene-butadiene rubber, styrene-butadiene rubber (SBR), natural rubber latex, vinyl acetate ethylene copolymers (VAE or EVA), other natural or synthetic rubbers, urethanes or polymers such as PET. While latex is one of the most commonly employed adhesive materials for holding tufts to the carpet backing, it should be recognized by those skilled in the art to which this disclosure pertains that carpets containing other adhesives can be used in the processes described herein.
  • a latex such as a carboxylic-styrene-butadiene rubber, styrene-butadiene rubber (SBR), natural rubber latex, vinyl acetate ethylene copolymers (VAE or EVA), other natural or synthetic rubbers, urethanes or polymers such as PET. While latex is one of the most commonly employed adhesive
  • the polyester can comprise a PET polymer such as LASER+® PET (available from DAK Americas), NAN YA® PET (Nan Ya Plastics Corporation, America), other PET polymers, or combisecnations thereof.
  • PET can be produced, for example, by a transesterification reaction of dimethyl terephthalate and ethylene glycol, or by esterification of terephthalic acid and ethylene glycol.
  • PET may be provided from both virgin and recycled resins.
  • the PET comprises recycled PET that is recovered from soda and water bottles.
  • the PET may be in flake or pellet form in any of the embodiments described herein. Further, a single polyester or a blend of two or more polyesters may be used. Unless otherwise noted, the polyester used in any of the embodiments of the invention may be virgin, recycled, or a blend thereof.
  • the fibers may be formed from the polymer by any method known in the art to produce fibers from a single polyester or from a blend.
  • the polymer can be extruded to have any shape or dimension suitable to polymeric carpet fibers.
  • the carpet fibers can undergo any post-spinning processes generally recognized as useful in the preparation of polymeric carpet fibers.
  • the fibers may be as-spun or heat-set.
  • fibers reference is made to items, recognized in the art as fibers, such as continuous filaments, monofilaments, staple fibers, and the like.
  • the fibers can be round or have other shapes, such as octalobal, delta, sunburst (also known as sol), scalloped oval, trilobal, tetra-channel (also known as quatra-channel), scalloped ribbon, ribbon, starburst, and the like.
  • the fibers may also be solid, hollow, or multi-hollow.
  • the fibers can be used to make yarns, and the fibers or yarns can be used to prepare a number of materials, particularly carpets, rugs, mats, and the like.
  • the fibers of the present invention may further comprise other components, such as, without limitation, finishing agents, delusterants, viscosity boosters, optical brighteners, matting agents (e.g ., titanium oxide), thermal stabilizing agents (e.g ., phosphorous compounds), anti-oxidative agents (e.g ., hindered phenol), anti-static agents, pigments, ultra-violet blocking agents, and combinations thereof.
  • finishing agents e.g ., titanium oxide
  • thermal stabilizing agents e.g ., phosphorous compounds
  • anti-oxidative agents e.g ., hindered phenol
  • anti-static agents e.g ., pigments, ultra-violet blocking agents, and combinations thereof.
  • the yarns may be prepared according to any method for preparing yarns recognized in the art as being useful therefore.
  • the yarn of the invention could be partially oriented yarn, spun drawn yarn, textured yarn, friction false-twisted yarn, and bulk continuous filament ("BCF") yarn.
  • Preferred steps in preparing BCF yarn includes spinning (e.g ., extruding, cooling, and coating filaments), single stage or multi-stage drawing (such as with heated rolls, heated pin or hot fluid assist) at a defined temperature and draw ratio, annealing, bulking, entangling, optionally relaxing, and winding the filaments on a package for subsequent use.
  • One improvement for reducing the amount of time and energy required to properly dye polyester fibers is a modifier that is mixed into the polymer of the fiber before the fiber is created, such as during an extrusion process.
  • a modifier is polybutylene adipate terephthalate (PBAT) (available from BASF SE, Ludwigshafen, Germany, under the ecoflex® brand).
  • PBAT polybutylene adipate terephthalate
  • One genus of suitable modifiers are branched polyester modifiers.
  • the PBAT modifier acts by adding amorphous zones to the structure of the fiber.
  • a fiber with decreased crystallinity, and therefore with more amorphous zones will exhibit greater dyeability than a fiber having a greater degree of crystallinity, even if the fiber is otherwise identical.
  • the amorphous zones provide more locations in the fiber for the dye to be taken up. While these amorphous zones decrease crystallinity and thus fiber tenacity, this disadvantage is offset by the increased take up of the dye by the fiber.
  • By using the modifier and increasing the take-up of the dye by the fiber i.e. increasing the dyeability of the fiber), achieving the desired shade occurs more quickly and less dye is required in the vat, or less time and machine energy are required, to dye the fiber.
  • the fiber (or a rug containing the fiber) can spend less time in the beck-dyeing vat. In a cushioned rug, this results in less dye being taken up by the backing, and less dye that must be removed from the backing prior to being provided to the consumer.
  • a scouring process for removing excess dye from a beck-dyed PET washable rug after dyeing involves submerging the dyed rugs in a vat of caustic chemicals, such as soda ash or sodium hydroxide, which act to remove excess dye from the fibers.
  • caustic chemicals such as soda ash or sodium hydroxide
  • This scouring process can be improved by adding dispersant chemicals, such as naphthalene sulfonate, to the vat.
  • the present inventors have found that by using a modifier in a PET fiber that allows for less dye to be used in the vat, or for faster dyeing, thereby reducing the amount of dye taking up by the backing, in combination with a scouring process using both caustic and dispersant chemicals to remove excess dye, it is possible to beck dye rugs made with PET fibers without the resultant rug having an undesirably stained backing or causing crocking or transfer of dye to the floor. In addition, the rugs are washable by the consumer.
  • the inventors are the first to combine a pre-dyeing fiber modifier with a post-dyeing scouring process using both caustic and dispersant chemicals.
  • the inventors By reducing the amount of dye required for the dyeing step, and then removing excess dye after the dyeing step, the inventors have invented a beck-dyed PET rug, and process for making the same, that is colorfast and washable.
  • the following method describes the process of making a cushioned rug using PET yarn and a PBAT modifier; one of skill in the art will readily recognize that the method may be practiced with different polyesters and modifiers.
  • MFS Multiple Rotating Screw
  • a BCF (bulked continuous filament) manufacturing process may generally be broken down into four steps: (1) preparing flakes of polyester polymer from post-consumer bottles for use in the process; (2) passing the flakes through an extruder that melts the flakes and purifies the resulting polymer; (3) feeding the polyester polymer into a spinning machine, and (4) adding a modifier into the spinning machine, where the spinning machine turns the polyester polymer (and modifier into filament or fiber for use in manufacturing yarns for carpets and rugs.
  • the MRS extruder includes a first single-screw extruder section 410 for feeding material into an MRS section 420 and a second single-screw extruder section 440 for transporting material away from the MRS section.
  • the molten polymer is cooled into pellets These pellets are then melted and fed into a BCF (or "spinning") machine.
  • BCF or "spinning" machine.
  • PBAT is also added to the spinning machine, which is configured to turn the molten polymer and PBAT into bulked continuous filament. If using virgin polymer (such as virgin PET), no purification step would be performed, and pellets of the virgin polymer would be added directly to the spinning machine.
  • the modifier is combined with the PET at a loading percentage from 1-16%. In a further embodiment, the modifier is combined with the PET at a loading percentage of 8%.
  • the spinning machine extrudes molten polymer through small holes in a spinneret in order to produce yarn filaments from the polymer.
  • the molten polymer cools after leaving the spinneret.
  • the yarn is then taken up by rollers and ultimately turned into filaments that are used to produce carpet and rugs.
  • the yarn produced by the spinning machine may have a tenacity between about 2 gram-force per unit denier (gf/den) and about 9 gf/den.
  • the resulting yarn has a tenacity of at least about 2 gf/den.
  • the spinning is performed at a temperature within the range of 220°C-350°C. In a further embodiment, the spinning is performed at 280°C.
  • the yarn is tufted to a primary backing to form a "face fabric.”
  • the tufted carpet is taken to a Coater where liquid foam or adhesive material is pumped directly onto the back of the carpet. As the carpet moves under the applicator roller, the backing material is scraped or gauged to the desired thickness.
  • the carpet may pass through a preheat oven to allow a pattern to be embossed into the backing material. The material is then taken through a heated oven or alternate energy source to cure the foam or adhesive to form a cushioned rug.
  • the cushioned rug is then cut and sewn and put into a batch size suitable to be beck-dyed in a vat of disperse dye.
  • the size of the batch is dependent on the capacity of the beck machine.
  • the rugs are loaded into the beck and desired ambient water level is added. Water content is at a range of a 3/1 ratio up to a 20/1 ratio to the weight of the rugs.
  • Disperse dye is then added to the beck.
  • the beck water is then heated at a controlled rate up to 212F causing the dye to adhere to the fiber.
  • the rugs are circulated in the beck until the dye is evenly distributed on the fiber.
  • the dye water is drained and the beck is refilled with water for a rinse cycle.
  • the rinse water is then drained. Rinse cycle can be repeated as necessary. If the rugs require scouring, the beck will fill with water again to begin the scouring cycle. If the rugs do not require scouring, the rugs will
  • the cushioned rug is scoured so as to remove excess dye.
  • the beck is filled with water again.
  • Caustic liquid such as a liquid comprising soda ash or sodium hydroxide is added to the beck.
  • the caustic liquid may include a dispersant.
  • the dispersant is naphthalene sulfonate.
  • the caustic liquid is at a pH from 7.5-11.
  • the rugs are circulated in the beck in a water temperature ranging from ambient up to 212°F. The scouring water is then drained and the beck goes back into rinsing mode before the rugs are moved to the drying process.
  • the caustic liquid is at a pH of about 7.5 8, 8.5, 9, 9.5, 10, 10.5, or 11. In alternate embodiments, the caustic liquid is at a pH of greater than or less than about 7.5, 8, 8.5, 9, 9.5, 10, 10.5, or 11.
  • the process may utilize a polymer flow extrusion system other than the MRS extruder described above.
  • the alternative extrusion system may include for example, a twin screw extruder, a multiple screw extruder, a planetary extruder, or any other suitable extrusion system.
  • the process may include a plurality of any combination of any suitable conical screw extruders ( e.g ., four twin screw extruders, three multiple screw extruders, etc.).
  • the melted components can be fed directly into a suitable spinning machine to be combined with the modifier and turned into fiber. Recycled PET flake is fed into the extruder from one feeder and the modifier is fed into the extruder from another feeder.
  • recycled PET pellets are fed into the extruder from one feeder and the modifier is fed into the extruder from another feeder.
  • virgin PET pellets are fed into the extruder from one feeder and the modifier is fed into the extruder from another feeder.
  • recycled PET pellets and modifier are mixed together in one feeder before melting, and the pellet mixture is fed into the extruder.
  • virgin PET pellets and modifier are mixed together in one feeder before melting and the pellet mixture is fed into the extruder.
  • recycled PET pellets are mixed with virgin PET pellets and fed into the extruder from one feeder and the modifier is fed into the extruder from another feeder.
  • recycled PET pellets, virgin PET pellets, and the modifier are mixed together in one feeder before melting and the pellet mixture is fed into the extruder.
  • additives such as delusterants, colorants, stabilizers, etc., as discussed previously.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Carpets (AREA)
EP18208540.7A 2018-11-13 2018-11-27 Gepolsterte teppiche mit polyestergarn und verfahren zu deren herstellung Pending EP3653787A1 (de)

Priority Applications (7)

Application Number Priority Date Filing Date Title
CA3118551A CA3118551A1 (en) 2018-11-13 2019-11-08 Polyester yarn cushioned rugs and methods of manufacturing same
CN201980074694.4A CN113015466A (zh) 2018-11-13 2019-11-08 聚酯纱线缓冲地垫及其制造方法
PCT/US2019/060414 WO2020102013A1 (en) 2018-11-13 2019-11-08 Polyester yarn cushioned rugs and methods of manufacturing same
EP19884686.7A EP3880038A4 (de) 2018-11-13 2019-11-08 Gepolsterte teppiche aus polyestergarn und verfahren zu ihrer herstellung
MX2021005544A MX2021005544A (es) 2018-11-13 2019-11-08 Alfombras acolchadas con hilo de poliester y metodos de fabricacion de las mismas.
AU2019379532A AU2019379532A1 (en) 2018-11-13 2019-11-08 Polyester yarn cushioned rugs and methods of manufacturing same
US17/811,783 US20220341089A1 (en) 2018-11-13 2022-07-11 Bath rug scouring modifier

Applications Claiming Priority (1)

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US201862760667P 2018-11-13 2018-11-13

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EP3653787A1 true EP3653787A1 (de) 2020-05-20

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EP19884686.7A Pending EP3880038A4 (de) 2018-11-13 2019-11-08 Gepolsterte teppiche aus polyestergarn und verfahren zu ihrer herstellung

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EP (2) EP3653787A1 (de)
CN (1) CN113015466A (de)
AU (1) AU2019379532A1 (de)
CA (1) CA3118551A1 (de)
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WO (1) WO2020102013A1 (de)

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EP3835480A1 (de) * 2019-12-10 2021-06-16 Aladdin Manufacturing Corporation Kombinationsgarn

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US20030152743A1 (en) * 1999-04-26 2003-08-14 Atsushi Matsunaga Base cloth for tufted carpet and tufted carpet using the same
US20120282431A1 (en) * 2010-07-21 2012-11-08 E.I. Du Pont De Nemours And Company Mixed polyester yarns and articles made therefrom
US8597553B1 (en) 2012-05-31 2013-12-03 Mohawk Industries, Inc. Systems and methods for manufacturing bulked continuous filament

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AU2011308482B2 (en) * 2010-10-01 2015-12-10 Beaulieu Group, Llc Lightweight carpet products and method of manufacture thereof
TWI623659B (zh) * 2014-03-05 2018-05-11 Shinkong Synthetic Fibers Corp Polyester fiber manufacturing method, polyester fiber, yarn, and fabric

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Publication number Priority date Publication date Assignee Title
US4143093A (en) * 1977-04-07 1979-03-06 Chemische Werke Huls Ag Polyester threads and fibers having increased dye affinity
US20030152743A1 (en) * 1999-04-26 2003-08-14 Atsushi Matsunaga Base cloth for tufted carpet and tufted carpet using the same
US20120282431A1 (en) * 2010-07-21 2012-11-08 E.I. Du Pont De Nemours And Company Mixed polyester yarns and articles made therefrom
US8597553B1 (en) 2012-05-31 2013-12-03 Mohawk Industries, Inc. Systems and methods for manufacturing bulked continuous filament

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AU2019379532A1 (en) 2021-05-27
CN113015466A (zh) 2021-06-22
US20220025575A1 (en) 2022-01-27
WO2020102013A1 (en) 2020-05-22
MX2021005544A (es) 2021-06-18
EP3880038A4 (de) 2022-11-02
US20220341089A1 (en) 2022-10-27
EP3880038A1 (de) 2021-09-22
CA3118551A1 (en) 2020-05-22

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