U.S. patent application number 10/042861 was filed with the patent office on 2003-07-10 for method of manufacturing a carpet having an odor control agent.
Invention is credited to Bandy, Terry, Freeman, Danny, Peters, Frank, Prettyman, Jim.
Application Number | 20030126688 10/042861 |
Document ID | / |
Family ID | 21924126 |
Filed Date | 2003-07-10 |
United States Patent
Application |
20030126688 |
Kind Code |
A1 |
Peters, Frank ; et
al. |
July 10, 2003 |
Method of manufacturing a carpet having an odor control agent
Abstract
The present invention is a method for treating a fibrous
material to control odor associated with deposits of organic
matter. The present invention involves the steps of providing a
fibrous material; applying an effective amount of an odor treatment
solution which includes a bacteria splore blend wherein the
solution has a pH within the range of 1 to 12. The invention also
contemplates simultaneously applying an odor control agent and an
anti-soil treatment to carpet fibers.
Inventors: |
Peters, Frank; (Chattanooga,
TN) ; Prettyman, Jim; (Powder Springs, GA) ;
Freeman, Danny; (Ringgold, GA) ; Bandy, Terry;
(Rockey Face, GA) |
Correspondence
Address: |
TROUTMAN SANDERS LLP
BANK OF AMERICA PLAZA, SUITE 5200
600 PEACHTREE STREET , NE
ATLANTA
GA
30308-2216
US
|
Family ID: |
21924126 |
Appl. No.: |
10/042861 |
Filed: |
January 9, 2002 |
Current U.S.
Class: |
8/115.51 |
Current CPC
Class: |
D06M 16/00 20130101;
D06M 16/003 20130101 |
Class at
Publication: |
8/115.51 |
International
Class: |
D06M 010/00 |
Claims
We claim:
1. A method for manufacturing a floor covering comprising of
fibers; said method comprising: providing a carpet fiber; applying
an odor control solution to said carpet fiber; said odor control
solution including a bacteria spore blend and a bacteria spore
blend binder wherein said solution has a pH within the range of 1
to 12.
2. The method of claim 1 wherein said odor control solution has a
pH range of 5 to 8.
3. The method of claim 1 including curing said odor control
solution.
4. The method of claim 4 wherein said odor control solution is
cured within a dry heat zone.
5. The method of claim 1 wherein said bacteria spore blend is in a
quantity of 0.9% to 1.29% product on carpet as a percentage of face
yarn weight
6. The method of claim 1 wherein said bacteria spore blend binder
is a fluorochemical.
7. The method of claim 6 wherein said fluorochemical component of
said odor treatment solution is in the range of 1.25% to 4.0%.
8. The method of claim 5 wherein said order treatment solution is
applied in a wet add on amount between 5% to 25%.
9. The method of claim 8 wherein said wet add on amount is 15
%.
10. The method of claim 1 wherein said bacteria spore blend binder
is a hydrocarbon.
11. The method of claim 1 wherein the fibers are dyed prior to the
application of said odor control solution.
12. A method for treating fibers used for floor coverings, said
method comprising: providing a carpet fiber; applying an odor
control agent to said carpet fiber; applying an anti-soil treatment
to said carpet fiber; wherein said applications of said odor
control agent and anti-soil treatment are applied topically and
simultaneously to said carpet fiber.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed towards a method for
applying an odor control agent to carpet or other floor coverings
made from fibrous material at various manufacturing stages. The
odor control agent controls odor associated with deposits,
particularly spills of organic material, on carpet fibers or other
fibrous materials.
BACKGROUND OF THE INVENTION
[0002] Carpet is widely used as a floor covering in both
residential and commercial application. Carpet is very versatile,
offering numerous qualities including durability, aesthetics,
comfort, safety, warmth and quietness. With modem manufacturing and
dyeing techniques, carpeting may also be provided in almost any
color, texture and pattern. Carpet may be manufactured from diverse
types of materials including natural materials such as wool or
cotton, or synthetic materials from various polymers such as
polypropylene, polyamide, etc. Each of these materials will be
referenced herein as carpet fibers and includes these fibers
utilized in other fiber floor coverings. The majority of carpet,
particularly for residential and commercial use, is manufactured
from synthetic polymer material such as polypropylene, polyester,
and polyamide. Among the polyamides, T-6 and T-6,6 are common.
Regardless of the material used in the manufacture, a typical
synthetic yarn manufacturing process involves first extruding the
carpet fiber and converting to continuous filament or staple yarns
through a series of air entangling, drafting, carding, mechanical
twisting, or other means to create a single threadline made up of
numerous individual fibers made up of various natural and synthetic
materials.
[0003] Various finishes and lubricants are applied at each of these
stages to either enable further processing, provide
identifications, enhance performance properties, or help enhance
final carpet appearance. Threadlines, in various combinations, are
wound and rewound on bobbins at various stages in the manufacturing
process before being ready to be dyed prior to tufting into carpet,
or, in the case of solution-dyed yams in which the fibers are
intrinsically dyed in the extrusion process, to be tufted. Methods
to pre-dye yam, in addition to that mentioned for solution-dyed
extruded yams, include the skein dye method in which spun or
filament yams are dyed in vats or tanks with or without pressure,
and a stock dyed method in which spun fibers are vat dyed before
making them into yam. In both cases, further mechanical twisting
and heat setting processes occur before the yam is ready to be
tufted. Finishes and lubricants are also applied to the yam after
these stages in the manufacturing process.
[0004] Carpet floor coverings made from polypropylene, polyester,
wool and nylon may be susceptible to odors and staining from
organic sources. In order to prevent staining, it is known in the
industry to use stain blockers. The stain blockers act to prevent
or reduce the ability of organic dyes, particularly acid dye
colorants from chemically reacting with and bonding to the nylon.
The carpets are also commonly coated with a fluorochemical or
hydrocarbron anti-soiling agent. These agents reduce the tendency
of soil to adhere to the fiber. Examples of such stain blockers are
illustrated in U.S. Pat. Nos. 4,680,212 and 4,925,707.
[0005] Generally, fluorochemicals are topically applied to carpet.
One method is to form an aqueous dispersion of the fluorochemical
and then spray that dispersion on the top face of the carpet.
Another method is to make an aqueous based foam containing the
fluorochemical and then apply the foam to the top face of the
carpet. Heat is usually applied to drive off excess water and to
fix the fluorochemical to the carpet fibers.
[0006] In addition to staining, especially in residential
locations, the possibility of deposits of organic matter such as
feces or urine from babies and pets can result in not only soiling
of the carpet but also a lingering odor and may, in extreme cases,
require the replacement of the carpet. Furthermore, bacteria may
grow from the soil organic matter. These bacteria may have the
potential of causing mold and mildew. Some of these bacteria may
themselves give rise to odor due to incomplete digestion of organic
material. There have been attempts to reduce the presence and
number of bacteria present in carpet by utilizing various
anti-microbial agents such as described in U.S. Pat. Nos. 4,110,504
and 5,024,840. The use of anti-microbials, while reducing the
number of bacteria associated with carpet, may raise other concerns
such as the potential that some of the bacteria may become
resistant to effects of the anti-microbials.
[0007] Many bacterial and fungal genera are known for use in odor
control due to their capability for producing enzymes that are
capable of breaking down organic material. Such bacteria are
particularly useful where the organic material, if allowed to
remain, will give rise to malodors. Several such bacterial and
fungal genera such as Bacillus, Lactobacillus, Enterobacter,
Streptococcus, Rhizopus, Nitrosomonas, Nitrobacter, Pseudomonas,
Alcaligens and Klebsiella, among others, are known for use in such
applications with Bacillus being the most prevalent in use in
various applications.
[0008] For example, preparations of active Bacillus in a vegetative
form suitable for spraying or otherwise distributing on a deposit,
especially of pet urine and feces, on a carpet for controlling odor
are presently marketed by The Bramton Company of Dallas, Tex. under
the trademark OUTRIGHT. The bacterial preparations are used to
deodorize a deposit by application directly on the deposit.
[0009] However, application of an odor treatment after installation
of the carpet is only available if an individual notices the
organic deposit. This may be difficult for commercial carpet
installations and in some residences due to the size of the carpet
or location of the organic deposit.
[0010] Accordingly, there is a need in the art for an effective
odor treating agent that can be manufactured into carpet fibers and
other similar floor coverings so that it does not have to be
applied by the carpet owner.
[0011] There is also a need in the art for an odor treating agent
that does not have to be reapplied in the event of a new deposit,
such as a dormant or sporulated bacterial form, that would become
active only when needed.
[0012] There is a further need in the art for a manufacturing
technique that would bind such an odor treating agent into carpet
fibers in a manner which is cost effective.
[0013] Furthermore, there is a need in the art for a manufacturing
technique that provides a carpet with an anti-soiling property and
odor treating property that is easy and economical to conduct.
SUMMARY OF THE INVENTION
[0014] The present invention is a method for manufacturing a floor
covering comprising of fibers. The method includes providing a
carpet fiber and applying an odor control solution to the fiber
carpet. The odor control solution includes a bacteria spore blend
and a bacteria spore blend binder wherein the solution has a pH
within the range of 1 to 12.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention will be more readily understood from a reading
of the following specifications and by reference to the
accompanying drawings forming a part thereof, wherein an example of
the invention is shown and wherein:
[0016] FIG. 1 is illustrates the application of an odor treatment
solution to a pre-dyed carpet fiber;
[0017] FIG. 2 is a block diagram illustrating an exemplary method
of performing the present invention wherein the odor control agent
and the odor control agent binder are topically applied to the
tufted carpet yarn simultaneously with the application of an
anti-soiling treatment before the carpet yarn is dried during the
continuous dyeing process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The present invention is directed towards a method for
applying an odor control agent to carpet fibers or other floor
coverings made of fibrous materials during the carpet manufacturing
process or to the fibers themselves prior to the carpet
manufacturing process for controlling odor associated with deposits
of organic material. For the purposes of this disclosure, the odor
control agent is a bacterial form or forms referenced herein as the
"bacteria spore blend".
[0019] Many bacterial genera are known to produce enzymes capable
of breaking down organic material. Such bacteria are particularly
useful where the organic material, if allowed to remain, will give
rise to malodors. Several such bacterial genera such as Bacillus,
LactoBacillus, Enterobacter, Streptococcus, Nitrosomonas,
Nitrobacter, Pseudomonas, Alcaliaens and Klebsiella amongst others
are known for use in such applications, with Bacillus and
Lactobacillus being the most prevalent in use in various
applications. Strains of bacteria from any of the above noted
genera are useful in practicing the present invention. Preferably,
the bacterial preparation for use in the present invention is one
or more strains of Bacillus or LactoBacillus. More preferably, the
strains of bacteria for use in the present invention are selected
from Bacillus lichenifonnis, Bacillus pasteurii, Bacillus
laevolacticus and Bacillus amyloliquefaciens. Each of these species
have characteristics which make them most effective against
particular types of organic materials.
[0020] All of these species are capable of enhanced anaerobic and
aerobic growth. Bacillus pasteurii is known for superior lipase
production, while Bacillus laevolacticus has a very fast
germination cycle. Bacillus amyloliquefaciens is high in production
of protease enzymes.
[0021] The selection of the strains of bacteria for use in the
present invention may depend upon many factors. One such factor is
the nature of the organic material most commonly expected for the
particular application. For example, in a commercial application,
the most commonly expected deposits would be soil tracked in from
out-of-doors, beverages such as coffee, tea, other food and the
like, especially in a restaurant environment, and possibly, inks or
toners for printers and other office equipment. Many of these
materials are high in fatty components so the bacterial preparation
may be enhanced for strains having high activity against such
materials. One example of such a bacteria is Bacillus pasteurii
described above.
[0022] In a residential environment, the nature of the deposits may
differ with out-of-doors soils. For example, beverages, food and
urine and feces from pets and children being the most commonly
encountered. Depending upon the nature of the deposited material,
the bacteria spore blend may be selected to contain strains having
enhanced activity against such materials. Another factor which may
affect the nature of the deposit is the geographical location of
the installed carpet. This factor would especially relate to the
nature of deposits of out-of-doors soil and to the nature of food
deposits. Different regions are known to have different soil types
and different regions may also have differences in the foods
commonly consumed due to cultural and environmental factors. In
addition, the temperature of the carpet to be treated will
influence the activity of the bacteria. Depending on the strain
selected, the bacteria will tend to exhibit enhanced activity at
higher temperatures. At lower ambient temperatures, more active
strains may be desired.
[0023] The bacteria spore blend will typically comprise one or more
strains selected from the genera and species described above. When
utilizing a mixture of more than one strain, each of the individual
strains may comprise between 3% and 97% of the total of the
bacteria present in the bacteria spore blend. Depending upon the
bacteria, these percentages are based on the total cell number or
colony forming units or the total mass of the bacterial
preparation. For the Bacillus, the percentages are based on total
cell number. Preferably, each of the strains is present in
sufficient numbers to make up 10% to 70% of the total bacteria in
the bacteria spore blend. When mixtures of more than two strains
are employed, each of the strains is preferably present in an
amount of from 20% to 40% of the total bacteria in the bacteria
spore blend. Particularly preferred bacteria spore blends for
general use in almost all applications are as follows:
1 % of total bacteria Species Range Preferred Bacillus
licheniformis 20-60 40 Bacillus pasteurii 10-30 20 Bacillus
laevolacticus 10-30 20 Bacillus amylolicruefaciens 10-30 20
[0024] In a preferred embodiment of the present invention, an
effective amount of bacteria spore blend comprising one or more
strains selected from the group consisting of Bacillus
licheniformis, Bacillus pasteurii, Bacillus laevolacticus and
Bacillus amyloliquefaciens, and combinations thereof, is provided
in a state in which the bacteria spore blend may be applied to a
carpet fiber or other fibrous material. The effective amount of
bacteria spore blend is a sufficient amount of bacteria to provide
a relatively uniform coverage of the fiber such that when any
portion of the carpet is exposed to a deposit of an odor causing
organic material, the bacteria will undergo rapid growth and
consume the odor causing material. The factors which can affect the
number of bacteria to be used relate in most part to the nature of
the carpet material. Such factors include the nature of the fiber
in terms of the material, e.g. nylon or polypropylene and the like,
the characteristics of the yam in the terms of the denier and
number of filaments and the characteristics of the fiber in terms
of the number of yams and the twist. These factors relate to the
nature of the carpet in terms of the weight (oz) and height of the
yams. All of these factors will affect the amount of exposed
surface of the fibers which might be covered by the bacteria spore
blend. For most applications on carpet, between about 10.sup.6 and
10.sup.8 cells per gram of carpet fiber having a weight between
about 20 oz and 40 oz is most effective with 10.sup.7 cells per
gram of carpet fiber being most preferred.
[0025] The bacteria spore blend may be provided as a simple aqueous
preparation of a suspension of the Bacillus species in a suitable
aqueous carrier, such as in distilled water, tap water, a saline
solution, foam, spray or other such aqueous solutions. Preferably,
the aqueous composition comprises the odor controlling dormant
bacterial strain or strains and an effective amount of bacteria
spore blend binder. The binder may be a fluorochemical,
hydrocarbon, or any other topically applied treatments such as
anti-stats, yam spin finishes, lubricant, etc.
[0026] When utilized with the bacteria spore blend binder the
Bacillus species may be provided as active cells. The term "active
cells" encompass cells in a vegetative form capable of immediate
growth when exposed to food sources usually utilized by the
bacteria. The term "dormant cells" is intended to encompass cells
which are in a state which are required to be activated before they
can undergo growth. One example of a dormant cell is a sporulated
form of the bacteria where the spores must undergo activation and
germination before growth of the bacteria can occur.
[0027] As noted above, due to the protective effects of the
bacteria spore blend binder, the active bacteria would be protected
from the possible effects of environmental factors. If the bacteria
are provided in an active form, it is thought that they may become
dormant after the application by undergoing sporulation until a
deposit of organic material is encountered. In a preferred
embodiment, the bacteria are provided in an already dormant or
sporulated form. By providing the bacteria in a dormant or
sporulated form, the bacteria are further protected from
environmental factors which may prove detrimental to active
bacterial cells. These environmental factors may include low
moisture or humidity, as the carpet or other fibrous material would
generally be kept in a dry state. Other factors may include
exposure to heat, chemical agents, radiation from sunlight as well
as the exposure to air for those strains which may be predominantly
anaerobic.
[0028] The sporulated or dormant strains of bacteria become
activated and undergo germination in response to being exposed to
organic material including organic material which can cause odors.
The factors which promote the activation of the dormant or
sporulated bacteria include the moisture and various organic
compounds present in the deposit of organic material. Once
activated, the bacteria undergo growth and replication, consuming
the organic material in the deposit until the material is consumed.
After the material is consumed, the bacteria will then become
dormant by undergoing sporulation to await exposure to another
deposit of organic material. It is thought that the bacteria will
also be somewhat cannibalistic, in that as the bacteria break down
after the depletion of the organic material, the degradation
products of the break down would be utilized as a food source by
other of the bacteria. Once the potential energy source is reduced
and the number of bacteria is also reduced, it is thought that the
remaining bacteria undergo sporulation to return to a dormant
state.
[0029] The bacteria spore blend odor control treatment can be
applied to the carpet fibers at various stages of the manufacturing
process. Additionally, the bacteria spore blend odor control
treatment may be applied directly to the fibers prior to
manufacturing. The following examples illustrate exemplary
techniques for practicing the present invention.
[0030] FIGS. 1 and 2 illustrate an exemplary method of performing
the present invention wherein the bacteria spore blend is topically
applied to carpet utilizing a bacteria spore blend binder. Various
carpet fiber compositions are suitable for bacteria spore blend
application. For the purposes of this disclosure, the carpet fiber
may consist of nylon 6, nylon 6,6, olefin, olefin nylon blends,
extruded solution dyed nylon, extruded solution dyed polyester,
polypropylene, wool, cotton or acrylic or polyester fibers or
combination thereof. Each of these carpet fiber compositions are
equally suitable for practicing the present invention and may be
utilized in other fibrous floor coverings.
[0031] For this embodiment, the bacteria spore blend is applied to
the carpet fibers to provide the carpet fibers with effective
resistance to organic odors. Preferably, the bacteria spore blend
binder is provided in solution with the bacteria spore blend.
Preferably, the bacteria spore blend binder may be a
fluorochemical, a hydrocarbon, or other topically applied
treatment. The advantage of using a specific bacteria spore blend
binder is that additional characteristics may be incorporated into
the carpet fibers. For example, if a fluorochemical binder is
utilized, anti-soiling properties may be incorporated into the
carpet as well as acting as a binding agent for the bacteria spore
blend. Hereinafter, the bacteria spore blend and bacteria spore
blend binder are referred to as an odor treatment agent.
[0032] In the preferred embodiment, prior to application to the
carpet, the odor treatment agent is diluted with a diluting agent
which is preferably water to provide an odor treatment solution.
Preferably, the odor treatment agent is intermixed with the water
such that the odor treatment agent is 7.5% to 10.8% of the odor
treatment solution wherein the bacteria spore blend component is of
an amount resulting in a product on carpet as a percentage of face
yam weight of 0.9% to 1.29%. Additionally, the odor treatment
solution has a pH range between 1.0 to 12.0 with the preferable pH
range being from 5.0 to 8.0. The odor treatment solution may be
applied to the carpet fibers prior to manufacturing of the carpet
or onto the carpet directly. If the odor treatment solution is
applied to the carpet fibers prior to manufacturing, the carpet
fibers must be pre-dyed.
[0033] When the odor treatment solution is applied to the carpet
during manufacturing, it is important that the odor treatment
solution be applied after all dying processes are complete. In the
preferred embodiment, the odor treatment solution is applied at 15%
wet add on, however wet add ons of between 5% to 25% are
acceptable. Once applied, the odor treatment solution is cured.
While the odor treatment solution may cure at ambient temperature,
it is preferred that the carpet with the odor treatment solution is
cured in a dry heat zone wherein the face temperature of the fibers
are exposed to normal drying temperatures.
[0034] It has been found by the inventors, that two different
properties may be applied to the carpet simultaneously saving
product costs and manufacturing time. For instance, when utilizing
an anti-staining agent such as a fluorochemical or a hydrocarbon as
the bacteria spore blend binder during the odor treatment process,
if a sufficient amount of fluorochemical or hydrocarbon is utilized
in the odor treatment solution, the carpet will also be able to
incur an anti-staining property. This requires that an additional
amount of fluorochemical or hydrocarbon be present in the odor
treatment solution other than an amount which would function solely
as a binder for the bacteria spore blend.
[0035] If a fluorochemical is utilized as a bacteria spore blend
binding agent, the fluorochemical component of the odor treatment
solution is preferably 1.25% to 4.0% fluorine with a product on
carpet of 150 ppm fluorine to 600 ppm fluorine. Accordingly, with
this preferred embodiment, the carpet incorporates an odor control
agent resulting from the incorporation of the bacteria spore blend
bound to the carpet fibers via utilization of the fluorochemical in
addition to incorporating an anti-soiling agent via the presence of
the additional fluorochemical. This is the preferred embodiment as
the carpet is treated with two separate desired treatments
simultaneously resulting in cost savings.
[0036] In addition to spraying the odor treatment solution onto the
carpet, the odor treatment solution may be applied via foam. When
applied as a foam, the odor treatment solution has the same
characteristics as previously described. When applied as foam the
odor treatment solution may be required to be associated with a
foam stabilizer and is preferably applied at a blow ratio of
between 4:1 to 10:1.
[0037] Alternatively, a hydrocarbon may be utilized as the bacteria
spore blend binder. When a hydrocarbon known as PM3180, provided by
3M Corporation of St. Paul Minn., was utilized, the odor treatment
agent consisted of between 2 to 4% of the odor treatment solution
with the product on yield percentage of face fiber of between 0.3%
and 0.6% and applied at pH of between 1.0-12.0 with the preferable
range being between 5.0 to 8.0 to achieve the desired anti-soiling
properties.
[0038] In yet another alternative embodiment, the bacteria spore
blend can be topically applied to carpet yarns using a yarn spin
finish binder. Effective resistance to organic odors can be
achieved by applying effective amounts of bacteria spore blend
during the extrusion process. At this stage in the manufacturing
process, the carpet yarn consists of extruded solution dyed nylon,
extruded solution dyed polyester and polypropylene. The details of
the extrusion process are known to those skilled in the art and
thus it is beyond the scope of this disclosure to examine it in
detail here. For the purposes of this embodiment, the extruded
carpet yarn is treated with bacteria spore blend, either in liquid
form or by utilizing an aqueous medium as described in detail in
the embodiment previously described, at levels of product on carpet
of 0.9% to 1.29%.
[0039] In yet another alternative embodiment of the present
invention, bacteria spore blend may be applied to pre-dyed carpet
fibers in liquid form, along with fluorochemical compounds, at a
stage upstream from the final winding process that turns the carpet
fibers into yarn.
[0040] Although various preferred embodiments of the present
invention have been described herein in detail, it will be
appreciated by those skilled in the art, that variations may be
made thereto without departing from the spirit of the invention or
the scope of the appended claims.
* * * * *