MULTICOLORED TUFTED TEXTILES AND METHODS OF MAKING THE SAME

TECHNICAL FIELD

This disclosure relates to textile materials and methods of making the same, and more particularly to multicolored tufted textiles and their methods of manufacture.

BACKGROUND

Within the textile industry, and particularly the carpet industry, consumers increasingly demand products showing increasingly complex patterns and originality. One method that manufacturers use to produce unique and complex patterns involves the use of multiple colors within a particular textile. However, this is traditionally accomplished by the use of pre-dyed yarns, which can limit the number of colors used due to limited placements for yarn bobbins on the associated manufacturing equipment. Further, this limits the ability to manufacture a patterned product in a wide assortment of colors, as the colored yarn bobbins would need to be exchanged for each run with a different color combination. Multiple colors may instead be imprinted on an undyed textile using a printing process, but this provides an unsatisfactory end product especially with tufted textiles, where the looseness of the fibers may lead to muddling of the intended pattern. There is a clear need for tufted textile products and methods of manufacturing the same that would allow for a broader diversity of coloration and pattern.

SUMMARY

The present disclosure provides multicolored tufted textiles, for example carpets, that contain multiple types of pile yarns that are able to selectively absorb dye when the textile is subjected to a piece dyeing process.

In a first aspect, a tufted textile is provided comprising: a primary backing material; and a plurality of pile yarns stitched within the primary backing material, each pile yarn having a facing portion which projects away from the primary backing material and a backing portion embedded within the primary backing material; wherein the plurality of pile yarns comprises a first plurality of pile yarns formed from one or more polyamide polymers and a second plurality of pile yarns formed from one or more polyester polymers; and wherein the facing portion is dyed and the backing portion is not dyed.

In some embodiments of the first aspect, the first plurality of pile yarns absorbs a first dye. In some embodiments of the first aspect, the second plurality of pile yarns absorbs a second dye. In some embodiments of the first aspect, the second plurality of pile yarns does not absorb the first dye. In some embodiments of the first aspect, the tufted textile further comprises a secondary backing.

In some embodiments of the second aspect, the first plurality of pile yarns has a greater dye affinity for the dye than the second plurality of pile yarns. In other embodiments of the second aspect, the second plurality of pile yarns has a greater dye affinity for the dye than the first plurality of pile yarns.

A multicolored textile is also provided, according to some embodiments, by applying one or more dyes to the undyed textile according to the first or second aspects.

In some embodiments of the first or second aspect, the tufted textile comprises a tufted carpet.

In a third aspect, a method for preparing a multicolored tufted textile is provided comprising:

- tufting a first plurality of undyed pile yarns formed from one or more polyamide polymers and a second plurality of undyed pile yarns formed from one or more polyester polymers into a backing material to form an undyed tufted textile; and applying a dye to the tufted textile;
- wherein the first plurality of undyed pile yarns has a greater dye affinity for the dye than the second plurality of undyed pile yarns.

In some embodiments of the third aspect, the dye comprises one or more acid dyes.

In a fourth aspect, a method for preparing a multicolored tufted textile is provided comprising:

tufting a first plurality of undyed pile yarns formed from one or more polyamide polymers and a second plurality of undyed pile yarns formed from one or more polyester polymers into a backing material to form an undyed tufted textile; and

applying a dye to the tufted textile;

wherein the second plurality of undyed yarns has a greater affinity for the dye than the first plurality of undyed pile yarns.

In some embodiments of the fourth aspect, the dye comprises one or more disperse dyes.

In a fifth aspect, a method for preparing a multicolored tufted textile is provided comprising:

tufting a first plurality of undyed pile yarns formed from one or more polyamide polymers and a second plurality of pile yarns formed from one or more polyester polymers into a backing material to form an undyed tufted textile;

applying a first dye to the tufted textile, wherein the first plurality of undyed pile yarns as a greater dye affinity for the first dye than the second plurality of undyed pile yarns; and

applying a second dye to the tufted textile, wherein the second plurality of undyed pile yarns has a greater dye affinity for the second dye than the first plurality of undyed pile yarns.

In some embodiments of the fifth aspect, the first dye is applied prior to the second dye. In other embodiments of the fifth aspect, the second dye is applied prior to the first dye. In further embodiments of the fifth aspect, the first dye and the second dye are applied simultaneously. In some embodiments of the fifth aspect, the first dye comprises one or more acid dyes. In some embodiments of the fifth aspect, the second dye comprises one or more disperse dyes.

In a sixth aspect, a tufted textile is provided prepared by the methods described herein according to any one of the third through fifth aspects. In some embodiments of the third through sixth aspect, the tufted textile comprises a tufted carpet.

The tufted textiles of the first and/or second aspects may or may not be obtained using the methods of the third through fifth aspects listed above. The tufted textiles of the first and/or second aspects may further show preferred characteristics equal or similar to those of the tufted textiles produced by the methods according to the third through fifth aspects, without necessarily having been obtained in that manner.

In some embodiments of any one of the first through sixth aspects, the one or more polyamide polymers include a polymer selected from polyamide 16, polyamide 46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide 610, polyamide 612, polyamide 6T, polyamide 6I, polyamide 66, polyamide 610, polyamide 612, polyamide 6T, polyamide 6I, polyamide MXD6, polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212, polyamide 12T, polyamide PACM12, polyamide TMDT, polyamide 6, polyamide 11, polyamide 12, and combinations thereof.

In some embodiments of any one of the first through sixth aspects, the one or more polyester polymers include polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), or combinations thereof.

The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIGS. 1-3 are top views of dyed tufted textiles according to various implementations.

FIG. 4 is a cross-sectional view of a dyed tufted carpet according to one implementation.

FIG. 5-7 are cross-sectional schematic views of a tufted carpet according to one implementation.

FIG. 8 is cross-sectional schematic view of a tufted carpet according to another implementation.

FIG. 9 is a cross-sectional schematic view of a tufted carpet according to another implementation.

FIG. 10 is a cross-sectional schematic view of a tufted carpet according to another implementation.

FIG. 11 is a cross-sectional schematic view of a tufted carpet according to another implementation.

FIG. 12 is a cross-sectional schematic view of a tufted carpet according to another implementation.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

The compositions and methods of the appended claims are not limited in scope by the specific compositions and methods described herein, which are intended as illustrations of a few aspects of the claims, and any compositions and methods that are functionally equivalent are intended to fall within the scope of the claims. Various modifications of the compositions and methods in addition to those shown and described herein are intended to fall within the scope of the appended claims. Further, while only certain representative compositions and method steps disclosed herein are specifically described, other combinations of the compositions and method steps also are intended to fall within the scope of the appended claims, even in not specifically recited. Thus, a combination of steps, elements, components, or constituents may be explicitly mentioned herein; however, other combinations of steps, elements, components, and constituents are included, even though not explicitly stated.

The term “comprising” and variations thereof as used herein is used synonymously with the term “including” and variations thereof and are open, non-limiting terms. Although the terms “comprising” and “including” have been used herein to describe various embodiments, the terms “consisting essentially of” and “consisting of” can be used in place of “comprising” and “including” to provide for more specific embodiments of the invention and are also described. Other than in the examples, or where otherwise noted, all numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood at the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, to be construed in light of the number of significant digits and ordinary rounding approaches.

As used in the specification and the appended claims, the singular forms “a”, “an” and “the” include plural references unless the context clearly dictates otherwise.

“Optional” and “optionally” means that the subsequently describe event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

Any recited method can be carried out in the order of events recited or in any other order that is logically possible. That is, unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or description that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification.

In a second aspect, an undyed tufted textile is provided comprising: a primary backing material; and a plurality of pile yarns stitched within the primary backing material; wherein the plurality of pile yarns comprises a first plurality of pile yarns comprising a polyamide polymer and a second plurality of pile yarns comprising a polyester polymer; and wherein the first plurality of pile yarns has a different dye affinity for a dye than the second plurality of pile yarns. In some embodiments, the first plurality of pile yarns has a greater dye affinity for the dye than the second plurality of pile yarns. In some embodiments, the second plurality of pile yarns has a greater dye affinity for the dye than the first plurality of pile yarns. A multicolored textile is also provided by applying one or more dyes to the undyed textile described herein.

According to a third aspect, a method for preparing a multicolored tufted textile is provided comprising (1) tufting a first plurality of undyed pile yarns formed from one or more polyamide polymers as described herein and a second plurality of undyed pile yarns formed from one or more polyester polymers as described herein into a backing material to form an undyed tufted textile; and (2) applying a dye to the tufted textile, wherein the first plurality of undyed pile yarns has a greater dye affinity for the dye than the second plurality of undyed pile yarns. In some embodiments according to the third aspect, the dye comprises one or more acid dyes as described herein.

According to a fourth aspect, a method for preparing a multicolored tufted textile is provided comprising: (1) tufting a first plurality of undyed pile yarns formed from one or more polyamide polymers as described herein and a second plurality of undyed pile yarns formed from one or more polyester polymers as described herein into a backing material to form an undyed tufted textile; and (2) applying a dye to the tufted textile, wherein the second plurality of undyed yarns has a greater affinity for the dye than the first plurality of undyed pile yarns. In some embodiments according to the fourth aspect, the dye comprises one or more disperse dyes as described herein.

According to a fifth aspect, a method for preparing a multicolored tufted textile is provided comprising: (1) tufting a first plurality of undyed pile yarns formed from one or more polyamide polymers as described herein and a second plurality of pile yarns formed from one or more polyester polymers as described herein into a backing material to form an undyed tufted textile; (2) applying a first dye to the tufted textile, wherein the first plurality of undyed pile yarns has a greater dye affinity for the first dye than the second plurality of undyed pile yarns; and (3) applying a second dye to the tufted textile, wherein the second plurality of undyed pile yarns has a greater dye affinity for the second dye than the first plurality of undyed pile yarns. In some embodiments of the fifth aspect, the first dye comprises one or more acid dyes as described herein, and the second dye comprises one or more disperse dyes as described herein. In some embodiments of the fifth aspect, the first dye is applied prior to the second dye. In some embodiments of the fifth aspect, the second dye is applied prior to the first dye. In some embodiments of the fifth aspect, the first dye and the second dye are applied simultaneously.

In some embodiments according to any of the third through fifth aspects, the first plurality of undyed pile yarns are formed from polyamide 6,6. In some embodiments according to any of the third through fifth aspects, the first plurality of undyed pile yarns are formed from polyamide 6. In some embodiments according to any of the third through fifth aspects, the second plurality of pile yarns is formed from polyethylene terephthalate.

According to a sixth aspect, a tufted textile is provided produced by any one of the third through fifth aspects described herein. In some embodiments, the tufted textile comprises a tufted carpet.

FIGS. 1-3 illustrate top views of facing surfaces of dyed carpets 10, 20, 30 according to various implementations of the first aspect and the second aspect. And, FIG. 4 illustrates a cross sectional view of a dyed tufted carpet, such as carpets 10, 20, 30. Each carpet 10, 20, 30 comprises a plurality of pile yarns 100. The plurality of pile yarns 100 includes a first plurality of pile yarns 150 formed from at least a first polymer and a second plurality of pile yarns 160 formed from at least a second polymer. The first plurality of pile yarns 150 and the second plurality of pile yarns 160 are arranged in different patterns for each carpet 10, 20, 30.

The first plurality of pile yarns 150 is formed from one or more polyamide polymers. A polyamide is defined as a synthetic linear polymer whose repeating unit contains amide functional groups, wherein these amide functional groups are integral members of the linear polymer chain.

In some embodiments of any of the aspects described herein, the polyamide may have been formed by condensation polymerization of a dicarboxylic acid and a diamine. Representative examples of such dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-napthalene dicarboxylic acid, 3,4′-diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-naphthalenedicarboxylic acid, phthalic acid, 4,4′-methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediactic acid, fumaric acid, and maleic acid. Representative examples of such diamines include ethylene diamine, tetramethylene diamine, hexamethylene diamine, 1,9-nonanediamine, 2-methyl pentamethylene diamine, trimethyl hexamethylene diamine (TMD), m-xylylene diamine (MXD), and 1,5-pentanediamine.

In some embodiments of any of the aspects described herein, the polyamide may have been formed by condensation polymerization of an amino acid (such as 11-aminoundecanoic acid) or ring-opening polymerization of a lactam (such as caprolactam or w-aminolauric acid).

Representative examples of polyamides as may be used in the present disclosure include: aliphatic polyamides such as polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide 610, polyamide 612, polyamide 6T, polyamide 6I, polyamide MXD6, polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212, polyamide 12T, polyamide PACM12, polyamide TMDT, polyamide 611, and polyamide 1012; polyphthalimides such as polyamide 6T/66, polyamide LT/DT, and polyamide L6T/6I; and aramid polymers.

In some particular embodiments, the first plurality of pile yarns 150 is formed from polyamide 6,6. In other particular embodiments, the first plurality of pile yarns 150 is formed from polyamide 6.

In any of the aspects described herein, the first plurality of pile yarns 150 formed from one or more polyamide polymers can absorb a first dye. For example, in some embodiments, the first dye comprises one or more acid dyes. Acid dyes are water-soluble anionic dyes that are applied to fibers using neutral to acid dye baths. Attachment to the fiber is attributed, at least partially, to salt formation between anionic groups in the dyes and cationic groups in the fiber. In some embodiments, the acid dye may be selected from a leveling acid dye, a milling dye, or a metal complex acid dye. In some embodiments, the acid dye is selected from an anthraquinone type due, an azo dye, or a triarylmethane dye. Representative examples of acid dyes which may be used in the present disclosure include, but are not limited to, Acid Yellow 7, Acid Yellow 17, Acid Yellow 23, Acid Yellow 34, Acid Yellow 36, Acid Yellow 40, Acid Yellow 42, Acid Yellow 49, Acid Yellow 73, Acid Yellow 99, Acid Yellow 127, Acid Yellow 129, Acid Yellow 151 Acid Orange 3, Acid Orange 7, Acid Orange 8, Acid Orange 10, Acid Orange 24, Acid Orange 52, Acid Orange 60, Acid Orange 74, Acid Orange 116, Acid Orange 156, Acid Red 1, Acid Red 4, Acid Red 14, Acid Red 50, Acid Red 52, Acid Red 73, Acid Red 87, Acid Red 88, Acid Red 92, Acid Red 94, Acid Red 99, Acid Red 114, Acid Red 119, Acid Red 131, Acid Red 151, Acid Red 249, Acid Red 266, Acid Red 299, Acid Red 337, Acid Violet 1, Acid Violet 3, Acid Violet 7, Acid Violet 12, Acid Violet 17, Acid Violet 19, Acid Violet 43, Acid Violet 48, Acid Violet 49, Acid Violet 90, Acid Green 1, Acid Green 3, Acid Green 9, Acid Green 16, Acid Green 20, Acid Green 25, Acid Green 92, Acid Brown 14, Acid Brown 44, Acid Brown 97, Acid Brown 98, Acid Blue 1, Acid Blue 7, Acid Blue 9, Acid Blue 15, Acid Blue 25, Acid Blue 40, Acid Blue 45, Acid Blue 62, Acid Blue 80, Acid Blue 83, Acid Blue 90, Acid Blue 92, Acid Blue 113, Acid Blue 145, Acid Blue 158, Acid Blue 185, Acid Black 1, Acid Black 2, Acid Black 24, Acid Black 52, Acid Black 58, Acid Black 60, Acid Black 62, Acid Black 107, Acid Black 131, Acid Black 132, Acid Black 172, and Acid Black 194.

In addition, the second plurality of pile yarns 160 is formed from one or more polyester polymers. A polyester is defined as a synthetic linear polymer whose repeating units contain ester functional groups, wherein these ester functional groups are integral members of the linear polymer chain.

Typical polyesters as used in the present disclosure may be formed by condensation of a dicarboxylic acid and a diol. Representative examples of such dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid, 3,4′-diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-napthalene dicarboxylic acid, phthalic acid, 4,4′-methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediacetic acid, fumaric acid, and maleic acid. Representative examples of such diols include monoethylene glycol, diethylene glycol, triethylene glycol, poly(ethylene ether)glycols, 1,3-propanediol, 1,4-butanediol, poly(butylene ether)glycols, pentamethylene glycol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, 1,14-tetradecanediol, 1,16-hexadecanediol, cis-1,4-cyclohexanedimethanol, and trans-1,4-cyclohexanedimethanol.

Representative examples of polyesters include poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(butylene terephthalate) (PBT), poly(ethylene isophthalate), poly(octamethylene terephthalate), poly(decamethylene terephthalate), poly(pentamethylene isophthalate), poly(butylene isophthalate), poly(hexamethylene isophthalate), poly(hexamethylene adipate), poly(pentamethylene adipate), poly(pentamethylene sebacate), poly(hexamethylene sebacate), poly(1,4-cyclohexylene terephthalate), poly(1,4-cyclohexylene sebacate), poly(ethylene terephthalate-co-sebacate), and poly(ethylene-co-tetramethylene terephthalate).

In particular embodiments, the second plurality of pile yarns 160 are formed from polyethylene terephthalate.

In any of the aspects described herein, the second plurality of pile yarns 160 formed from one or more polyester polymers can absorb a second dye. In some embodiments, the second plurality of pile yarns 160 cannot absorb the first dye. In some embodiments of any of the aspects described herein, the second dye comprises one or more disperse dyes. Disperse dyes have low solubility in water, typically less than 1 mg/L, and are applied to the fibers as an extremely fine suspension. Upon attachment, the particles dissolve, and owing to their low molecular weight, migrate throughout. Disperse dyes are typically azo dyes or anthroquinone dyes. Representative examples of disperse dyes which may be used in the present disclosure include, but are not limited to, Disperse Yellow 1, Disperse Yellow 3, Disperse Yellow 5, Disperse Yellow 23, Disperse Yellow 42, Disperse Yellow 49, Disperse Yellow 54, Disperse Yellow 64, Disperse Yellow 82, Disperse Yellow 86, Disperse Yellow 163, Disperse Yellow 184, Disperse Yellow 211, Disperse Yellow 218, Disperse Yellow 224, Disperse Orange 3, Disperse Orange 25, Disperse Orange 29, Disperse Orange 30, Disperse Orange 37, Disperse Orange 41, Disperse Orange 44, Disperse Orange 73, Disperse Orange 76, Disperse Red 1, Disperse Red 4, Disperse Red 5, Disperse Red 15, Disperse Red 17, Disperse Red 50, Disperse Red 54, Disperse Red 55, Disperse Red 60, Disperse Red 65, Disperse Red 73, Disperse Red 82, Disperse Red 86, Disperse Red 91, Disperse Red 135, Disperse Red 153, Disperse Red 167, Disperse Red 177, Disperse Red 179, Disperse Red 184, Disperse Red 319, Disperse Red 338, Disperse Red 359, Disperse Violet 1, Disperse Violet 4, Disperse Violet 26, Disperse Violet 28, Disperse Violet 31, Disperse Violet 48, Disperse Violet 91, Disperse Green 9, Disperse Brown 1, Disperse Blue 3, Disperse Blue 7, Disperse Blue 26, Disperse Blue 27, Disperse Blue 35, Disperse Blue 55, Disperse Blue 56, Disperse Blue 60, Disperse Blue 64, Disperse Blue 73, Disperse Blue 79, Disperse Blue 87, Disperse Blue 102, Disperse Blue 165, Disperse Blue 183, Disperse Blue 281, Disperse Blue 291, and Disperse Black 9.

In some embodiments of any of the aspects described herein, the pile yarns 100 may further comprise one or more additives including, but limited to: flame retardant additives, for example decabromodiphenyl ether and triarylphosphates such as triphenyl phosphate; reinforcing agents such as glass fibers; thermal stabilizers, for example thermal conductivity improvers such as zinc oxide and titanium oxide; ultraviolet light stabilizers such as resorcinol monobenzoates, phenyl salicylate and 2-hydroxybenzophenones; hindered amine stabilizers such as benzotriazole, benzophenone, oxalanilide, and cerium oxide; impact modifiers; flow enhancing additives; ionomers; liquid crystal polymers; fluoropolymers; olefins including cyclic olefins; polyamides; ethylene vinyl acetate copolymers; stabilizing agents such as ortho-phosphoric acid, triphenylphosphate, and triethylphosphino acetate; delustering agents such as titanium oxide; carriers such as o-phenylphenol, p-phenylphenol, o-dichlorobenzene, trichlorobenzene, monochlorobenzene, biphenyl, methyl salicylate, butyl benzoate, benzyl benzoate, benzoic acid, benzalacetone, and methyl cinnamate; leveling agents such as bishydroxymethyloxazoline, diaryl ethers, ditolyl ether, sodium di-naphthylmethane-B,B-disulfonate, ammonium dodecylbenzene sulfonate, sodium tetrapropylbenzene sulfonate, homopolymers or oligomers of N-vinylpyrrolidone and poly(tetrahydrofuran); and porosity additives such as metal oxalate complexes, organic sulfonate salts, jade powder, and zeolite powder.

The fibers used to make the pile yarns 100 described herein may be formed from the polymer by any method known in the art to produce fibers from a single or blended polyamide or polyester. The polymer can be extruded to have any shape or dimension suitable to polymeric fibers. Moreover, the fibers can undergo any post-spinning processes generally recognized as useful in the preparation of polymeric fibers. For example, 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 used to make yarns, and the fibers or yarns can be used prepare tufted textiles as described herein, such as carpets, rugs, mats, and the like.

The pile yarns 100 may be prepared according to any method for preparing yarns recognized in the art. For example, the yarns of the present disclosure could be partially oriented yarn, spun drawn yarn, textured yarn, friction false-twisted yarn, and bulk continuous filament (“BCF”) yarn. Example steps in preparing BCF yarn include 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, entangling, optionally relaxing, and winding the filaments on a package for subsequent use. The pile yarns 100 may alternatively comprise staple fibers of varying lengths.

FIGS. 5-7 are schematic cross-sectional views of a tufted carpet, such as the carpets 10, 20, 30 shown in FIGS. 1-3, according to one implementation. As shown in FIG. 5, the plurality of yarns 100 are tufted (or stitched) through a primary backing material 102. Each yarn 100 has a facing portion 103 that projects away from the primary backing material and a backing portion 104 that is at least partially embedded within the primary backing material 102. The facing portion 103 of each yarn 100 is dyed, and the backing portion 104 of each yarn 100 is not dyed.

The primary backing 102 may be a woven or non-woven fabric. The primary backing 102 has an exposed surface 110 and a back surface 112 that are opposite and spaced apart from each other. The portion of the pile yarns 100 extending from the exposed surface 110 of the tufted textile 10 is the facing portion 103, and the portion of the pile yarns 100 at least partially embedded within the primary backing 102 comprise the backing portion 104.

The primary backing 102 is a supportive scrim through which the pile yarns 100 are tufted, and frequently is 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.

After the yarns 100 are tufted through the primary backing layer 102, the tufted carpet may be dyed. Subsequent to dyeing, a glue layer 114 is applied to the back surface 112 and the backing portion 104 of the yarns 100, as shown in FIGS. 5 and 6. The glue layer 114 sets the yarns 100 within the primary backing 102. The loops 106 are also cut to create pile 117, as shown in FIGS. 6-7. The loops 106 may be cut before the glue layer 114 is applied or after the glue layer 114 is applied. The glue layer 114 is latex, but other known adhesives can be used, for example resins.

FIG. 8 illustrates another implementation in which the plurality of yarns 100 are tufted through a primary backing 202 and a layer of glue 214 that is applied to the back surface 212 of the primary backing 202 before tufting.

FIG. 9 illustrates another implementation in which the plurality of yarns 100 are tufted through a primary backing 302 and a layer of glue 314 that is applied to the facing surface 310 of the primary backing 302 before tufting. And, FIG. 10 illustrates a further implementation of FIG. 9 in which a second glue layer 316 is applied to the back surface 312 of the primary backing 302 after the yarns 100 are tufted through the primary backing 302 and the glue layer 314. In another implementation, which is not shown, glue layers may be applied to the facing and back surfaces of the primary backing prior to (or after) tufting to create a sandwiched backing structure, and the yarn may be tufted through the sandwiched structure.

FIG. 11 illustrates another implementation in which a secondary backing 416 is laminated to the back surface 412 of the primary backing 402 to give the textile added dimensional stability. The secondary backing 416 is a woven or non-woven fabric that is adhered to the back surface 412 of the primary backing 402, sandwiching therein the backing portion 104 of the yarns 100. The secondary backing is frequently made of polypropylene; however other backing types, such as jute, PVC (polyvinyl chloride), polyurethane, and PET, can be used. Embodiments of non-woven fabrics that may be used as the secondary backing may include, but are not limited to, spun-bond, wet-laid, melt-blown, and air-entangled fabrics.

FIG. 12 illustrates another implementation in which a filler material, such as calcium carbonate, and an adhesive material are mixed together in a slurry 514 in various concentrations, and the slurry 514 is applied to the back surface 512 of primary backing 502 to serve as an adhesive for coupling the primary backing 502 to a secondary backing, such as secondary backing 416 described above. Typically, the amount of filler is greater than the amount of adhesive material. For example, a representative filler-to-adhesive ratio can comprise about 80 percent by weight calcium carbonate to about 20 percent by weight adhesive. While calcium carbonate is one of the most commonly employed filler materials, it should be recognized by those skilled in the art that textiles (for example carpets) containing other filler materials can be used.

The adhesive material within the slurry 514 binds to the back surface 512 of the primary backing 502 and the surface of the secondary backing that faces the back surface 512 of the primary backing 502. The adhesive material can include a latex, such as 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.

In the embodiments shown, the tufted textiles are cut pile carpets. However, in other embodiments, the carpet may be a loop pile carpet or the carpet may comprise both cut piles and loop piles. In other embodiments, the tufted textile can comprise a rug, a carpet tile, a mat, or the like.

In some embodiments of any of the aspects described herein, the one or more dyes may be applied to the undyed tufted textile using any number of dyeing techniques as would be known to a person skilled in the art. In some embodiments, the one or more dyes may be applied to the tufted textile using a piece dyeing process. In some embodiments, the piece dyeing process comprises beck dyeing, where rolls of the undyed tufted textile are immersed individually into a dye bath at elevated temperature. First, undyed pile yarns are assembled as components of the tufted textile. The assembled textile, for example a carpet, is then immersed in a dye bath at an elevated temperature. In some embodiments, the piece dyeing process may be a continuous dyeing process, where the tufted textile is passed under dyeing equipment that flows dye solution onto the assembled textile instead of requiring immersion within a dye bath. In other embodiments, the tufted textile may be dyed by a jet spray application process.

In other embodiments, the one or more dyes may be applied to the tufted textile using a print dyeing process. Numerous print dyeing processes for dyeing of textiles are available that may be used in the present methods. For example, the tufted textile may be placed in a flatbed containing a screen that is used to print a pattern onto the textile. In another example, jet applicators may be used to spray dye onto specific positions of the textile, creating color patterns.

In some embodiments of any of the aspects described herein, one or more acid dyes and one or more disperse dyes are applied to the tufted textile. In some embodiments, the one or more acid dyes are applied prior to the one or more disperse dyes. In other embodiments, the one or more disperse dyes are applied prior to the one or more acid dyes. In further embodiments, the one or more acid dyes and the one or more disperse dyes are applied simultaneously. In some embodiments, the first plurality of pile yarns has a greater dye affinity for the one or more acid dyes than the second plurality of pile yarns, and the second plurality of pile yarns has a greater dye affinity for the one or more disperse dyes than the first plurality of pile yarns.

A number of embodiments of the disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.

By way of non-limiting illustration, examples of certain embodiments of the present disclosure are given below.

EXAMPLES

A tufted carpet consisting of at least 1 PTT or PET yarn and at least 1 Nylon yarn is introduced to either a beck or continuous dye range process. The carpet is white after tufting with no colored yarns visible. Alternatively, pre-dyed yarns with dye enhancing/prohibiting additives can be used to add another dimension, albeit not being necessary to create a multicolored carpet using the described process.

Dye Process

A yellow, red, and blue dye from each of a dispersed and acid dye system are used. Each dye is individually metered into the same dye solution before being applied to the carpet to produce the desired finished colors. The dye solution containing both dispersed and acid dyes is either applied simultaneously to the width of the carpet (continuous dyeing) or in a single dye bath (beck dyeing). The Nylon yarn is dyed from the acid dyes in the solution, and the PTT or PET yarn is dyed from the dispersed dyes in the solution. The PTT or PET yarn does not absorb any of the acid dyes as it has no affinity for acid dye. Using this process, a tufted carpet is dyed any color combination desired.

The compositions and methods of the appended claims are not limited in scope by the specific compositions and methods described herein, which are intended as illustrations of a few aspects of the claims and any compositions and methods that are functionally equivalent are intended to fall within the scope of the claims. Various modifications of the compositions and methods in addition to those shown and described herein are intended to fall within the scope of the appended claims. Further, while only certain representative compositions and method steps disclosed herein are specifically described, other combinations of the compositions and method steps also are intended to fall within the scope of the appended claims, even if not specifically recited. Thus, a combination of steps, elements, components, or constituents may be explicitly mentioned herein; however, other combinations of steps, elements, components, and constituents are included, even though not explicitly stated.

MULTICOLORED TUFTED TEXTILES AND METHODS OF MAKING THE SAME

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