CUT PILE CARPET WITH COLOR ACCENTS AND METHODS OF MANUFACTURE THEREOF

Abstract

A multicolored and accented carpet includes a plurality of tufts of color accented fiber including two or more differently colored extruded solution dyed yarns and a base yarn twisted together whereby a plurality of color transitions are provided along the length of the single accented fiber. A cut pile carpet is produced, having the appearance of a space dyed carpet, with the fade and bleach resistance of a solution dyed carpet.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 62/218,797 filed Sep. 15, 2015, the entirety of which is hereby incorporated herein by reference for all purposes.

TECHNICAL FIELD

The present invention relates generally to the field of carpet, and the design and manufacturing thereof. The invention relates more particularly to cut pile carpet having color accents provided by a tri-color solution-dyed yarn, to the multi-color solution dyed carpet yarn, and to methods and processes for manufacture of such carpet and yarn.

BACKGROUND

In residential cut pile carpet applications, color highlights are typically achieved by the incorporation of yarns that have color accents applied in a process known as “space dyeing.” Carpets with color accents and highlights are growing in popularity as they keep a clean appearance longer than a solid color carpet. In a typical space dye process, a single end of yarn is processed through a machine which has a series of computer controlled applicators or jets which apply dye (color) in various patterns (long and short dots) along the length of the yarn. These color patterns provide color accents when the yarn is tufted into a carpet. The end of yarn with color accents applied (“spaced dyed yarn”) is twisted with another end of yarn without accents. The non-accented yarn can be pre-colored (“solution dyed”) or have no colorant added (“natural white yarn”). The 2-ply yarn bundle is then heat set. This process uses steam and heat to impart twist memory to the yarn. The twist is locked in place which allows carpets to have resistance to foot traffic.

The yarn with colored accents (“space dye”) is then planted with regular non-accented yarn (“natural yarn or solution dyed”) on a tufting machine (a 12 to 15 foot wide computer controlled high speed sewing machine). The tufting machine then tufts the yarns together in a primary backing to produce the carpet with color accents and highlights. Depending on whether the non-accented or white “natural” yarns have color added “solution dyed”, additional dyeing and coloring may be necessary after the tufts are formed in the primary backing, and before application of the secondary backing.

However, space-dyed yarns and other color-additive processes by which accents and colors are added to yarns after fiber development are known to have additional benefits with respect to the carpet's durability, lifespan and overall appearance. Carpets with colored accents provided by “space dyed” yarns are not only aesthetically pleasing, for example because of the multi-colors in the carpet, but they additionally have the ability to mask soiling and walkout patterns that traditional solid color carpets show after years of use in residential homes and apartments. They do however, have a susceptibility to sunlight fading and can become faded when exposed to harsh cleaning chemicals such as household bleach (sodium hypochloride solutions). Moreover, additional manufacturing steps utilized to dye the yarns results in additional capital and labor expenses to produce multicolored and accented carpets.

Some carpet fiber manufacturing machines (e.g., extrusion machines) have the ability to produce a yarn bundle that contains three different colors of fiber within the bundle. The extrusion machines are known as “tri-color extrusion machines”. The machines have traditionally been used to produce fibers utilized in loop pile carpets of the sort primarily used in commercial applications, but not in the production of cut pile or tufted carpets of the sort more typically used in residential applications.

Accordingly, it has been found that needs exist for a non-space-dyed color accented and highlighted carpet, to provide the soil and traffic hiding capabilities of traditional space dyed accented carpets plus the additional feature of resistance to sunlight fading and resistance to strong household cleaners and bleach (sodium hypochloride). It is to the provision of a cut pile carpet, carpet yarns for producing such carpet, and methods of manufacture and use thereof meeting these and other needs that the present invention is primarily directed.

SUMMARY

In example embodiments, the present invention provides an extrusion or solution-dyed multicolored and/or color-accented or highlighted carpet, and manufacturing methods and processes for producing such carpet without the use of space-dying processes. The resulting carpet provides the attractive appearance of space dyed carpets, but having the benefit of the fade resistance and bleach resistance of solution dyed carpets. In further embodiments, the invention provides a carpet yarn having a multi-color solution dyed fiber twisted together with a single ply of solid colored fiber. Further embodiments of the invention provide methods of manufacture and use of such carpet and carpet yarn.

In one aspect, the invention relates to a multicolored carpet including a primary backing material, and a plurality of piles tufted with the primary backing material to form a carpet. In example forms, at least a portion of the piles of the carpet include color accented 2-ply yarns. In example embodiments, the color accented 2-ply yarns include a single ply tri-colored solution dyed fiber twisted together with a single ply of solid colored fiber. In example embodiments, one or more piles tufted with the primary backing material are in the form of solid color 2-ply yarns.

Optionally, one or more piles tufted with the primary backing material in the form of a barber pole yarn. In example embodiments, the barber pole yarn includes a 2-ply yarn having two differing colors of pre-colored, solution dyed fibers. In example embodiments, about 10-70% of the piles tufted with the primary backing include color accented 2-ply yarns. According to one example embodiment, about 33% of the piles tufted with the primary backing include color accented 2-ply yarns. In example embodiments, the color accented 2-ply yarn in combination with the barber pole yarn provides a plurality of color transitions along a length of the carpet. In one example embodiment, the carpet includes cut piles. In another example embodiment, the carpet includes a combination of cut piles and loop piles.

In another aspect, the invention relates to a method of manufacturing multicolored and color accented carpet including providing a color accented 2-ply yarn, providing a primary backing, and tufting the color accented 2-ply yarn into the primary backing to form the carpet. In example embodiments, the color accented 2-ply yarn includes at least two differently colored extruded solution dyed yarns twisted together, wherein twisting of the at least two colored extruded solution dyed yarns results in a plurality of color transitions along a length of the color accented 2-ply yarn.

In example embodiments, prior to tufting the color accented 2-ply yarn into the primary backing, the color accented 2-ply yarn is twisted together with a main fiber, and wherein twisting of the color accented 2-ply yarn about the main fiber provides for a plurality of color transitions along the length thereof. In one example embodiment, the method further includes tufting barber pole yarn into at least a portion of the primary backing. In example embodiments, the barber pole yarn includes a 2-ply yarn having two differing colors of pre-colored, solution dyed fibers. In another example embodiment, the method further includes tufting solid color 2-ply yarns into the primary backing.

In another aspect, the invention relates to a multicolored and color accented cut pile carpet including at least one pile in the form of color accented 2-ply yarn, at least one pile in the form of barber pole yarn, and at least one pile in the form of solid color 2-ply yarn. In example embodiments, the at least one color accented 2-ply yarn includes a single ply tri-colored solution dyed fiber twisted together with a single ply of solid colored fiber. In example embodiments, the barber pole yarn includes a 2-ply yarn having two differing colors of pre-colored, solution dyed fibers. In example embodiments, about 33% of the piles comprise the color accented 2-ply yarn.

These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of the invention are exemplary and explanatory of preferred embodiments of the invention, and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

FIG. 1 is a plan view of three colored yarns prior to being twisted together to form a single ply accented yarn, according to an example embodiment of the present invention.

FIG. 2 is a plan view of the single ply accented yarn formed by twisting the yarns of FIG. 1 together, according to an example embodiment of the present invention.

FIG. 3 is a plan view of the single ply accented yarn of FIG. 2 being twisted together with a main fiber to form a 2-ply tri-color accented yarn, according to an example embodiment of the present invention.

FIG. 4 is a plan view of the resulting 2-ply tri-color accented yarn of FIG. 3 formed by twisting together the single accented yarn of FIG. 2 with a main fiber, according to an example embodiment of the present invention.

FIG. 5 is a schematic elevation view of a tufted carpet having piles of 2-ply tri-color accented yarns and regular yarns forming a multicolored and accented carpet according to an example embodiment of the present invention.

FIG. 6 is a chart showing ΔE values of a plurality of color combinations according to example embodiments of the present invention.

FIG. 7 shows a perspective view of a of component of a yarn extrusion and twisting machine showing draw rolls of the extrusion machine, which are provided to stretch the fibers for strengthening.

FIG. 8 is a close up perspective view of a finished package of tri-colored accented fiber according to an example embodiment of the present invention.

FIG. 9 is a plan view of a multicolored and accented carpet according to an example embodiment of the present invention.

FIG. 10 is a close up view of the multicolored and accented carpet of FIG. 9.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The present invention may be understood more readily by reference to the following detailed description of the invention taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.

Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.

In example embodiments, the present invention generally relates to a color accented fiber, for example, wherein two or more solution dyed yarns comprising differing colors are twisted together to form a color accented fiber. In example forms, the two or more yarns are extruded using an extruding machine and each yarn is solution dyed to provide a desired color. In example forms, the extrusion machine may be an Orlicon-Neumag extrusion machine. Optionally, according to other example embodiments, other tri-color extrusion machines may be used to form the yarns, for example, a Neumag SD5, Plantex, Impianti, Filteco, Bermag or other tri-color extrusion machines. According to typical example forms, each of the two or more yarns are generally a solid color (which is generally different from the other colors of the two or more yarns), and whereby twisting the yarns together provides a resulting yarn comprising a plurality of color accents. For example, depending on the colors and twist of the yarns, the resulting twisted yarn comprises a plurality of color accents or highlights at points or segments along its length, for example, which is substantially visibly similar to a traditional space dyed color accented fiber.

With reference now to the drawing figures, wherein like reference numbers represent corresponding parts throughout the several views, FIGS. 1-4 show a process for forming a 2-ply tri-color accented yarn 22 according to an example embodiment of the present invention. In example embodiments, about three colored yarns or fibers 10, 12, 14 are twisted together to form a single accented yarn 16 (see FIGS. 1-2), and then the single accented yarn 16 is then twisted together with an additional solid colored yarn or main fiber 20 to form a 2-ply tri-color accented yarn 22 (see FIG. 4). The solid colored fiber 20 is generally provided without accents and can be pre-colored (e.g., solution dyed) or can be a non-colored yard (e.g., a natural white yarn). After the twisting, the 2-ply tri-color accented yarn 22 is taken through a heat setting process by which twist memory is provided to the yarn. Alternatively, in other example embodiments, only two or more than three colored yarns can be twisted together to form the single multi-color accented yarn, for example, when more or fewer colors are desired.

According to example forms, the fibers 10, 12, 14 and 16 can be formed from one or more materials including polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polyamides (nylon 6 or nylon 6,6), polypropylene (PP), olefins or any polymer fiber as desired. Optionally, other natural or synthetic materials (or combinations thereof) may be used as desired.

In example forms, the twist process by which the fibers 16 and 20 are twisted together results in one of the three colors (of the fibers 10, 12, 14) being positioned along the exterior of the 2-ply tri-color accented yarn 22 at different segments or positions along the length L of the yarn (see FIG. 4). In example embodiments, the 2-ply tri-color accented yarn 22 comprises a plurality of accents (e.g., color transitions) along the length L thereof. For example, starting from the top end of the 2-ply tri-color accented yarn 22, a segment of yarn 10 is visible, followed by a segment of yarn 14, followed by a segment of yarn 12, and so forth along the entire length L of the yarn. In example forms, the twist process causes one of the yarns 10, 12, 14 to become present along the exterior thereof randomly by chance, for example, wherein there is generally no set values to control which of the yarns 10, 12, 14 will be exposed for a given length of the 2-ply tri-color accented yarn 22. However, according to additional example embodiments, one or more parameters may be configured with the twist process such that the 2-ply tri-color accented yarn 22 comprises a desired pattern of colors, and for example, wherein the span or length of each colored segment can be configured as desired.

In example embodiments, prior to forming the carpet, the 2-ply tri-color accented yarn 22 is generally planted with regular non-accented yarn 24 (e.g., natural yarn or solution dyed yarn) on a tufting machine (e.g., 12-15 foot wide computer controlled high speed sewing machine). In some example forms, the regular non-accented yarn 24 is in the form of 2-ply solid colored solution dyed yarn. The tufting machine then forms tufts of the yarn within a primary backing material to form a carpet greige cloth 30 (see FIG. 5). As shown in FIG. 5, the carpet greige cloth 30 comprises a plurality of tufts including tufts formed from the 2-ply tri-color accented yarn 22 and tufts formed from the regular non-accented yarn 24. According to preferred forms, the carpet greige cloth 30 is in the form of cut pile carpet. Optionally, the carpet greige cloth 30 may be in the form of loop pile, or a combination of both cut pile and loop pile. According to some example forms, the thread-up configurations for the tufting machine are A-A-A-B or AB AB, for example, where A is the non-accented regular fiber 24 and B is the 2-ply tri-color accented yarn 22.

According to example embodiments, the ΔE values (i.e., the color difference or perceived “distance” between two colors, for example according to the International Commission on Illumination (CIE) CIELAB color scale or color space) of the fibers determine the effect of the colors and their exposure throughout the plurality of tufts formed in the carpet 30. According to one form, the ΔE values comprise a ΔL value, a Δa value and a Δb value. To provide a preferred effect of the tri-color accents (e.g., a generally high contrast), the ΔL value is about 50, the Δa value is about 19, and the Δb value is about 19. Optionally, to provide a tonal effect, the Δa and Δb values can be set at about 10. Optionally, the ΔL value, Δa value and Δb value can be set as desired, for example, to provide the desired effect. According to example forms, for example as depicted in FIG. 6, the ΔE values (ΔL, Δa, and Δb) can be configured to produce a plurality of color combinations. For example, sample A includes three colors including beige, black, and orange. As shown, each of the three colors comprises a ΔE value. According to some example forms, the tolerance level ΔE CMC is generally set between about 0.5-1.0.

According to some example embodiments, if the regular non-accented fiber 24 is a pre-colored solid color (e.g., solution dyed), then the carpet cloth (greige goods) of FIG. 5 has SBR carpet backing applied prior to packaging for shipment. However, if the non-accented regular yarn 24 (“natural white yarn”) requires additional color to be applied, the carpet cloth can be over-dyed with aqueous dyes into the desired color in the background. The background color is generally a light to medium neutral shade that is lighter than the color accented fiber, for example, which will allow the carpet to exhibit color highlights. Once the carpet cloth (greige goods) has been dyed, a secondary backing and SBR latex can be applied and the carpet can be packaged and prepared for shipment.

According to example forms, the present invention provides a more consistent color blend, and a better quality carpet with contrasting color accents, which is more light-fast and color enhanced and provides superior fade resistance compared to previously known carpet manufactured using space dye processes. Furthermore, the present invention preferably eliminates the space dying step of previously known manufacturing processes and thus reduces the costs associated therewith.

According to an alternate example embodiment of the present invention, rather than extruding the colored yarns, twisting the yarns, and then heat setting the yarns (see FIGS. 1-4), the yarns may go through an air entangling and twist tack process. In another aspect, the color accented 2-ply yarn 22 is comprised of two 2-ply tri-colored solution dyed fibers, for example, wherein two single accented yarns 16 are twisted together, for example, rather than twisting the single accented yarn 16 with the main fiber 20. In example embodiments, these two fibers are twisted together which creates a plurality of color accents along the length of the yarn. Optionally, these color accented 2-ply yarns can be combined with a solid color 2-ply yarn. For example, in another aspect, the color accented 2-ply yarn comprising two tri-colored solution dyed fibers is combined with solid colored yarn to produce a color accented multi-color carpet.

In example embodiments and as depicted in FIG. 11, a pair of draw rolls of an extrusion machine can be provided to stretch the fibers 10, 12, 14 to strengthen them, for example prior to being twisted together to form the single accented yarn 16. After the fibers 10, 12, 14 are twisted together, the single accented yarn 16 is generally rolled up on a spool to form a finished package 40 of tri-color accented fiber 16, for example, as depicted in FIG. 8. The finished package 40 is then arranged to be planted with the regular non-accented yarn 24 on the tufting machine, for example, to form the carpet greige cloth 30.

FIG. 9 shows a color accented multi-color carpet 50 according to an example embodiment of the present invention. In example forms, the carpet 50 is formed from a combination of 2-ply tri-color accented yarn 22 regular non-accented yarn 24. In example embodiments, the carpet 50 comprises cut pile, however, in other example embodiments, the carpet 50 can comprise loop pile, or a combination of cut pile and loop pile. FIG. 10 shows a close up, detailed view of the color accented multi-color carpet 50.

In another example embodiment, the present invention relates to methods or processes of manufacturing multicolored and color accented carpet, and to carpet produced by such methods. In example embodiments, the manufacturing method or process comprises providing a single accented yarn, the single accented yarn comprising at least two differently colored extruded solution dyed yarns and a main yarn twisted together, wherein twisting of the at least two colored extruded solution dyed yarns and the main yarn together results in a plurality of color transitions along a length of the single accented yarn; and tufting the single accented yarn into a primary backing to form a carpet.

In another example embodiment, the invention relates to a method of manufacturing multicolored and color accented carpet comprising providing a color accented 2-ply yarn, the color accented 2-ply yarn comprising at least two differently colored extruded solution dyed yarns twisted together, wherein twisting of the at least two colored extruded solution dyed yarns results in a plurality of color transitions along a length of the color accented 2-ply yarn; providing a primary backing; and tufting the color accented 2-ply yarn into the primary backing to form the carpet. In some example embodiments, prior to tufting the color accented 2-ply yarn into the primary backing, the color accented 2-ply yarn is twisted together with a main fiber, and wherein twisting of the color accented 2-ply yarn about the main fiber provides for a plurality of color transitions along the length thereof.

According to another example embodiment, the invention relates to a multicolored and color accented cut pile carpet comprising at least one pile in the form of a color accented 2-ply yarn, at least one pile in the form of a barber pole yarn, and at least one pile in the form of a solid color 2-ply yarn. In example embodiments, the at least one color accented 2-ply yarn comprises a single ply tri-colored solution dyed fiber twisted together with a single ply of solid colored fiber. In example embodiments, the barber pole yarn comprises a 2-ply yarn comprising two differing colors of pre-colored, solution dyed fibers, which are twisted together. In example embodiments, about 33% of the piles comprise the color accented 2-ply yarn. Optionally, the multicolored and color accented carpet can comprise a combination of color accented 2-ply yarn and solid color 2-ply yarn, or for example, can comprise a combination of color accented 2-ply yarn and barber pole yarn.

While the invention has been described with reference to preferred and example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.

Claims

1. A multicolored carpet comprising:

a primary backing material; and

a plurality of piles tufted with the primary backing material to form a carpet,

wherein at least a portion of the piles of the carpet comprise color accented 2-ply yarns, the color accented 2-ply yarns comprising a single ply tri-colored solution dyed fiber twisted together with a single ply of solid colored fiber.

2. The multicolored carpet of claim 1, further comprising one or more piles tufted with the primary backing material in the form of solid color 2-ply yarns.

3. The multicolored carpet of claim 1, further comprising one or more piles tufted with the primary backing material in the form of a barber pole yarn.

4. The multicolored carpet of claim 3, wherein the barber pole yarn comprises a 2-ply yarn comprising two differing colors of pre-colored, solution dyed fibers.

5. The multicolored carpet of claim 1, wherein between about 10-70% of the piles tufted with the primary backing comprise color accented 2-ply yarns.

6. The multicolored carpet of claim 5, wherein about 33% of the piles tufted with the primary backing comprise color accented 2-ply yarns.

7. The multicolored carpet of claim 3, wherein the color accented 2-ply yarn in combination with the barber pole yarn provides a plurality of color transitions along a length of the carpet.

8. The multicolored carpet of claim 1, wherein the carpet comprises cut piles.

9. The multicolored carpet of claim 8, wherein the carpet comprises a combination of cut piles and loop piles.

10. A method of manufacturing multicolored and color accented carpet, the method comprising:

providing a color accented 2-ply yarn, the color accented 2-ply yarn comprising at least two differently colored extruded solution dyed yarns twisted together, wherein twisting of the at least two colored extruded solution dyed yarns results in a plurality of color transitions along a length of the color accented 2-ply yarn;

providing a primary backing; and

tufting the color accented 2-ply yarn into the primary backing to form the carpet.

11. The method of claim 10, wherein prior to tufting the color accented 2-ply yarn into the primary backing, the color accented 2-ply yarn is twisted together with a main fiber, and wherein twisting of the color accented 2-ply yarn about the main fiber provides for a plurality of color transitions along the length thereof.

12. The method of claim 11, further comprising tufting barber pole yarn into at least a portion of the primary backing.

13. The method of claim 12, wherein the barber pole yarn comprises a 2-ply yarn comprising two differing colors of pre-colored, solution dyed fibers.

14. The method of claim 11, further comprising tufting solid color 2-ply yarns into the primary backing.

15. A multicolored and color accented carpet formed by the method of claim 10.

16. The method of claim 10, further comprising cutting at least a portion of the piles of the carpet.

17. A multicolored and color accented cut pile carpet comprising:

at least one pile in the form of a color accented 2-ply yarn;

at least one pile in the form of a barber pole yarn; and

at least one pile in the form of a solid color 2-ply yarn.

18. The multicolored and color accented cut pile of claim 17, wherein the at least one color accented 2-ply yarn comprises a single ply tri-colored solution dyed fiber twisted together with a single ply of solid colored fiber.

19. The multicolored and color accented cut pile of claim 17, wherein the barber pole yarn comprises a 2-ply yarn comprising two differing colors of pre-colored, solution dyed fibers.

20. The multicolored and color accented cut pile of claim 17, wherein about 33% of the piles comprise the color accented 2-ply yarn.