Patent Application
20240026604
The invention relates to fabrics, particularly in carpets, comprising a cationically-dyeable polyester effect yarn, dyed with a basic dye, and a background polyamide or polyester yarn, not dyed with a basic dye, and wherein the fabric has been overdyed with a disperse or acid dye. The invention further relates to methods of preparing such overdyed fabrics, and articles comprising such fabrics, such as rugs and mats.
Some carpets are made with two types of yarns. The first is known as an effect yarn, and polyesters are dyed (often space-dyed) prior to tufting, typically with a disperse dye. The second yarn is known as a “background yarn,” and is typically undyed, but may be dyed with a different dye. After tufting both yarns, the carpet is then overdyed with a different dye, usually a disperse dye.
There is generally little or no effect on the coloration of the effect yarn due to the overdyeing process, as the colors of the effect yarn are saturated. However, some of the dye from the effect yarn will bleed into the background yarn during the overdyeing. This bleeding results in a loss of color rendition and contrast in the final product.
Accordingly, a need exists for a carpet comprising an effect yarn and a background yarn tufted together, with improved colorfastness in the effect yarn during a subsequent overdyeing process, to improve color rendition and contrast in the finished carpet. A need also exists for improved methods of making such carpets.
An embodiment of the invention is a carpet comprising pile, said pile comprising a first yarn and a second yarn, said pile being tufted into a primary backing;
An embodiment of the invention is a carpet comprising a woven facecloth, said woven facecloth comprising a first yarn and a second yarn, said first yarn being interwoven with said second yarn;
An embodiment of the invention is a method of manufacturing a carpet, said method comprising overdyeing a carpet facecloth with a disperse dye or an acid dye:
An embodiment of the invention is a woven fabric comprising a first yarn interwoven with a second yarn;
An embodiment of the invention is a carpet comprising any woven fabric as described above.
Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. In the following description, various components may be identified as having specific values or parameters, however, these items are provided as exemplary embodiments. Indeed, the exemplary embodiments do not limit the various aspects and concepts of the present invention as many comparable parameters, sizes, ranges, and/or values may be implemented. The terms “first,” “second,” and the like, “primary,” “exemplary,” “secondary,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. 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.
Each embodiment disclosed herein is contemplated as being applicable to each of the other disclosed embodiments. All combinations and sub-combinations of the various elements described herein are within the scope of the invention. Further, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.
It is understood that where a parameter range is provided, all integers and ranges within that range, and tenths and hundredths thereof, are also provided by the embodiments. For example, “5-10%” includes 5%, 6%, 7%, 8%, 9%, and 10%; 5.0%, 5.1%, 5.2% . . . 9.8%, 9.9%, and 10.0%; and 5.00%, 5.01%, 5.02% . . . 9.98%, 9.99%, and 10.00%, as well as, for example, 6-8%, 7-9%, 5.1%-9.9%, and 5.01%-9.99%.
As used herein, “about” in the context of a numerical value or range means±1, ±5, or ±10% of the numerical value or range recited or claimed.
As used herein, “cationic-dyeable polyester” or “cationically-dyeable polymer” refers to a polymer which has been modified so as to allow cationic molecules, such as cationic dyes, to bind thereto. Cationic-dyeable polymers are anionic.
As used herein, a “basic dye” is a dye known/made to dye anionic fibers. Those skilled in the art will readily know these.
As used here, “face fabric,” or “carpet,” refers to yarns or fibers in combination with a primary backing.
As used herein, to “secure” two objects together means to fix or attach the objects to each other, by means such as an adhesive or otherwise.
An embodiment of the invention is a carpet comprising pile, said pile comprising a first yarn and a second yarn, said pile being tufted into a primary backing;
An embodiment of the invention is a carpet comprising a woven facecloth, said woven facecloth comprising a first yarn and a second yarn, said first yarn being interwoven with said second yarn;
In an embodiment, said second yarn comprises a polyester.
In an embodiment, said second yarn comprises a polyamide.
In an embodiment, said first yarn has been dyed with a basic dye; and wherein said second yarn has been dyed with a second dye, or is undyed.
In an embodiment, said carpet has been overdyed with a disperse dye.
In an embodiment, said first yarn comprises polyethylene terephthalate (PET) or polytrimethylene terephthalate (PTT).
In an embodiment, said first yarn comprises sulfonated entities. In a further embodiment, said first yarn comprises sulfur in a concentration of at least 1000 ppm by weight.
In an embodiment, at least one of said first yarn and said second yarn comprises continuous filaments. In a further embodiment, said continuous filaments are bulked continuous filaments.
In an embodiment, said carpet has at least one additional cationically-dyeable polyester yarn.
In an embodiment, said carpet has at least one additional polyester or polyamide yarn.
In an embodiment, said second yarn comprises a polyamide, and said carpet has been overdyed with an acid dye.
In an embodiment, said first yarn has been space-dyed.
In an embodiment, said first yarn comprises cationically-dyeable polyethylene terephthalate (PET) or cationically-dyeable polytrimethylene terephthalate (PTT).
In an embodiment, said first yarn comprises sulfonated entities. In a further embodiment, said first yarn comprises sulfur in a concentration of at least 1000 ppm by weight.
In an embodiment, at least one of said first yarn and said second yarn comprises continuous filaments. In a further embodiment, said continuous filaments are bulked continuous filaments.
In an embodiment, said carpet has at least one additional cationically-dyeable polyester yarn.
In an embodiment, said carpet has at least one additional polyester or polyamide yarn.
An embodiment of the invention is a method of manufacturing a carpet, said method comprising overdyeing a carpet facecloth with a disperse dye or an acid dye:
In an embodiment, said second yarn comprises a polyester, and said carpet is overdyed with a disperse dye.
In an embodiment, said second yarn comprises a polyamide.
In an embodiment, said carpet facecloth further comprises at least one additional yarn comprising a polyester or a polyamide, which has been dyed with a second or a third dye, or is undyed.
An embodiment of the invention is a woven fabric comprising a first yarn interwoven with a second yarn;
In an embodiment, said second yarn comprises a polyester, and said fabric has been overdyed with a disperse dye.
In an embodiment, said second yarn comprises a polyamide, and said fabric has been overdyed with a disperse dye or an acid dye.
An embodiment of the invention is a carpet comprising any woven fabric as described above.
The primary backcoating or precoat 130, if present, generally comprises carboxylated latex (e.g., a styrene-butadiene-based latex), PVC (polyvinylchloride), EVA (ethylene-vinyl acetate), or other polymer-based material, and the secondary backcoating 140 may also include these same polymers. This primary and/or secondary backcoating may be foamed polymer. One or both of the primary backcoating 130 and secondary backcoating 140 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. In certain situations, calcium carbonate can be used with other common materials such as metal salts. The carpet 100 may be produced with the filler in one or both of the primary backcoating 130 and secondary backcoating 140 comprising waste carpeting as all or part of the filler. As an alternative, 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 backcoating.
In making the carpet 100, generally, for the embodiment depicted in
The primary backing 120 is a supportive scrim through which the tufts are tufted, and frequently comprises a polyolefin, such as polyethylene or polypropylene; however, other materials such as polyester (including, for example, PET) can be used. For example, slit tapes made from PET may be used. The secondary backing 140 is a fabric that is adhered behind the primary backing, sandwiching therein the back of the tufts with the backcoating 130. The secondary backing 140 is frequently made of polypropylene; however other backing types, such as jute, PVC (polyvinyl chloride), polyurethane, and PET, can be used. The secondary backing 140 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, and an adhesive material may be applied to the backside of the tufted carpet backing as a slurry in various concentrations. In a preferred embodiment, there is more filler than adhesive material. For example, 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 wide variety of different cationically-dyeable (i.e., anionic) polymers may be used in the effect yarn 112. In the art, cationically-dyeable polymers or yarns have often been referred to as “cationic polymers” or “cationic yams,” even though they are, in reality, anionic, so that cations may bind thereto. Thus, one of ordinary skill in the art will understand that elements traditionally referred to as cationic (such as polymers or yarns) are, in fact, cationically-dyeable. The cationically-dyeable polymer may be produced by any method suitable for producing a polymer capable of being dyed by a cationic (basic) dye. For example, a sulfonated monomer may be copolymerized with the polymer subunits so as to produce a sulfonated polymer. In an embodiment, the sulfonated monomer is sulfoisophthalic acid. In an embodiment, a sulfonated monomer is polymerized with polymer subunits at a higher percentage than will be used in the finished product, so as to produce a highly sulfonated copolymer; this highly sulfonated copolymer is then mixed with polymer and spun, so as to produce a cationically-dyeable polymer fiber.
Suitable methods for preparing cationically-dyeable polymers are found in, for example, U.S. Pat. Nos. 3,542,743, 3,846,507, 3,898,200, 5,108,684, 5,445,653, 5,889,138, 6,117,550, 6,133,382, and 9,745,415, the contents of each of which are incorporated herein by reference in their entirety.
In an embodiment, the cationically-dyeable polymer comprises sulfur in an amount of at least, at most, or about 1,000 ppm, 2,000 ppm, 3,000 ppm, 4,000 ppm, 5,000 ppm, 6,000 ppm, 7,000 ppm, 8,000 ppm, 9,000 ppm, 10,000 ppm, 15,000 ppm, 20,000 ppm, 25,000 ppm, 30,000 ppm, 35,000 ppm, 40,000 ppm, 45,000 ppm, 50,000 ppm, 60,000 ppm, 70,000 ppm, 80,000 ppm, 90,000 ppm, or 100,000 ppm, compared to the total mass of the polymer.
In an embodiment, the cationically-dyeable polymer is a cationically-dyeable polyester. For example, the polyester can comprise cationically-dyeable PET or cationically-dyeable PTT.
The effect yarn 112 is dyed prior to tufting, with a basic dye. In an embodiment, the effect yarn 112 is space-dyed prior to tufting. The basic dye may be any basic dye known in the art. In an embodiment, the fibers of the effect yarn 112 are dyed before being twisted into two ply form. In an embodiment, undyed fibers are spun into yarn, and the yarn is then dyed. This can be done with spun yarns or BCF yarns. In an embodiment, the dyeing method is selected from the group consisting of direct dyeing, stock dyeing, top dyeing, and yarn dyeing. In an embodiment, the yarn is dyed with the basic dye in a concentration of 1 g/l to 50 g/l.
A wide variety of different polymers may be used to make the background yarn 114. In an embodiment, the polymer is a polyamide. In an embodiment, the polyamide is nylon 6 (polycaprolactam) or nylon 66 (poly(hexamethylene adipamide)). In an embodiment, the polymer is a polyester. In an embodiment, the polyester is PET, PTT, or a blend thereof.
In an embodiment, the background yarn 114 is not dyed at all prior to tufting (i.e., is undyed). In an embodiment, the background yarn 114 is dyed prior to tufting with a dye different than that used to dye the effect yarn 112 prior to tufting. In an embodiment, the background yarn 114 is dyed with a disperse dye prior to tufting.
Unless otherwise noted, the polymer used in any of the yarns of the embodiments of the invention may be virgin, recycled, or a blend thereof.
For both the effect yarn 112 and the background yarn 114, the fibers may be formed from their respective polymer by any method known in the art to produce fibers from a single polymer or from a blend. The polymer can be extruded to have any shape or dimension suitable to polymeric carpet fibers. Moreover, 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. By “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 are formed into yarns, and the fibers or yarns can be used to prepare a number of materials, particularly carpets, rugs, mats, and the like.
The yarns or 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.
Each of the yarns, independently, may be prepared according to any method for preparing yarns recognized in the art as being useful therefore. For example, each 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.
The yarns may be tufted in any pattern or arrangement known in the art. In an embodiment, the effect yarn and the background yarn are each distributed to create a design effect.
In another embodiment, there are discrete regions of facecloth comprising only the effect yarn, along with discrete regions of facecloth comprising only the background yarn. In an embodiment, the facecloth will comprise these discrete regions next to each other, creating sharp boundaries, with a visual effect that is more pronounced due to the lack of bleeding during the overdyeing process.
In another embodiment, the facecloth comprises discrete regions, but also contains intermediate areas forming a gradient between 100% effect yarn regions and 100% background yarn regions. The gradient in these intermediate areas will be more easily controllable due to the sharper contrast between effect yarns and background yarns, again due to the lack of bleeding during the overdyeing process.
In an embodiment, one or more of the effect and background yarn is a multi-ply yarn. In various embodiments, the multi-ply yarn is a two-ply, three-ply, four-ply, or five-ply yarn. one or more plys of the multiply yarn is cationically dyeable, while the other plys are not. Further, the other plys may be the same as the background yarn or maybe varied from the background yarn. The cationically dyeable yarn may be dyed prior to assembly of the multiply yarn or the yarn may be assembled prior to application of the cationic dye. Two ply yarns of this different configuration are often called barber pole yarns. These barber yarns are well known to those skilled in the art. In an embodiment, all yarns in a multi-ply yarn are identical.
The yarns may be present in the tufted facecloth in any density suitable for carpets. Carpet density (CD) is known to be calculated in ounces per cubic yard, via the formula
CD=(FW*36)/PH
where FW is face weight (the weight of the carpet per square yard of carpet, measured in ounces), and PH is the pile height of the carpet, in fractions of an inch. In an embodiment, the carpet density is at least, at most, or about 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, 5,000, 5,500, 6,000, 6,500, 7,000, 7,500, or 8,000 ounces per cubic yard.
In an embodiment, the carpet comprises at least, at most, or about 1,000, 1,500, 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, 5,000, 5,500, 6,000, 6,500, 7,000, 7,500, or 8,000 piles per square meter of effect yarn. In an embodiment, the carpet comprises at least, at most, or about 1,000, 1,500, 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, 5,000, 5,500, 6,000, 6,500, 7,000, 7,500, or 8,000 piles per square meter of background yarn.
In an embodiment, effect yarns make up 1-99% of the total piles of the carpet. In an embodiment, effect yarns make up at least, at most, or about 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% of the total piles of the carpet.
In an embodiment, background yarns make up 1-99% of the total piles of the carpet. In an embodiment, background yarns make up at least, at most, or about 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% of the total piles of the carpet.
Following tufting, the facecloth 125 or carpet 100 is overdyed with a dye. In an embodiment, the dye is a disperse dye. In alternate embodiments, the dye is an acid dye.
In an embodiment, as a result of the manufacturing process, the effect yarn will be dyed along its entire length. In an embodiment, the effect yarn is formed into a barber pole with a background yarn, and then tufted or woven alongside background yarn, then overdyed.
In an embodiment, the pH used is 2.0 to 3.0. In an embodiment, useful dyes are, Yellow GL, Red GRL and Blue GRL liquid dyes. In an embodiment, buffer, wetter and defoamer are used. In an embodiment, the singles yarn is dyeset at 275° F. In an embodiment the two ply yarn is heatset at 290° F.
As discussed above, a need exists for overdyed carpets containing a dyed effect yarn and a background yarn, and having improved color rendition and contrast between the different yarns.
The present inventors have found that by using a cationically-dyeable polymer in the effect yarn, dyeing the effect yarn with a basic dye prior to tufting, and using a polyester or polyamide background yarn, there is no bleeding of the basic dye onto the background dye during the overdyeing process. As a result, better color rendition and contrast is attained in the final carpet product. This also applies to embodiments in which the background yarn is dyed prior to the overdyeing process, using a dye different than the basic dye used to dye the effect yarn.
While embodiments have been illustrated and described in detail above, such illustration and description are to be considered illustrative or exemplary and not restrictive. The same applies to the steps below, which are non-limiting illustrations of a way in which to practice the invention. It will be understood that changes and modifications may be made by those of ordinary skill within the scope and spirit of the following claims. In particular, embodiments within the scope of the invention include any combination of features from different embodiments described above and below.
Step 1: Obtaining the Effect Yarn
The fibers may be obtained via any process known in the art for preparing fibers from polymer, as described hereinabove. The cationically-dyeable effect yarn, comprising a polymer, is dyed prior to tufting, using a basic dye (
Step 2: Obtaining the Background Yarn
As noted, the background yarn is a polyester or polyamide yarn, and may be undyed, or dyed with a dye or pigmented other than that used to dye the effect yarn. The background yarn may also comprise other components as listed hereinabove. The effect yarn may be pigmented also.
Step 3: Preparing Tufted Face Fabric
In this embodiment, the effect yarn and the background yarn are both tufted to a primary backing to form a “face fabric” (
Step 4: Overdyeing
The carpet, with or without the primary backcoating and/or secondary backcoating is then overdyed, with a disperse dye or acid dye (
The carpets described herein may be prepared with more than one different kind of effect yarn, and/or more than one kind of background yarn. For example, two different polymers may be used to prepare a first and a second effect yarn, wherein the first and the second effect yarns may be dyed with the same basic dye, or with a different basic dye. Alternatively, the same polymer may be used to form a first portion of effect yarn and a second portion of effect yarn, wherein the first portion is dyed with a different basic dye than is the second portion.
Similarly, two different polyesters or polyamides may be used to prepare a first and a second background yarn. Both of these may be undyed prior to the overdyeing step; in other embodiments, both may be dyed or pigmented with the same dye prior to tufting, or with different dyes prior to tufting, or one may be dyed and one may be undyed. Alternatively, the same polymer may be used to form a first portion of effect yarn and a second portion of effect yarn, wherein the first portion is dyed with a different basic dye than is the second portion. In another embodiment, the same polyester or polyamide may be used to form a first portion of background yarn and a second portion of background yarn, wherein the first portion is dyed with a different dye than is the second portion prior to tufting, or wherein one portion is dyed while the other is undyed prior to tufting.
Further, while the above description primarily relates to fabrics prepared by tufting an effect yarn and a background yarn into a primary backing, an alternate embodiment uses a woven fabric, rather than a tufted fabric, with the same benefits. Specifically, an effect yarn as described above is interwoven with a background yarn as described above. After the two yarns are interwoven, they are overdyed with a disperse dye. The yarns may be single or multi-ply, and may be of any shape known in the art. The yarns may be woven using any technique known in the art. Following the formation of the woven fabric, they may be used to prepare a carpet in the same manner as the tufted fabric described above, including via application of a primary and/or secondary backcoating.
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of this disclosure. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
The present application claims priority to and the benefit of U.S. Patent Application No. 63/120,534 filed on Dec. 2, 2020, the contents of which are hereby incorporated by reference herein its entirety for all purposes.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2021/060989 | 11/29/2021 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63120534 | Dec 2020 | US |
