Patent Grant
7374808
The present invention is directed to applying color, pattern, design, and/or the like by means of a jet dye process, or any other secondary or post pattern application process, including but not exclusively transfer printing, silk screen printing and rotary printing, etc., to a bonded carpet, where the yarn in the carpet is all white (no dye applied) or a light color or where the yarn is treated chemically or where the yarn is pre-dyed with a single or multiple colors. The bonded carpet preferably has a face weight of less than 25 oz/yd2.
When carpets are woven, the design is created by locking pre-colored (Skein Dyed) yarn into a warp and weft weaving construction. The design or face pile and backing are literally created at one and the same time as the loom operates. Although the results are a beautiful carpet, there is a significant draw back, in that if one wishes to make the carpet in a lower price point (looser construction, lighter weight, etc.) then the aesthetic detail of the design will deteriorate significantly. Looser, cheaper, lighter, and lower price point are all common terms used when referring to a carpet construction of approximately 22 to 24 oz in weight, 2/56 yarn count, 0.25 inch pile height, and 7 pick/ends by 5 row construction.
To create a lower cost carpet, the weaver must reduce the materials used in the carpet, in other words a looser construction. In so doing, the dots per inch are also reduced and the design detail is greatly effected. Usually, the cheaper the carpet the cheaper looking it is.
A typical, low priced woven carpet construction, is about 5 rows by 7 pick/ends, or 35 dots per inch. Therefore, the very low dots per inch (DPI) matrix gives the design motifs a ragged or blocky look because the dots per inch are so large.
The final result is a product with less market appeal, “Cheap Looking Carpet.”
The aspect ratio of dots per inch is arbitrary. This is again an outcome of the design being locked into the weave. The standard warp setting on a loom is fixed, typically 7 ends (picks) per inch. The weft is variable, say 5, 6, 7, 8, 9, 10 rows per inch. Therefore, to change the density of the carpet, (thicker or thinner, more or less expensive, etc.) you would create the weave thus, 5 rows by 7 ends (35 DPI) which would be an inexpensive carpet or, 10 rows by 7 ends, (70 DPI) which would be a very expensive carpet. Very expensive, good quality, high end, and higher price point are all common terms for a carpet construction which is approximately 32-36 oz in weight, 2/56 yarn count, 0.50 inch pile height, and 7×8 to 7×10 rows and picks per inch.
The problem is, there is an aspect ratio in the dots per inch. They are not square dots but rectangles, for example a 7 row by 7 ends is a square dot, but a 10 row by 7 ends is a rectangular dot. This causes problems when weaving for example, a rug.
When the aspect ratio of the dots is a rectangle, the woven rug can only be woven in one direction. To turn the rug at 90° to maximize the use of the carpet web, would distort the design in either the length or width directions. The only dot matrix that might work is the 7×7 square dot but then one would be tied into only one price point when weaving rugs.
The same design cannot be created on multiple weave constructions. Since the design and weave construction are inseparable, you cannot create the same design on different woven price points (constructions, heavier, lighter, etc. as described above). Obviously, if a design is created on a 10×7 DPI, it cannot be the same when transferred onto a 5×7 DPI, because of the loss of detail, only a facsimile can be made.
If one is weaving carpet on a loom, one can only weave a single construction at a time. It is not possible to make running changes to the construction of a woven carpet, either to change its weight or texture from cut to loop pile. In other words, it is possible only to make one price point (construction, heavier, lighter, etc.) or pile type of carpet at a time on one loom. To alter the construction or pile type, the loom must be stopped and adjusted, thus creating significant inefficiencies.
The new method of the present invention eliminates or addresses all of the three-fold problems previously mentioned and takes advantage of a bonded verses a woven or tufted carpet.
In accordance with one embodiment of the present invention, a bonded white yarn carpet is passed under a jet-dye patterning applicator by means of a conveyor. Such a jet-dye machine and process is described in U.S. Pat. No. 3,969,779 hereby incorporated by reference. The carpet passes under the jet-dye gunbars of a given number. Each gunbar holds a different dye color. Using design software, the jets shoot dye onto the carpet and form designs and patterns of infinite variety and color. The dyes are then fixed, washed, dried and finished. The advantage of the present invention is that the design or patterning is a separate and independent process, from the construction of the bonded carpet itself. Dots per inch can now be determined independently of the carpet so that bonded carpets of various weights, constructions, thickness, etc., can have designs applied to them that are of a consistently fine detail. For example, a design can now be created using a DPI of for example, 10×10, 20×20, 40×40, or 60×60 and applied to a bonded carpet with a low face weight and the design will no longer look cheap and ragged. Also, a DPI of 20×20 (400) or 40×40 (1600), cannot be made on a conventional weaving loom. 16×7 or 112 DPI is the maximum for conventional weaving looms.
Since the design application of the present invention is independent of the carpet construction, the aspect ratio can be a square, for example 20×20 DPI or 10×10 DPI. Therefore designs of all types, including rugs, runner and borders can be turned at 90° to maximize the utilization of the bonded carpet base, without design distortion.
The same design can be created on multiple weave constructions. Since the design application of the present invention is independent of the carpet construction, the exact same design can be placed on any bonded carpet and it can be done in the same run without stopping the design applicator, thus significantly improving efficiencies over the old method.
One object of the invention is to create a low weight fusion bonded carpet tile with white, undyed yarn that is 100% colored (dyed) in piece dye tile form with consistent uniformity and good seamability. Also, the water based latex adhesive used in the bonding process allows greater precision in the degree of penetration of the adhesive up the stalk of yarn. This degree of penetration effects how much yarn is available to be dyed by the patterning process. The dye penetrates down the yarn stalk and stops where it meets the latex. The low face weight and high degree of penetration of the latex provides a limited amount of yarn available for dyeing. This keeps the dye near the surface of the yarn yielding bright colors and very distinct pattern clarity or definition. This high degree of latex penetration also keeps the yarn stalk fairly stiff and erect. This stiff, erect pile orientation keeps the yarn in place at the tile edges which allows the carpet tiles to be dyed preferably with pattern and installed with the tile joints being visually imperceptible. This good seamability characteristic is highly desirable in installed carpet tile so that the carpet looks more like seamless broadloom carpet rather than individual modular tile squares.
Modifications can be made in accordance with the present invention. For example, the method or equipment for fusion bonding of the white yarn can vary, different types of adhesives can be used to bond the yarn, different primary backings or substrates can be used to hold the yarn and the adhesive, and different ways of folding the yarn to make carpet can be used. In accordance with the invention, it is preferred to use a water based latex adhesive, because other adhesive technologies may not allow the degree of control of penetration up the yarn stalk during the bonding process.
The method or equipment for application of the dye to form the color can vary. There can be different colors, dye stuff types, dye formulas, and different patterns of color. Different carpet patterning machines can be used to apply the color to the white or light carpet tile.
Also, although it is preferred to use white yarn, it is contemplated that other colors such as a light beige can be used.
Further, a clear dye or light beige dye can be used in patterning the image or design on the carpet tile so that all of the exposed pile is dyed to avoid areas of white undyed pile which may tend to stain or show dirt.
In one embodiment, the present invention is directed to a low face weight fusion bonded cut pile patterned carpet tile.
The preferred elements of an exemplary embodiment of the invention are:
Selected benefits of the invention are:
In accordance with a preferred embodiment of the present invention, there is provided a fusion bonded carpet tile made with white, undyed yarn that can be 100% colored with dye applied by an injection dyeing or jet dyeing patterning process. This white bonded tile is preferably constructed with a low yarn face weight (less than 25 oz/yd2). Also, the face construction lends itself to patterning in such a way that the dye applied by, for example, jet dyeing or injection dyeing is uniform across the surface of the carpet tile without nonuniformities, visible at the tile edges.
With respect to
With reference to
Although it is preferred to dye the background color and design or pattern of the rug or carpet in a single step as shown in
If the end product is, for example, an area rug, one can apply an edging, ribbing, piping or surging by gluing, sewing, or otherwise attaching the edging thereto.
With reference to
In accordance with a preferred embodiment of the present invention and
The cut, bonded carpet tiles or blanks with a white face yarn are then dyed with a jet dye or injection dyeing patterning process. This is a dye injection process where different colors are applied to the face of the carpet tile with tiny dyejets. The carpet tile is then steamed in a saturated steam cloud for approximately four minutes to permanently fix the colored dyestuff into the yarn fiber. Next the carpet tile is washed to remove any unfixed dyes as well as auxiliary chemicals used with the dyes to aid the dyeing process. The carpet tile is next dried in a hot air oven where hot air is blown onto the face of the tile to remove the moisture. The hot air is typically blown at high velocity. The patterned carpet tiles are then cooled, sheared, trimmed, packaged, and shipped.
One object of the invention is to create a low weight fusion bonded carpet tile with white, undyed yarn that is 100% colored (dyed) in piece dye tile form with consistent uniformity and good seamability. Also, the water based latex adhesive used in the bonding process allows greater precision in the degree of penetration of the adhesive up the stalk of yarn. This degree of penetration effects how much yarn is available to be dyed by the patterning process. The dye penetrates down the yarn stalk and stops where it meets the latex. The low face weight and high degree of penetration of the latex provides a limited amount of yarn available for dyeing. This keeps the dye near the surface of the yarn yielding bright colors and very distinct pattern clarity or definition. This high degree of latex penetration also keeps the yarn stalk fairly stiff and erect. This stiff, erect pile orientation keeps the yarn in place at the tile edges which allows the carpet tiles to be dyed and installed with the tile joints being visually imperceptible. This good seamability characteristic is highly desirable in installed carpet tile so that the carpet looks more like seamless broadloom carpet rather than individual modular tile squares.
Modifications can be made in accordance with the present invention. For example, the method or equipment for fusion bonding of the white yarn can vary, different types of adhesives can be used to bond the yarn, different primary backings or substrates can be used to hold the yarn and the adhesive, and different ways of folding the yarn to make carpet can be used. In accordance with the invention, it is preferred to use a water based latex adhesive, because other adhesive technologies may not allow the same degree of control of penetration up the yarn stalk during the bonding process.
The method or equipment for application of the dye to form the color can vary. There can be different colors, dye stuff types, dye formulas, and different patterns of color. Different carpet patterning machines can be used to apply the color to the white carpet tile.
Also, although it is preferred to use white yarn, it is contemplated that other colors such as a light beige can be used.
Further, a clear dye or light beige dye can be used in patterning the image or design on the carpet tile so that all of the exposed pile is dyed to avoid areas of white undyed pile which may stain or show dirt.
In accordance with the present invention, the white bonded substrate may be formed of 2 ply yarn, 56 yards to the oz, 100% wool, 100% nylon or other post dyeable natural, synthetic or blend yarn, 80% nylon, 20% wool, or the like, and have a face weight of preferably less than 28 oz/yd2, more preferably about 15-27 oz/yd2, and may be bonded from a white or light yarn or a solid colored yarn which can be dyed or printed (over dyed or over printed) to produce the final effect. For example, when a white yarn is used to produce a white bonded carpet substrate or blank, the background color of the rug is printed along with the design or pattern if that color is not white. Alternatively, if the yarn is a dyed or colored yarn (solution dyed, yarn dyed, naturally colored, or the like), then the design or pattern is printed thereon, but the background color is already created by the yarn itself.
U.S. Pat. Nos. 6,203,881; 5,948,500; 5,540,968; 5,545,276; and 4,522,857 describe methods or processes forming cushioned carpet tile or carpet which is either tufted or bonded and are hereby incorporated by reference.
U.S. Pat. Nos. 5,567,257 and 5,443,881 disclose methods for forming heat stabilized bonded pile fabric wherein in at least one embodiment a bonded pile fabric of enhanced stability is formed using low levels of adhesive by tacking the yarn by heat fusion to an open weave base layer prior to application of adhesive. The adhesive which is preferably a low viscosity latex is applied through an open weave base layer to further bond the pile. An apparatus for making the bonded pile fabric is also provided. U.S. Pat. Nos. 5,567,257 and 5,443,881 are hereby incorporated by reference.
As shown is
With reference to
With respect to
In accordance with the present invention, color, pattern, design, and/or the like is applied by means of a jet dye process, or any other secondary or post pattern application process, including but not exclusively transfer printing, silk screen printing, rotary printing, etc., to a bonded carpet, where the yarn in the carpet is all white (no dye applied) or light colored or where yarn is treated chemically or where the yarn is pre-dyed with a single or multiple colors. Although it is preferred to have the carpet fusion bonded with latex adhesive, the bonded carpet can be made with other conventional bonding processes.
With reference to
With respect to
As shown in
Carpet and carpet tiles having cushion backings are known and described for example in U.S. Pat. Nos. 4,522,857; 5,540,968; 5,545,276; 5,948,500; and 6,203,881, all hereby incorporated by reference herein.
Preforming and curing the foam base of the composite of urethane foam and backing material is described, for example, in U.S. Pat. Nos. 4,171,395; 4,132,817; and 4,512,831, all hereby incorporated by reference herein.
A superior cushion backed carpet tile or modular cushion back tile on the market today, for example, sold under the trademark Comfort Plus® by Milliken & Company of LaGrange, Ga. has a primary carpet fabric with a face weight of about 20 to 40 oz/yd 2, a hot melt layer of about 38 to 54 oz/yd 2, a cushion of about 0.10 to 0.2 inches thick, with a weight of about 28 to 34 oz/yd2, and with a density of about 18 lbs. per cubic foot, and has an overall product height of about 0.4 to 0.8 inches. This superior cushion back carpet tile provides excellent resilience and underfoot comfort, exhibits performance characteristics that rate it for very heavy commercial use, and has achieved a notable status throughout the industry as having excellent look, feel, wear, comfort, cushion, performance, and the like. Such a superior cushion back carpet tile is relatively expensive to produce due to the high quality and quantity of materials utilized therein.
With respect to
The primary carpet 112 (
The preferred polyurethane-forming composition is disclosed in U.S. Pat. No. 5,104,693, hereby incorporated by reference. The polyurethane-forming composition also preferably contains a silicone surfactant to improve frothability and stability in the form of an organo-silicone polymer such as are disclosed generally in U.S. Pat. No. 4,022,941 hereby incorporated by reference.
In accordance with at least one embodiment of the present invention, there is provided a carpet substrate or blank especially adapted for dye injection printing and having a flat, short, dense, vertical pile. Such a substrate provides for high resolution, good color, dye injection printing and may provide for such printing with less dye and less bleeding of dye.
While the invention has been described and disclosed in connection with certain preferred embodiments and procedures, it is by no means intended to limit the invention to such specific embodiments and procedures. Rather it is intended to cover all such alternative embodiments, procedures, and modifications thereto as may fall within the true spirit and scope of the invention. For example, although a woven or non-woven backing or release material 270, 370, felt, and 170 is shown in each of
This application claims priority to and benefit of U.S. Provisional Patent Application Ser. No. 60/219,979, filed Jul. 21, 2000, hereby incorporated by reference herein.
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