U.S. patent number 3,751,777 [Application Number 05/161,334] was granted by the patent office on 1973-08-14 for process for making tufted pile carpet.
Invention is credited to Sohinder Nath Chopra, Dorothy Ellen Lackie, Hilaire Marcel Turmel.
United States Patent |
3,751,777 |
Turmel , et al. |
August 14, 1973 |
PROCESS FOR MAKING TUFTED PILE CARPET
Abstract
The present invention relates to a carpet tufted with a
fibrillatable yarn and a method of fibrillating the yarn in the
carpet to thereby deluster and consolidate the pile. More
particularly, the present invention relates to the discovery that a
high velocity fluid stream directed at the pile of a carpet tufted
of a fibrillatable yarn delusters, fibrillates, entangles and
consolidates the pile thereof.
Inventors: |
Turmel; Hilaire Marcel
(Drummondville, Quebec, CA), Lackie; Dorothy Ellen
(Drummondville, Quebec, CA), Chopra; Sohinder Nath
(Hawkesbury, Ontario, CA) |
Family
ID: |
22580775 |
Appl.
No.: |
05/161,334 |
Filed: |
July 9, 1971 |
Current U.S.
Class: |
28/159;
28/167 |
Current CPC
Class: |
D05C
17/026 (20130101) |
Current International
Class: |
D05C
17/02 (20060101); D05C 17/00 (20060101); D05c
015/00 () |
Field of
Search: |
;28/DIG.1,72.2,72P |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Rimrodt; Louis K.
Claims
What is claimed:
1. A process for making a tufted pile carpet by tufting a carpet
with pile loops of a fibrillatable face yarn and thereafter
fibrillating said loops with a fluid stream, wherein said fluid
stream impinges on said carpet's face at an angle of between about
70.degree. to about 90.degree. and said fluid stream has a velocity
measured at the nozzle of between about 500 to about 3,000 feet per
second, whereby some of said fibrils intertwine and entangle with
each other.
2. A process as in claim 1 wherein the fibrillatable face yarn is a
bicomponent, each component having a different crimp potential.
3. A process as in claim 1 wherein the fibrillatable face yarn is
prepared by extruding a thermoplastic resin with a foaming
agent.
4. A process as in claim 1 wherein the fibrillatable face yarn is a
highly oriented tape.
5. A process as defined in claim 1 further comprising the step of
coating said carpet pile with a resin emulsion.
6. A process as defined in claim 5 wherein said resin emulsion is
selected from the group consisting of polypropylene, polyethylene,
polyvinyl chloride or acrylic resin and is applied in
concentrations of between about 1 to about 10 percent, based on the
weight of the pile.
7. A process as defined in claim 5 further comprising the step of
introducing the carpet to a drying oven maintained at between about
100.degree. to about 150.degree.C. for between about 15 to about 40
minutes to cure the emulsion.
8. A process as defined in claim 1 comprising the further step of
needle punching the carpet pile subsequent to the fibrillation of
said face yarn.
Description
BACKGROUND OF THE INVENTION
The trend towards thick, heavy pile carpet, i.e., closely woven
pile wherein the individual loops are of relatively light denier
and closely compacted, has evolved several substantial problems in
the manufacture thereof, the most notable of which is the inherent
difficulty of tufting relatively light denier yarns. Specifically,
the reduced dimensions of light denier yarns coupled with the
increased number of yarns required per unit of area to effect the
necessary cover makes it difficult for the tufting needle to
pick-up, properly position and control the yarn loop during the
tufting operation. Use of fibrillated yarns for the pile has not
been an entirely satisfactory solution to this problem
notwithstanding their very desirable bloom and cover, since the low
denier and consequential reduced dimensions of each of the ends of
a particular fibrillated yarn loop does not alleviate the inherent
difficulty associated with the tufting operation.
SUMMARY OF THE INVENTION
The present invention addresses itself to this problem of producing
thick compacted carpet pile tufted of relatively light denier
yarns. The solution thereto as will be described in greater detail
hereinafter, comprises first, tufting the carpet with a
fibrillatable yarn and, thereafter, passing a high speed fluid jet
over the tufted carpet to fibrillate the yarn.
Heretofore fibrillatable yarns were not believed practical or
desirable for tufted carpet uses, specifically because of their
tape-like appearance, high luster, and poor resilience. That is,
the poor appearance caused by excessive shine and tendency of the
pile made therefrom to mat all but eliminated consideration of
these yarns for use in a carpet or carpet-type environment. The
present invention has found, however, that after treatment, in a
manner to be more fully disclosed hereinafter, these yarns not only
have lost their luster and have become substantially resilient but
they have all the advantages of a fibrillated yarn, such as
desirable bloom and coverability per loop. Equally as important
these changes are accomplished without any of the attendant
disadvantages previously associated with fibrillated yarns, such as
difficulty to control during the tufting operation. Thus, a
two-fold advantage has been realized with the present invention;
first, the fibrillatable yarns used in the tufting operation can be
of relatively heavy denier making them very easy to work with and
control during tufting; and, second, a thick, luxurient pile can be
obtained easily and inexpensively.
DETAILED DESCRIPTION OF THE INVENTION
The desire for thick, heavy pile carpet comprised of closely
compacted, relatively light denier yarns has presented considerable
difficulty in the tufting operation, due primarily to the inability
of the tufting needle to properly grasp, position and control these
yarns. One possible solution, using fibrillated yarns which have
excellent bloom and provide maximum cover per loop has not been
entirely satisfactory. The principal disadvantage being that the
individual fibrils or ends of each fibrillated yarn loop are of
relatively light denier and are, thus, equally as difficult for the
tufting needle to handle as unfibrillated, light denier yarns. The
needs has thus arisen for a method of making thick, heavy pile
carpets without the attendant disadvantages of tufting the carpet
of relatively light denier materials.
The instant invention addresses itself to this problem and has
surprisingly discovered that relatively heavy denier yarns can be
used to produce a desirable thick, heavy, compacted pile for a
carpet if the tufting material is fibrillatable and, if, after
tufting, the fibrillatable pile loops are subjected to
fibrillatable by a high velocity fluid stream. Heretofore,
fibrillatable yarns were considered as impractical and undesirable
for carpet use because of their very high luster or shine and low
resilience, which often resulted in matting during use. With the
present invention, however, not only is the undesirable luster of
these materials significantly reduced but the pile is surprisingly
resilient and remains resilient even after considerable use. This
resiliency compares quite favorably and in some cases is superior
to carpet pile tufted of a prefibrillated yarn. Subsequent
investigation has shown that when the carpet is tufted with a
fibrillatable material which is thereafter fibrillated, the
foundations of the pile loops are not affected, thus giving greater
support to the loops and enhancing resiliency. In addition, with
the present invention the carpet may be tufted with an easy to
handle heavy denier yarn and the resulting product, after
fibrillation, has all the coverability and appearance advantages of
a carpet tufted of a fibrillated yarn.
More specifically, any yarn capable of fibrillation, such as a
bi-component, or a fiber prepared by extruding a thermoplastic
resin with a foaming agent or otherwise containing a foaming agent,
or a highly oriented tape, and the like can now be used as the
tufting material for a carpet. The denier of the yarn in its
unfibrillated form, i.e., as used during the tufting operation, is
not critical, although it is preferred that it be of sufficient
denier for the tufting needle to readily grasp, position and
control it during the tufting operation. It is considered
essential, however, that after tufting and fibrillation of the yarn
each yarn loop contain at least four free fibril ends per linear
inch, with a preferred range of free fibril ends per linear inch
being between about 20 to about 200. It is also considered
essential that the individual fibril ends have a relatively low
denier, with a preferred range being between about 10 and about
100. It should be understood at this juncture that the process of
the present invention does not merely encompass voluminizing of the
yarn loops after tufting, although voluminizing does occur, nor
does it pertain to fluid jets used in conjunction with the tufting
needle to guide and control positioning of the pile loop. When
fully understood it will be appreciated that the present invention
comprises a complete restructuring of the individual yarn loops
from substantially single unit structures having one end per loop
to a multi-element structure having, as stated above about 20 to
about 400 free fibril ends per loop. It will also be appreciated
that there is a corresponding reorientation in the apportionment of
denier substantially unitary structure to a multi-end structure,
each end or fibril having a desired denier in the range of from
about 10 to about 100.
The procss, per se comprises tufting a carpet with a fibrillatable
yarn in a manner well known in the art and then, directing a high
velocity fluid stream at the pile of the carpet to fibrellate the
individual yarn loops. The fluid stream may be, for example, air,
preferably heated or super heated air or steam and the like. This
high velocity fluid stream which may be passed over the carpet pile
or alternatively the carpet pile may be passed by the fluid stream,
serves to fibrillate, entangel, consolidate and deluster the pile
loops. In a preferred form of the present invention the velocity of
the fluid stream is between about 500 to about 3000 feet per
second, measured at the nozzle and the pressure is between about 20
to about 100 psi, also measured at the nozzle. It is also preferred
that the fluid stream impinge on the face of the carpet at an
eighty degree angle to the carpet, with a most preferred range
being between about seventy to about ninety degrees. Quite
surprisingly and unexpectedly this treatment imparts a very soft
hand and desirable texture characteristics to the pile.
Desirably, the carpet structure is continuously passed through the
region of the fluid jet forces about a relatively sharp angle, such
that the individual pile loops are directly exposed to the
application of relatively uniform fibrillative forces throughout
their pile length. Thus, the carpet may be passed under a series of
fluid jets applied to the face thereof while passing about, e.g., a
freely rotating roll, through an angle of 15.degree. to
105.degree., preferably less than 75.degree.. Most effectively, the
apex angle employed is acute.
Equally as unexpected it has been found that by adjusting the
nozzle positions and movements on a multi-nozzle device it is
possible to impose a new pattern on what was a patternless carpet
or to super-impose a new pattern on a carpet already having a
pattern. It has also been discovered that when the fluid stream
comprises hot air or stream, the individual fibrils tend to curl or
crimp in a helical pattern which further enhances the resilience
and bloom of each individual pile loop. Especially desirable
results with hot air or steam as the fluid stream are obtained when
the fibrillatable yarn is a bi-component each component of which
has a different crimp potential. These yarns may be prepared, for
example, by dividing a polymer melt into at least two portions and
subjecting the portions to different thermal and/or shear history
prior to recombining the portions and extruding them through a
common die. Additionally, if the fluids are super hot, for example,
about 300.degree.C., it is possible to controllably burn intricate
patterns and designs into the face of the carpet concurrently with
fibrillation of the loops.
The present invention has also discovered that additional
delustering of the carpet pile can be accomplished in either of two
ways or combinatons thereof. A first method for additional
delustering involves coating the carpet pile after treatment as
described above with a resin emulsion such as polypropylene,
polyethylene, polyvinyl chloride or an acrylic resin with preferred
concentration of these emulsions being at the one percent to about
10 percent level based on the weight of the carpet pile. In a
preferred embodiment of this process the carpet is placed in a
drying oven, maintained at about 100.degree. to about
150.degree.C., for between about 15 to about 40 minutes, to dry and
cure the emulsion. This process has the added advantage of
enhancing the stiffness of the loops and correspondingly the
resilience of the pile.
Alternatively, it has been found that additional delustering of the
pile can be obtained by needle punching the carpet also after
fibrillation of the fibrillatable yarn, as described above. This
particular method produces an interesting three dimensional effect
somewhat similar to a needle punch pad and has the added advantage
of increasing the degree of fibrillation of the pile loops. Thus,
for example, if a particularly lusterious fibrillatable yarn is
used to tuft the carpet so that additional delustering is desired;
or, if the particular end use intended for the carpet necessitates
increased resilience for the pile, then the pile can be
additionally delustered and made more resilient by treating the
pile with a suitable emulsion and baking, as described above.
Similarly, if it is desired to substantially increase the amount of
fibrillation, or the amount of fibrillation in selected areas of
the carpet, this may be accomplished by needle punching the carpet
where desired.
The following examples demonstrate without limiting preparation of
carpets according to the present invention.
EXAMPLE I
A coarse fibrillatable polypropylene tape was produced by adding 1
percent of a blowing agent to a polypropylene resin and extruding
the resin. 2-ply fibrillatable yarn (having two ends of 1,800
denier twisted one turn in the S direction) was used to produce a
level loop pile carpet on a 5/32 inch gauge tufter with a stitch
density of 8 stitches per inch and a pile height of 0.300 inches.
The backside of the carpet was coated with a common latex compound
in a standard carpet finishing machine. A sample of the carpet was
exposed to a jet of steam at 80 psi, the nozzle having a
rectangular opening of 1/16 inch by 1 inch. The nozzle was held
over the carpet in touch with the pile face and the carpet was
moved under the nozzle along the axis of the tufting lines at 1
foot per minute. After one pass, the same action was repeated over
the adjacent area so as to cover the whole width of the sample.
Fine fibrillation of the carpet face resulted in a soft woolen hand
and delustered appearance.
EXAMPLE II
The fibrillated carpet produced above in Example I was then treated
with a 5 percent concentration of polypropylene emulsion. The
emulsion was applied with a brush to the extent of 1 percent by
weight. The carpet sample was then inserted in an oven at
125.degree.C. and was left there for 15 minutes. When cooled to
room temperature, the carpet showed dull appearance and somewhat
stiffer hand. This carpet was then subjected to floor traffic.
After 30,000 treads, the carpet maintained excellent appearance,
reduced gloss and good resilience.
EXAMPLE III
Before the carpet produced in Example I above was latexed, a sample
was removed from the Greige carpet, The Griege carpet was exposed
to the fibrillation action of the steam nozzles. The fibrillated
pile carpet was then coated with an emulsion as in Example II, and
then latexed at 145.degree.C., staying in the drying oven for 20
minutes. It was found that the fibrils had curled and entangled
with each other due to the high heat in the oven producing a fine
wooly hand and appearance.
EXAMPLE IV
The Greige fibrillated carpet of Example III was passed through a
needle loom and 500 needle insertions per square inch of the carpet
face were applied. The carpet pile height was reduced by this
action and a pad of uniformed thickness of 0.100 inches was
obtained. The primary backing of the carpet which is generally on
the back of the pile carpet had migrated to the center of the felt
pad.
As this invention may be embodied in several forms without
departing from the spirit or essential character thereof, the
present embodiments are illustrative and not descriptive. The scope
of the invention is defined by the appended claims rather than by
the description preceeding them and all embodiments which fall
within the meaning and range of equivalency of the claims are,
therefore, intended to be embraced by those claims.
* * * * *