U.S. patent application number 15/302428 was filed with the patent office on 2017-01-19 for multicolor carpet and method of making same.
This patent application is currently assigned to INVISTA NORTH AMERICA S.AR.L.. The applicant listed for this patent is INVISTA NORTH AMERICA S.AR.L.. Invention is credited to Elizabeth G McFarland, Wae-Hai TUNG.
Application Number | 20170016160 15/302428 |
Document ID | / |
Family ID | 54288358 |
Filed Date | 2017-01-19 |
United States Patent
Application |
20170016160 |
Kind Code |
A1 |
TUNG; Wae-Hai ; et
al. |
January 19, 2017 |
MULTICOLOR CARPET AND METHOD OF MAKING SAME
Abstract
A multicolor carpet comprising a plurality of tufted yarns,
wherein the yarns comprise solution-dyed bulked continuous
filaments, wherein at least one of the yarns is of a different
color than any of the other yarns, wherein the yarns have not been
twisted, and wherein the yarns have not been heatset.
Inventors: |
TUNG; Wae-Hai; (Marietta,
GA) ; McFarland; Elizabeth G; (Calhoun, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
INVISTA NORTH AMERICA S.AR.L. |
Wilmington |
DE |
US |
|
|
Assignee: |
INVISTA NORTH AMERICA
S.AR.L.
Wilmington
DE
|
Family ID: |
54288358 |
Appl. No.: |
15/302428 |
Filed: |
April 8, 2015 |
PCT Filed: |
April 8, 2015 |
PCT NO: |
PCT/US2015/024862 |
371 Date: |
October 6, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61978082 |
Apr 10, 2014 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D05C 17/026
20130101 |
International
Class: |
D05C 17/02 20060101
D05C017/02 |
Claims
1. A multicolor carpet comprising a plurality of tufted yarns of at
least two different colors, wherein the yarns comprise
solution-dyed bulked continuous filaments, wherein the yarns have
not been twisted, and wherein the yarns have not been heatset.
2. The multicolor carpet of claim 1 wherein the carpet has an
appearance rating of at least 3 when subjected to a walk test
according to ASTM D6119.
3. The multicolor carpet of claim 1 wherein the carpet has not been
subjected to any downstream wet processing after tufting.
4. The multicolor carpet of claim 1 wherein yarns contain less than
30 moderate interlace nodes per meter.
5. The multicolor carpet of claim 1 wherein yarns contain less than
20 moderate interlace nodes per meter.
6. The multicolor carpet of claim 1 wherein yarns contain less than
5 severe interlace nodes per meter.
7. The multicolor carpet of claim 1 wherein the carpet has a pile
height of 0.5 inches or less.
8. The multicolor carpet of claim 1 wherein the carpet has a pile
height of 0.375 inches or less.
9. The multicolor carpet of claim 1 wherein the carpet has a face
weight in range of about 12 to about 50 ounces per yard.
10. The multicolor carpet of claim 1 wherein the carpet has a face
weight in range of about 18 to about 40 ounces per yard.
11. The multicolor carpet of claim 1 wherein the carpet comprises
between 2 to 8 different color yarns.
12. The multicolor carpet of claim 1 wherein the yarns are
comprised of a plurality of filaments, and wherein at least a
portion of the yarns are comprised of filaments of at least two
different colors.
13. The multicolor carpet of claim 1 wherein the carpet is
comprised of a plurality of tufts, wherein each tuft is comprised
of at least one tufted yarn.
14. The multicolor carpet of claim 13 wherein the majority of tufts
are immediately adjacent to at least one other tuft comprised of
tufted yarn of at least one different color.
15. The multicolor carpet of claim 13 wherein each tuft is
immediately adjacent to at least one other tuft comprised of tufted
yarn of at least one different color.
16. The multicolor carpet of claim 1 wherein there is no 12 square
inch area of the carpet covered by yarns of only a single
color.
17. The multicolor carpet of claim 1 wherein there is no 4 square
inch area of the carpet covered by yarns of only a single
color.
18. The multicolor carpet of claim 1 wherein there is no single
square inch area of the carpet covered by yarns of only a single
color.
19. The multicolor carpet of claim 1 wherein the solution-dyed
bulked continuous filaments are formed from filaments selected from
the group consisting of polyamides, polypropylenes, polyesters and
copolymers and blends thereof.
20. The multicolor carpet of claim 1 wherein the solution-dyed
bulked continuous filaments are formed from nylon 6,6
filaments.
21. The multicolor carpet of claim 1 wherein the solution-dyed
bulked continuous filaments further comprises an aromatic sulfonate
or an alkali metal salt thereof.
22. The multicolor carpet of claim 21 wherein the carpet has a
stain rating of at least 5.
23. The multicolor carpet of claim 21 wherein the carpet has a
stain rating of about 10.
24. The multicolor carpet of claim 21 wherein the aromatic
sulfonate is 5-sulfoisophthalate.
25. The multicolor carpet of claim 1 wherein the plurality of
tufted yarns further comprises at least one conductive
filament.
26. The multicolor carpet of claim 25 wherein the amount of
conductive filaments is sufficient to form an antistatic
carpet.
27. A multicolor carpet comprising a plurality of tufted yarns,
wherein the yarns comprise solution-dyed bulked continuous
filaments, wherein the solution-dyed bulked continuous filaments
further comprises an aromatic sulfonate or an alkali metal salt
thereof, wherein at least one of the yarns is of a different color
than any of the other yarns, wherein the yarns have not been
twisted, and wherein the yarns have not been heatset.
28. A multicolor carpet comprising a plurality of tufted yarns,
wherein the yarns comprise solution-dyed bulked continuous
filaments, wherein the solution-dyed bulked continuous filaments
further comprises an aromatic sulfonate or an alkali metal salt
thereof, wherein at least one of the yarns is of a different color
than any of the other yarns, wherein the plurality of tufted yarns
further comprises at least one conductive filament , wherein the
yarns have not been twisted, and wherein the yarns have not been
heatset.
29. The method of making a multicolor carpet comprising the step of
tufting a plurality of yarns to form a carpet, wherein the yarns
comprise solution-dyed bulked continuous filaments, wherein at
least one of the yarns is of a different color than any of the
other yarns, wherein the yarns have not been twisted, and wherein
the yarns have not been heatset.
30. The method of claim 29 wherein the carpet has an appearance
rating of at least 3 when subjected to a walk test according to
ASTM D6119.
31. The method of claim 29 wherein the carpet has not been
subjected to any downstream wet processing after tufting.
32. The method of claim 29 wherein yarns contain less than 30
moderate interlace nodes per meter.
33. The method of claim 29 wherein yarns contain less than 5 severe
interlace nodes per meter.
34. The method of claim 29 wherein the carpet has a pile height of
0.5 inches or less.
35. The method of claim 29 wherein the carpet has a face weight in
range of about 12 to about 50 ounces per yard.
36. The method of claim 29 wherein the carpet comprises between 2
to 8 different color yarns.
37. The method of claim 29 wherein the yarns are comprised of a
plurality of filaments, and wherein at least a portion of the yarns
are comprised of filaments of at least two different colors.
38. The method of claim 29 wherein the carpet is comprised of a
plurality of tufts, wherein each tuft is comprised of at least one
tufted yarn.
39. The method of claim 38 wherein the majority of tufts are
immediately adjacent to at least one other tuft comprised of tufted
yarn of at least one different color.
40. The method of claim 38 wherein each tuft is immediately
adjacent to at least one other tuft comprised of tufted yarn of at
least one different color.
41. The method of claim 29 wherein there is no 12 square inch area
of the carpet covered by yarns of only a single color.
42. The method of claim 29 wherein there is no 4 square inch area
of the carpet covered by yarns of only a single color.
43. The method of claim 29 wherein there is no single square inch
area of the carpet covered by yarns of only a single color.
44. The method of claim 29 wherein the solution-dyed bulked
continuous filaments are formed from filaments selected from the
group consisting of polyamides, polypropylenes, polyesters and
copolymers and blends thereof.
45. The method of claim 29 wherein the solution-dyed bulked
continuous filaments are formed from nylon 6,6 filaments.
46. The method of claim 29 wherein the solution-dyed bulked
continuous filaments further comprises an aromatic sulfonate or an
alkali metal salt thereof.
47. The method of claim 46 wherein the carpet has a stain rating of
at least 5.
48. The method of claim 46 wherein the aromatic sulfonate is
5-sulfoisophthalic acid.
49. The method of claim 29 wherein the plurality of tufted yarns
further comprises at least one conductive filament.
50. The method of claim 49 wherein the amount of conductive
filaments is sufficient to form an antistatic carpet.
51. An article of manufacture, at least a portion of which
comprises the multicolor carpet of any of claims 1 through 50.
Description
FIELD OF THE INVENTION
[0001] The invention relates to multicolor carpets formed from
solution-dyed, BCF fibers.
BACKGROUND OF THE INVENTION
[0002] Polymers have long been the most prevalent material used for
forming yarns for use in the carpet industry. Therefore, there is a
continuing interest to develop less costly and more environmentally
friendly methods of carpet production.
[0003] Multicolor carpets are widely used to provide consumers with
various design options for flooring designs. These carpets are
typically formed from direct tufted, white acid dyeable staple
fibers. Colors are printed on theses carpets after the carpet
fibers are tufted. Printed carpets do not have sharp color
registration, acceptable stain resistance and good color fastness.
Some direct tufted nylon carpets are sold as floor coverings in
automotive interiors, mainly in solid colors. However, due to
bonding issues, antistatic fiber cannot be used in automotive
carpeting. For these reasons, direct tuft carpets have not found
broad acceptance for residential or commercial markets.
[0004] Carpets that are suitable for use for residential purposes
typically require additional process steps to meet the necessary
quality standards. Residential carpet processing consists of many
steps including cable twisting, heatsetting, dyeing and applying
low pH stain block chemicals. These steps are costly and unfriendly
to the environment due to extensive consumption of energy, water,
steam and low pH chemicals. Cable twisting and heatsetting are
required to make aesthetically attractive carpets with good tip
definition. However, the tip definition of cable twisted carpets
deteriorates with traffic due to twist unrevealing that results in
worn out look.
[0005] Therefore, there is a need for multicolor carpets with
improved stain resistance and color fastness that also meet the
quality standards necessary for residential and commercial
markets.
SUMMARY OF THE INVENTION
[0006] The present invention relates to a multicolor carpet that is
direct tufted and meets the quality standards needed for use in
residential and commercial markets. The multicolor carpets of the
current invention eliminate costly and environmentally unfriendly
steps typically necessary for carpets that are sold into the
residential and commercial flooring markets. These eliminated steps
can include, twisting, heatsetting, dyeing and downstream wet
processing.
[0007] In one nonlimiting aspect of the present invention, a
multicolor carpet is disclosed comprising a plurality of tufted
yarns of at least two different colors, wherein the yarns comprise
solution-dyed bulked continuous filaments, wherein the yarns have
not been twisted, and wherein the yarns have not been heatset.
[0008] In another nonlimiting aspect of the present invention, a
multicolor carpet is disclosed comprising a plurality of tufted
yarns of at least two different colors, wherein the yarns comprise
solution-dyed bulked continuous filaments, wherein the
solution-dyed bulked continuous filaments further comprises an
aromatic sulfonate or an alkali metal salt thereof, wherein the
yarns have not been twisted, and wherein the yarns have not been
heatset.
[0009] In another nonlimiting aspect of the present invention, a
multicolor carpet is disclosed comprising a plurality of tufted
yarns of at least two different colors, wherein the yarns comprise
solution-dyed bulked continuous filaments, wherein the
solution-dyed bulked continuous filaments further comprises an
aromatic sulfonate or an alkali metal salt thereof, wherein the
plurality of tufted yarns further comprises at least one conductive
filament , wherein the yarns have not been twisted, wherein the
yarns have not been heatset.
[0010] In another embodiment aspect of the present invention, a
method of making a multicolor carpet is disclosed, wherein the
method comprises the step of tufting a plurality of yarns of at
least two different colors to form a carpet, wherein the yarns
comprise solution-dyed bulked continuous filaments, wherein the
yarns have not been twisted, and wherein the yarns have not been
heatset.
[0011] In another nonlimiting aspect of the present invention, an
article of manufacture is disclosed, at least a portion of which
comprises a multicolor carpet comprising a plurality of tufted
yarns of at least two different colors, wherein the yarns comprise
solution-dyed bulked continuous filaments, wherein the yarns have
not been twisted, and wherein the yarns have not been heatset.
[0012] In another nonlimiting aspect of the present invention, an
article of manufacture is disclosed, at least a portion of which
comprises, a multicolor carpet comprising a plurality of tufted
yarns of at least two different colors, wherein the yarns comprise
solution-dyed bulked continuous filaments, wherein the
solution-dyed bulked continuous filaments further comprises an
aromatic sulfonate or an alkali metal salt thereof, wherein the
yarns have not been twisted, and wherein the yarns have not been
heatset.
[0013] In another nonlimiting aspect of the present invention, an
article of manufacture is disclosed, at least a portion of which
comprises, a multicolor carpet comprising a plurality of tufted
yarns of at least two different colors, wherein the yarns comprise
solution-dyed bulked continuous filaments, wherein the
solution-dyed bulked continuous filaments further comprises an
aromatic sulfonate or an alkali metal salt thereof, wherein the
plurality of tufted yarns further comprises at least one conductive
filament , wherein the yarns have not been twisted, and wherein the
yarns have not been heatset.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1A and FIG. 1B are images of multicolor carpets of the
current invention.
[0015] FIG. 2A, FIG. 2B and FIG. 2C are images of multicolor
carpets of the current invention.
[0016] FIG. 3A and FIG. 3B are images of multicolor carpets of the
current invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Provided by the present invention are multicolor carpets
comprising a plurality of tufted yarns of at least two different
colors, wherein the yarns have not been twisted, and wherein the
yarns have not been heatset. Also provided is a method for
production of carpets and articles of manufacture, at least a
portion of which comprise the multicolor carpets disclosed
herein.
[0018] It is common for carpet that is used for residential or
commercial purposes to be twisted, heatset and be subjected to
downstream wet processing to achieve desirable properties. The
multicolor carpets of the current invention are not subjected to a
twisting step, such as ply twisting or cable twisting, or a
heatsetting step which give a tufted carpet tip definition.
Downstream wet processing steps can include dyeing, and the
application of stain resist or soil resist chemistries. Contrary to
what would be expected, the inventors have found that multicolor
carpets of the current invention can be produced with satisfactory
aesthetics, wear performance and staining properties. Furthermore,
the multicolor carpets of the current invention simulate the
appearance of twisted and heatset yarns in tufted fabrics, without
being subjected to twisting, heatsetting or any downstream wet
processing after tufting.
[0019] Without being bound by any particular theory, it is believed
that in order to achieve a multicolor carpet with satisfactory
aesthetics the yarn used must be smooth and have good interlace
without containing a large number of interlace nodes. Interlace
nodes with a diameter less than 30% of the main yarn body are
considered to be severe tight interlace nodes. Interlace nodes with
a diameter less than 50% of the main yarn body are considered to be
moderate interlace nodes. In one nonlimiting embodiment of the
current invention, the multicolor carpets are formed from solution
dyed BCF yarns that contain less than 5 severe interlace nodes per
meter and less than 30 moderate interlace nodes per meter. In
another nonlimiting embodiment of the current invention, multicolor
carpets are formed from solution dyed BCF yarns that are
essentially free of severe interlace nodes. In another nonlimiting
embodiment of the current invention, the multicolor carpets are
formed from solution dyed BCF yarns that contain less than 20
moderate interlace nodes per meter. The number of moderate and
severe interlace nodes are determined by visual inspection
according to the Node Evaluation Procedure, defined below.
[0020] The multicolor carpets of the current invention can be
formed in various carpet constructions that are known in the
industry. In one nonlimiting embodiment of the current invention,
the multicolor carpets have a pile height of 0.5 inches or less. In
another nonlimiting embodiment of the current invention, the
multicolor carpets have a pile height of 0.375 inches or less. In
one nonlimiting embodiment of the current invention, the multicolor
carpets have a face weight in the range of about 12 to about 50
ounces per yard. In another nonlimiting embodiment of the current
invention, the multicolor carpets have face weight in the range of
about 18 to about 40 ounces per yard.
[0021] The multicolor carpets of the current invention can be
formed from yarns of denier and filament count that that are known
for use in carpet manufacturing. In nonlimiting embodiments of the
current invention, the yarns comprise solution-dyed bulked
continuous filaments (BCF) yarns. In one nonlimiting embodiment of
the current invention, the yarns have a denier in the range from
about 500 denier to about 3000 denier. In another nonlimiting
embodiment of the current invention, the yarns have a denier in the
range from about 1100 denier to about 1800 denier.
[0022] The multicolor carpets of the current invention can be
formed from yarns from a plurality of colors. In one nonlimiting
embodiment of the current invention, the multicolor carpets
comprise between 2 to 8 different color yarns. In nonlimiting
embodiments, yarns may comprise filaments of at least 2 different
colors.
[0023] In one nonlimiting embodiment of the current invention, the
multicolor carpet is comprised of a plurality of tufts, wherein
each tuft is comprised of at least one tufted yarn. In another
nonlimiting embodiment each tuft is comprised of tufted yarn of a
single color.
[0024] Without being bound any particular theory, it is believed
that the patterns formed from the use of different color yarns
create the color definition necessary for the multicolor carpets to
have an acceptable aesthetic look that is comparable to carpets
formed from yarns that have been subjected to several additional
texturing steps. To maximize the color definition in the multicolor
carpet, the use of a single color yarn over large areas of the
carpet should be minimized. For a two color carpet an ABAB thread
up can be used. For a three color carpet an ABCABC thread up can be
used. For a four color carpet an AB, CD two ends per needle thread
up can be used.
[0025] In one nonlimiting embodiment of the current invention, the
majority of tufts are immediately adjacent to at least one other
tuft comprised of tufted yarn of at least one different color. In
another nonlimiting aspect, each tuft is immediately adjacent to at
least one other tuft comprised of tufted yarn of at least one
different color. In another nonlimiting embodiment of the current
invention, there is no 12 square inch area of the carpet covered by
yarns of only a single color. In another nonlimiting embodiment,
there is no 4 square inch area of the carpet covered by yarns of
only a single color. In yet another nonlimiting embodiment of the
current invention, there is no single square inch area of the
carpet that is covered by yarns of only a single color.
[0026] The multicolor carpets of the present invention also exhibit
excellent durability. In one nonlimiting embodiment of the current
invention, the carpet has an appearance rating of at least 3 when
subjected to a walk test according to ASTM D6119. In another
nonlimiting embodiment of the current invention, the carpet has an
appearance rating of at least 4.5 when subjected to a walk test
according to ASTM D6119.
[0027] In a nonlimiting embodiment of the current invention, the
multicolor carpet of the current invention may be comprised of
bulked continuous filaments formed from solution-dyed polyamide
polymer. Suitable polyamides include fiber forming polyamides known
in the art to be suitable for the formation of bulked continuous
filament fibers, having sufficient viscosity, tenacity, chemical
stability and crystalinity to be at least moderately durable in
such application. The at least one polyamide resin may be selected
from the group consisting of nylon 5,6; nylon 6/6; nylon 6; nylon
7; nylon 11; nylon 12; nylon 6/10;, nylon 6/12; nylon DT; nylon 6T;
nylon 61; and blends or copolymers thereof. In one embodiment, the
solution-dyed bulked continuous filaments are formed from nylon 6,6
polymer.
[0028] In another nonlimiting embodiment, the solution-dyed bulked
continuous filaments are formed from aliphatic carbon filaments,
especially polypropylene.
[0029] Suitable polyesters include fiber forming polyesters known
in the art. The at least one polyester resin may be selected from
the group consisting of polyethylene terephthalate,
polytrimethylene terephthalate, polybutylene terephthalate,
polyethylene naphthalate, polylactic acid (PLA) and blends or
copolymers thereof.
[0030] In embodiments of the current invention, the solution-dyed
bulked continuous filaments of the multicolor carpet further
comprise a cationic dye additive. The use of cationic dye additives
in thermoplastics has been discussed in U.S. Pat. No. 5,108,684 to
Anton, herein incorporated by reference. The use of cationic dye
additives impart stain resistant properties to the yarns used in
the current invention. Suitable cationic dye additives which may be
used include those aromatic sulfonates and their alkali metal salts
which are capable of copolymerizing with the polymeric raw
materials used to form the solution dyed bulk continuous filaments
of the current invention. In one nonlimiting embodiment of the
current invention, the cationic dye additive is
5-sulfoisophthalate. In another nonlimiting embodiment, the
5-sulfoisophthalate in the solution-dyed bulked continuous
filaments is in the range of about 1 to about 8 percent by weight.
In another nonlimiting embodiment, the 5-sulfoisophthalate in the
solution-dyed bulked continuous filaments is in the range of about
1 to about 4 percent by weight. In one nonlimiting embodiment of
the current invention, the multicolor carpet has a stain rating of
at least 5. In another nonlimiting embodiment of the current
invention, the carpet has a stain rating of about 10.
[0031] In one nonlimiting embodiment of the current invention, the
plurality of tufted yarns used in the multicolor carpet further
comprises at least one conductive filament. In another nonlimiting
embodiment, the amount of conductive filaments is sufficient to
form an antistatic carpet. Examples of conductive filaments that
can be used to impart antistatic properties to a carpet were
disclosed in U.S. Pat. Nos. 4,900,495 and 4,997.712, herein
incorporated by reference. In one nonlimiting embodiment of the
current invention, the conductive filaments is spin orientated and
has a nonconductive polymeric component coextensive with a
component of electrically conductive carbon dispersed in a
polymeric matrix wherein the nonconductive polymeric component of
the spin-oriented, conductive filaments is a melt-blend containing
a major amount of a nonconductive, fiber-forming polymeric
material.
[0032] The present invention also provides for a method of
manufacturing a multicolor carpet. In this method, a plurality of
yarns of at least two different colors are tufted to form a carpet,
wherein the yarns comprise solution-dyed, bulked continuous
filaments, wherein the yarns have not been twisted, and wherein the
yarns have not been heatset.
[0033] Also provided by the present invention are articles of
manufacture, at least a portion of which comprises a multicolor
carpet comprising a plurality of tufted yarns of at least two
different colors, wherein the yarns comprise solution-dyed bulked
continuous filaments, wherein the yarns have not been twisted, and
wherein the yarns have not been heatset.
[0034] Also provided by the present invention are articles of
manufacture, at least a portion of which comprises, a multicolor
carpet comprising a plurality of tufted yarns of at least two
different colors, wherein the yarns comprise solution-dyed bulked
continuous filaments, wherein the solution-dyed bulked continuous
filaments further comprises an aromatic sulfonate or an alkali
metal salt thereof, wherein the yarns have not been twisted, and
wherein the yarns have not been heatset.
[0035] Also provided by the present invention are articles of
manufacture, at least a portion of which comprises, a multicolor
carpet comprising a plurality of tufted yarns of at least two
different colors, wherein the yarns comprise solution-dyed bulked
continuous filaments, wherein the solution-dyed bulked continuous
filaments further comprises an aromatic sulfonate or an alkali
metal salt thereof, wherein the plurality of tufted yarns further
comprises at least one conductive filament , wherein the yarns have
not been twisted, and wherein the yarns have not been heatset.
Definitions
[0036] BCF--Bulked Continuous Filament
[0037] SIPA--sulfonated isophthalic acid
Test Methods
[0038] Walk Test: The durability of the carpet was measured by the
walk test under ASTM D6119 for creating surface appearance changes
in pile yarn floor covering form foot traffic.
[0039] Stain Resistance Test: Acid dye stain resistance is
evaluated using a procedure modified from the American Association
of Textile Chemists and Colorists (AATCC) Method 175-2003, "Stain
Resistance: Pile Floor Coverings." 9 wt % of aqueous staining
solution is prepared, according to the manufacturer's directions,
by mixing cherry-flavored KOOL-AID.RTM. powder (Kraft/General
Foods, White Plains, N.Y., a powdered drink mix containing, inter
alia, FD&C Red No. 40). A carpet sample (4.times.6-inch) is
placed on a flat non-absorbent surface. A hollow plastic 2-inch
(5.1 cm) diameter cup is placed tightly over the carpet sample.
Twenty mL of the KOOL-AID.RTM. staining solution is poured into the
cup and the solution is allowed to absorb completely into the
carpet sample. The cup is removed and the stained carpet sample is
allowed to sit undisturbed for 24 hours. Following incubation, the
stained sample is rinsed thoroughly under cold tap water, excess
water is removed by centrifugation, and the sample is dried in air.
The carpet sample was visually inspected and rated for staining
according to the FD&C Red No. 40 Stain Scale described in AATCC
Method 175-2003. Stain resistance is measured using a 1-10 scale.
An undetectable test staining is accorded a value of 10. Ratings
are determined by visual examination by a panel of evaluators.
[0040] Node Evaluation Procedure: The frequency of nodes formed by
the process, and the tightness of the discrete nodes formed, were
determined by visual observation. Typically, a length of yarn as
provided by the process is hung vertically, with no tension
applied. The length of yarn is 2.5-3 meters. Then, the number of
moderate and severe interlace nodes, in the form of entangled or
compacted regions, are counted along the length of the yarn. A
moderate interlace node is adjudged to have a yarn diameter of less
than 50% of the main yarn body. A severe interlace node is adjudged
to have a diameter of less than 30% of the main yarn body. The
routine is repeated for 4-5 more yarn segments representative a
given sample, and the values determined used to provide an average
number of moderate and severe interlace nodes for a given sample of
yarn.
[0041] The SDN BCF yarns used to make the multicolor carpets of the
current invention contain less than 5 severe interlace nodes per
meter and typically, no severe interlace nodes are observed. SDN
BCF yarns made by this process used in the current invention
comprise less than 30 moderate interlace nodes. In other aspects of
the current invention, the SDN BCF yarns comprise less than 20
moderate interlace per meter.
EXAMPLES
[0042] The following Examples demonstrate the present invention and
its capability for use. The invention is capable of other and
different embodiments, and its several details are capable of
modifications in various apparent respects, without departing from
the scope and spirit of the present invention. Accordingly, the
Examples are to be regarded as illustrative in nature and
non-limiting.
Example 1 (Comparative)
[0043] Two ends of 1500 denier, 6.5 dpf solution dyed BCE yarn were
ply twisted together (3.25 turns per inch) on a Volkman twisting
machine. Both BCF used in this example were earth tone color yarns
with slightly different shade (code as western sand and sand dune).
The cable twisted yarn was heatset on Superba at 265 F and
converted into 0.5 inch pile height, 18 oz/yd. cut pile carpet on a
5/32 gauge tufting machine, a typical construction for low weight
residential carpet.
[0044] The finished carpets was stained with Kool-aid for 24 hours,
rinsed with water and judged by a panel of experts to have a stain
rating of 6 in a 1 to 10 scale. This sample failed the
STAINMASTER.RTM. stain protection requirement.
[0045] This carpet sample was also tested for newness retention in
a Vetterman drum. After 5000 cycles, this sample had a severe worn
out pattern and was rated by a panel of experts to be unacceptable
as branded STAINMASTER.RTM. carpet.
Example 2 (Comparative)
[0046] A 1500 denier, 6.5 dpf medium earth tone color solution dyed
BCF yarn was tufted into a 18 oz/yd. 1/4'' pile height cut pile
carpet on a 1/12 gauge M-tufting machine. The finished solid color
carpet had no tip definition and rated by a panel of experts to be
aesthetically unacceptable for residential carpet.
Example 3 (Current Invention)
[0047] Three 1500 denier 6.5 dpf light, medium and dark earth tone
solution dyed BCF yarns, after having passed the Node Evaluation
Procedure, were alternately tufted into a 18 oz/yd. multicolor
1/4'' pile height cut pile carpet on a 1/12 gauge M-tufting
machine. The finished carpet had a different colored yarn tuft
separating it in each direction from any other yarn tuft of the
same color, and none of the yarns of the carpet were either twisted
or heat set. Overall the carpet gave an attractive appearance. The
mixture of colors in adjacent tufts gives a pseudo tip definition
that was similar to the tip definition created by cable twist and
heatset carpets.
[0048] The finished carpets was stained with Kool-aid for 24 hours,
rinsed with water and judged by a panel of experts to have a stain
rating of 10 in a 1 to10 scale. This sample passed the
STAINMASTER.RTM. stain protection requirement.
[0049] This carpet sample was also tested for newness retention in
a Vetterman drum. After 5000 cycles, this sample had no worn out or
crushed pattern. The tested carpet had the exact same look as the
untested carpet.
Example 4 (Current Invention)
[0050] Three 1500 denier 6.5 dpf light, medium and dark earth tone
solution dyed BCF yarn, after having passed the Node Evaluation
Procedure, were alternately tufted into a 22 oz/yd. multicolor
1/4'' pile height loop pile carpet on a 5/64 gauge M--tufting
machine. The finished carpet had an attractive appearance.
[0051] The finished carpets was stained with Kool-aid for 24 hours,
rinsed with water and judged by a panel of experts to have a stain
rating of 10 in a 1 to 10 scale. This sample passed the
STAINMASTER.RTM. stain protection requirement.
[0052] This carpet sample was also tested for newness retention in
a Vetterman drum. After 5000 cycles, this sample had no worn out
pattern. The tested carpet had the exact same look as the untested
carpet.
Example 5 (Current Invention)
[0053] 1500 denier, 13 dpf solution dyed BCF yarn made from
cationic dyeable polymer and, after having passed the Node
Evaluation Procedure, were tufted on a 1/10 gauge tufting machine
(color point by Card-Monroe Corporation). Two color light weight
carpets (19 oz/yds. 10/32 inch pile height, 10 stitches per inch)
with various patterns and color combinations were successfully
produced without any processing issue. The finished carpets had an
attractive appearance. The multicolor carpets formed from these
yarns are depicted in FIGS. 1A and 1B.
[0054] The finished carpets were stained with Kool-aid for 24
hours, rinsed with water and judged by a panel of experts to have a
stain rating of 10 in a 1 to 10 scale. These samples passed the
STAINMASTER.RTM. stain protection requirement.
[0055] These carpet samples were also tested for newness retention
in a Vetterman drum. After 5000 cycles, this sample had no visible
worn out pattern.
Example 6 (Current Invention)
[0056] 1500 denier, 13 dpf solution dyed BCF yarns made from
cationic dyeable polymer and having passed the Node Evaluation
Procedure were tufted on a 1/10 gauge tufting machine (color point
by Card-Monroe Corporation). Three color light weight carpets (19
oz/yds. 10/32 inch pile height, 10 stitches per inch) with various
patterns and color combinations were successfully produced without
any processing issue. The finished carpets had an attractive
appearance. The multicolor carpets formed from these yarns are
depicted in FIGS. 2A, 2B and 2C.
[0057] The finished carpets were stained with Kool-aid for 24
hours, rinsed with water and judged by a panel of experts to have a
stain rating of 10 in a 1 to 10 scale. These samples passed the
STAINMASTER.RTM. stain protection requirement.
[0058] These carpet samples were also tested for newness retention
in a Vetterman drum. After 5000 cycles, this sample had no visible
worn out pattern.
Example 7 (Current Invention)
[0059] 997 denier, 9 dpf solution dyed Nylon 66 BCF yarns made from
cationic polymer and having passed the Node Evaluation Procedure
were used for this example. In one case, two earth tone color yarns
(western sand, color A, antique white, color B) were used in odd
number needles and other two earth tone color yarns (Indian pottery
color C, sand dune color D) were used in even number needles on a
1/10 gauge CMC color point tufting machine. Medium weight carpets
(26 oz, 3/8'' pile height, 10 stitched per inch) were successfully
produced without any tufting issue. This sample was subject to
20,000 cycle walk test (ASTM D6119) at Professional test lab in
Dalton Georgia. The rating was 3.5. It was considered as a good
performing carpet. The multicolor carpet formed from these yarns is
depicted in FIG. 3A.
[0060] In another case, two grayish color yarns (Woodsmock, Burmese
gray) were used in odd number needles and another two grayish color
yarns (mineshaft, pearl) were used in even number needles on a 1/10
gauge CMC color point tufting machine. Medium weight carpet (32 oz,
3/8'' pile height, 10 stitches per inch) were successfully produced
without any processing issues. The multicolor carpet formed from
these yarns is depicted in FIG. 3B.
[0061] This sample was subjected to 20,000 cycle walk test at
Professional Testing Laboratory, Inc. (Dalton, Ga.). The rating was
4.5, which rates the sample as a superior performing carpet.
Example 8 (Current Invention)
[0062] A 1800 denier 90 filament tri-color Nylon 6 BCF yarn was
made on Neumag 3+ spinning machine. This yarn as spun, had 30
filaments each of black, gray and white color filaments. This yarn
was tufted on a 1/8 gauge cut pile tufting machine to form a 18
oz/yd. 10/32 inch pile height, 10 stitch per inch cut pile carpet.
It had an appearance of near solid color carpet but with
interesting light, medium and dark toner effect.
Example 9 (Current Invention)
[0063] A 1800 denier 102 filament tri-color polyester BCF yarn was
made on Neumag S+spinning machine. This yarn as spun, had 34
filaments each of black, dark brown and white color filaments. This
yarn was tufted on a 1/8 gauge cut pile tufting machine to form a
18 oz/yd. 10/32 inch pile height, 10 stitch per inch cut pile
carpet. It had an appearance of near solid color carpet but with
interesting light, medium and dark toner effect.
[0064] It should be noted that ratios, concentrations, amounts, and
other numerical data may be expressed herein in a range format. It
is to be understood that such a range format is used for
convenience and brevity, and thus, should be interpreted in a
flexible manner to include not only the numerical values explicitly
recited as the limits of the range, but also to include all the
individual numerical values or sub-ranges encompassed within that
range as if each numerical value and sub-range is explicitly
recited. To illustrate, a concentration range of "about 0.1% to
about 5%" should be interpreted to include not only the explicitly
recited concentration of about 0.1 wt % to about 5 wt %, but also
the individual concentrations (e.g., 1%, 2%, 3%, and 4%) and the
sub-ranges (e.g., 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%) within the
indicated range. The term "about" can include .+-.1%, .+-.2%,
.+-.3%, .+-.4%, .+-.5%, .+-.8%, or .+-.10%, of the numerical
value(s) being modified. In addition, the phrase "about `x` to `y`"
includes "about `x` to about `y`".
[0065] While the illustrative embodiments of the invention have
been described with particularity, it will be understood that the
invention is capable of other and different embodiments and that
various other modifications will be apparent to and may be readily
made by those skilled in the art without departing from the spirit
and scope of the invention. Accordingly, it is not intended that
the scope of the claims hereof be limited to the examples and
descriptions set forth herein but rather that the claims be
construed as encompassing all the features of patentable novelty
which reside in the present disclosure, including all features
which would be treated as equivalents thereof by those skilled in
the art to which the invention pertains.
* * * * *