CN113015466A

CN113015466A - Polyester yarn buffering ground mat and manufacturing method thereof

Info

Publication number: CN113015466A
Application number: CN201980074694.4A
Authority: CN
Inventors: 马克·布林德勒; 杰奎琳·基林斯; 梅利莎·诺思; 克里斯蒂娜·玛利亚·胡克; 阿尔弗雷德·斯克罗金斯
Original assignee: Aladdin Manufacturing Corp
Current assignee: Aladdin Manufacturing Corp
Priority date: 2018-11-13
Filing date: 2019-11-08
Publication date: 2021-06-22
Also published as: EP3880038A1; US20220341089A1; EP3880038A4; WO2020102013A1; CA3118551A1; MX2021005544A; US20220025575A1; EP3653787A1; AU2019379532A1

Abstract

The present invention relates to a cushioned floor mat comprising polyester yarns, particularly polyethylene terephthalate (PET) yarns, which contain a crystallinity-reducing modifier, such as a branched polyester modifier, in the polyester yarns. The invention further relates to a process for the preparation of such a cushioned floor mat.

Description

Polyester yarn buffering ground mat and manufacturing method thereof

Reference to related applications

This application claims the benefit of U.S. provisional application No. 62/760,667 filed on day 13, 11, 2018 and european application No. 18208540.7 filed on day 27, 11, 2018, the entire contents of which are incorporated herein by reference.

Technical Field

The present invention relates to washable floor mats comprising polyester yarns, particularly polyethylene terephthalate (PET) yarns, having a sufficiently low crystallinity to improve dye uptake and enable the rinse or cleaning process to remove excess dye molecules after the dyeing cycle. The invention further relates to a process for preparing such a washable floor mat.

Background

In the production of floor mats (carpet, rug, rug) and carpeting (carpet), there are several known methods of dyeing floor mats and carpets to a desired color. These methods include: 1) solution dyeing, wherein the dye is contained in the polymer of the fiber before the fiber is spun; 2) yarn dyeing, wherein the yarn is dyed after spinning but before tufting into a primary backing; 3) jet dyeing, wherein the dye is sprayed onto the fibre tufts after tufting; and 4) vat dyeing (beck dying), in which mats and carpets are immersed in a vat containing dye and water. One advantage of vat dyeing is that it is more economical to dye carpets in smaller batches of different colors than other methods.

Polyethylene terephthalate (PET) is a thermoplastic fibrous polymer resin in the polyester family, a common polymer for carpets and floor mats. PET carpets and mats are dyed with disperse dyes, which are generally water insoluble. The dye used for PET acts more like a stain adhering to the PET fiber. Such dyes also stain most other materials on the backing of carpets and mats. In carpet manufacture, the finished backing is applied after the dyeing process to avoid contamination. For vat-dyed mats, the base fabric is coated prior to dyeing. Therefore, the substrate is susceptible to contamination by the disperse dye.

To produce a washable floor mat, such as might be used in a bathroom or kitchen, a thickness of foam and/or adhesive is attached to the underside of a portion of the tufted primary backing. The foam and/or adhesive may provide cushioning and support. Unlike carpets, such mats are preferably washable by the consumer.

To date, PET floor mats have been produced primarily using solution dyeing or yarn dyeing for tufting. However, to meet consumer demand for variety and decor, it would be a competitive advantage for mat manufacturers if PET mats could be dyed using vat dyeing (also referred to in this context as piece dyeing). Small batches of mats produced in a variety of colors can be more efficiently manufactured. However, in view of the previously attached foam and/or adhesive backing (or "backing"), those skilled in the art will not appreciate that a PET floor mat can be cylinder dyed. The entire mat, including the tufted primary backing and the mat backing, will be immersed and saturated in the dye vat. It is believed that the amount of dye required to properly dye PET fibers has one or more undesirable characteristics, such as staining or spotting of the substrate, inability of the consumer to clean the mat, and dye discoloration and transfer, some of which is wiped off the mat and onto adjacent surfaces (e.g., floors). For darker colors, this would be considered particularly problematic, requiring more dye to be absorbed. When the consumer owns the mat, this often results in more excess dye remaining in the mat backing, which in turn increases the risk and severity of dye discoloration and transfer.

The process for removing excess dye after vat dyeing is known as "scouring" and generally involves dipping the dyed carpet or mat into caustic chemicals. This is not always completely effective, especially when an excess of dye is used, due to the low dyeability of PET fibers and/or the need to make dark fibers.

Accordingly, there is a need for a PET washable floor mat having improved dyeability and less discoloration, and for an improved process for making and washing such a washable floor mat.

Disclosure of Invention

According to a first aspect of the present invention, there is provided a floor mat comprising:

a) a textile fabric comprising polyester yarns, said polyester yarns comprising fibers or filaments of polyester, said fibers or filaments having an average percent crystallinity of less than about 30 percent, and said fibers or filaments comprising a crystallinity-reducing modifier; and

b) a backing layer secured to the textile fabric.

According to a second aspect of the present invention, there is provided a method of manufacturing a cushioned floor mat, the method comprising:

providing a greige fabric (greige fabric) comprising polyester yarns, said polyester yarns comprising fibers or filaments of polyester, said fibers or filaments having a percent crystallinity of less than about 30%, and said fibers or filaments comprising a crystallinity-reducing modifier;

securing the backing layer to the greige cloth to form an intermediate mat (intermediate mat);

carrying out vat dyeing on the intermediate ground mat by using a disperse dye to form a dyed ground mat; and

the dyed floor mat was scoured with alkaline liquor.

According to a third aspect of the present invention there is provided a cushioned floor mat made by any of the above processes.

Drawings

Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

figure 1 is a schematic cross-sectional view of a cushioned floor mat according to one embodiment of the present invention.

Fig. 2 is a cross-sectional view of a tufted carpet face according to a portion of an embodiment of the invention.

Fig. 3 is a perspective view of a MRS extruder suitable for use in a process for making bulked continuous filaments.

Detailed Description

The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. In the following description, various components may be identified as having particular values or parameters, however, these items are provided as exemplary embodiments. Indeed, the exemplary embodiments do not limit the various aspects and concepts of the invention, as many comparable parameters, sizes, ranges, and/or values may be implemented. The terms "first," "second," and the like, "primary," "exemplary," "secondary," and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Furthermore, the terms "a," "an," and "the" do not denote a limitation of quantity, but rather denote the presence of the referenced item.

It is contemplated that each embodiment disclosed herein may be applied to every other disclosed embodiment. All combinations and subcombinations of the various elements described herein are within the scope of the invention. Further, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

It should be understood that where parameter ranges are provided, embodiments also provide all integers and ranges within the range, as well as one tenth and one hundredth thereof. For example, "5-10%" includes 5%, 6%, 7%, 8%, 9%, and 10%; 5.0%, 5.1%, 5.2%. 9.8%, 9.9%, and 10.0%; and 5.00%, 5.01%, 5.02%. 9.98%, 9.99%, and 10.00%, and for example 6-8%, 7-9%, 5.1% -9.9%, and 5.01% -9.99%.

As used herein, in the context of a numerical value or range, "about" means ± 10% of the numerical value or range recited or claimed.

As used herein, "recycled" refers to any material or plastic waste after consumption.

As used herein, "backing" refers to a foam and/or adhesive layer. This is in contrast to primary or secondary backing in carpets.

As used herein, "face fabric" or "carpet" refers to a yarn or fiber that is combined with a primary backing and an optional secondary backing.

As used herein, the "percent crystallinity" (Xc) of a polyester material refers to the portion of the material that is crystalline as compared to the entirety of the material (which may contain both crystalline and amorphous portions). Percent crystallinity can be evaluated using differential scanning calorimetry (commonly referred to as DSC) and calculated using the following formula:

Xc＝(ΔH_f/ΔH_o)*100

wherein: Δ H_fMelting enthalpy of test sample in joules/gram (J/g), and Δ H_oEnthalpy of fusion for fully crystalline polymers. In some embodiments, the heating rate of the DSC process may be from 0.1 to 30 deg.C/min, or from 1 to 10 deg.C/min. In a preferred embodiment, the heating rate is 10 ℃/min.

As used herein, a "crystallinity-reducing modifier" is a modifier that, when added to the polymer from which the fiber or filament is made, reduces the crystallinity of the fiber or filament compared to the crystallinity of the fiber or filament in the absence of the modifier. In one embodiment, the crystallinity-reducing modifying agent reduces crystallinity by about 1 to about 90%. In one embodiment, the crystallinity-reducing modifying agent reduces crystallinity by greater than about 1 to 90%.

As used herein, a "greige" fabric is a fabric that is in some way unfinished, e.g., not dyed.

As used herein, "securing" two objects together refers to securing or attaching the objects to each other, such as by adhesive or other means.

As used herein, with respect to effect, "synergy" refers to the interaction or presence of two elements that produces a greater effect than would be expected based on the effect produced by each of those elements individually. In the present context, this term may refer to the case where the fiber F1 containing the modifier has a lower crystallinity than another fiber F2 lacking the modifier and having a higher crystallinity, or shows a greater improvement in dyeability, or some other property or performance metric than F2, the first of which contains the modifier but has the same crystallinity as F2 and the second of which lacks the modifier but has the same crystallinity as F1, than would be expected based on the improvement exhibited by the other two fibers.

Non-limiting examples of classes of disperse dyes include azobenzene derivatives and anthraquinone derivatives. Some disperse dyes may contain nitro, amine or hydroxyl groups.

a) a textile fabric comprising polyester yarns, said polyester yarns comprising fibers or filaments of polyester, said fibers or filaments having an average percent crystallinity of less than about 30%, and said fibers or filaments comprising a crystallinity-reducing modifier; and

b) a backing layer secured to the textile fabric.

According to some embodiments, the floor mat consists essentially of the textile fabric and the backing layer. According to some embodiments, the floor mat is comprised of the textile fabric and the backing layer.

According to some embodiments, the average percent crystallinity is less than about 29%, 28%, 27%, 26%, 25%, 24%, 23%, 22%, 21%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, or 1%.

According to some embodiments, the fibers or filaments of the polyester comprise polyethylene terephthalate (PET).

According to some embodiments, the backing layer comprises foam having a density in a range of about 2 ounces per square yard to about 50 ounces per square yard. In another embodiment, the backing layer comprises a polyurethane foam. In one embodiment, the backing layer comprises a viscoelastic foam material. In one embodiment, the backing layer comprises an adhesive. In another embodiment, the adhesive is a foam adhesive. In one embodiment, the adhesive is not a foam adhesive. In one embodiment, the floor mat does not include an adhesive.

According to some embodiments, the fibers or filaments of the polyester comprise the modifier in an amount of about 0.5% to about 16% by weight. According to some embodiments, the fibers or filaments of the polyester comprise the modifying agent in an amount less than, greater than, or equal to about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, or 16% by weight. According to some embodiments, the fibers or filaments of the polyester comprise the modifier in an amount of from about 1% to about 15%, from about 3% to about 14%, from about 5% to about 12%, or from about 8% to about 10% by weight. Preferably, the fibers or filaments of the polyester comprise the modifier in an amount of about 8% to about 10%. According to some embodiments, the modifier is a branched polyester. According to some embodiments, the modifier is polybutylene adipate terephthalate (PBAT).

According to some embodiments, the polyester yarn comprises continuous filaments. According to some other embodiments, the continuous filaments are bulked continuous filaments (bulked continuous filaments).

According to some embodiments, the polyester yarn exhibits increased dyeability as compared to a polyester yarn comprising fibers or filaments of polyester having the same degree of crystallinity but lacking the modifier. According to some other embodiments, the increase in dyeability is at least about 1% to at least about 300%. According to some other embodiments, the increase is at least 1% to at least 25%.

According to some embodiments, the fibers or filaments of polyester comprise recycled polyester. In one embodiment, the recycled polyester is recycled PET. According to some embodiments, the PET has been recycled from carpet waste or plastic bottles. According to some embodiments, the fibers or filaments of the polyester comprise recycled PET and virgin PET, and wherein the ratio of recycled PET to virgin PET is from about 99:1 to about 1: 99.

According to some embodiments, the floor mat is vat dyed. According to some embodiments, the textile fabric and the backing layer have been dyed simultaneously.

According to some embodiments, the floor mat further comprises at least one component selected from the group consisting of: finishing agents (finishing agents), delusterants, viscosity modifiers, optical brighteners, delusterants, heat stabilizers, antioxidants, antistatic agents, pigments, and ultraviolet stabilizers.

providing a greige goods fabric comprising polyester yarns, said polyester yarns comprising fibers or filaments of polyester, said fibers or filaments having a percent crystallinity of less than about 30%, and said fibers or filaments comprising a crystallinity-reducing modifier;

fixing the lining layer on the grey fabric to form an intermediate ground mat;

the dyed floor mat was scoured with alkaline liquor.

According to some embodiments, the greige goods fabric is obtained by a tufting process. According to some embodiments, the yarn is obtained by melt spinning or by extrusion spinning.

According to some embodiments, the lye comprises a dispersant. According to some other embodiments, the dispersant is a naphthalene sulfonate.

According to some embodiments, the fibers or filaments of the polyester are fibers or filaments comprising polyethylene terephthalate (PET) yarns.

According to some embodiments, the backing layer comprises foam having a density in a range of about 2 ounces per square yard to about 50 ounces per square yard. According to some other embodiments, the backing layer comprises a polyurethane foam. According to some embodiments, the backing layer comprises a viscoelastic foam material. According to some embodiments, the backing layer comprises an adhesive. According to some other embodiments, the adhesive is a foam adhesive. According to some embodiments, the adhesive is not a foam adhesive.

According to some embodiments, the polyester yarn comprises continuous filaments. According to some other embodiments, the continuous filaments are bulked continuous filaments.

According to some embodiments, the method further comprises the steps of: providing the polyester yarn, wherein the fibers or filaments of the polyester are extruded fibers or filaments obtained by melt extruding a molten polymer comprising the crystallinity-reducing modifier, and stretching the extruded filaments to obtain a crystallinity of less than 30%.

According to some embodiments, the fibers or filaments of polyester comprise recycled polyester. According to some embodiments, the recycled polyester is recycled PET. In one embodiment, the PET has been recycled from carpet waste or plastic bottles. According to some embodiments, the fibers or filaments of the polyester comprise recycled PET and virgin PET, and wherein the ratio of recycled PET to virgin PET is from about 99:1 to about 1: 99.

Figure 1 shows a schematic cross-sectional view of a cushioned floor mat 2 according to one embodiment of the present invention. As shown in fig. 1, the cushioned floor mat 2 is a layered structure comprising a top layer of face material 4 and a backing layer 6.

In the embodiment shown in fig. 1, the backing layer 6 comprises a single layer of foam. However, in other embodiments, the backing layer 6 may be a composite of multiple foam layers with an optional facestock layer on the bottom. For example, base fabrics of various densities and/or thicknesses may be secured together to produce various cushioning effects. These foams may also be embossed to form a pattern on the base fabric. In particular embodiments, the density of the foam may be 2 ounces per square yard to 50 ounces per square yard. In particular embodiments, the foam may have a thickness of up to 1 ". In one embodiment, the foam is in the form of an anti-slip layer. In a particular embodiment, the foam is a viscoelastic foam or a polyurethane foam. The foam may also be made from natural and synthetic latex rubbers.

The backing layer 6 may be a foamed adhesive which is secured to the facing 4 by its own adhesive properties. In an alternative embodiment, the foam may be a layer of foam material that has been laminated to the facing 4.

In one embodiment, the cushioned mat has an area of about 0.2 to about 10m². In one embodiment, the cushioned mat has an area of about 0.3 to 2m²。

Fig. 2 schematically illustrates one potential carpet construction of the face fabric 4 or carpet of the portion of fig. 1. Which is generally indicated by reference numeral 21. The carpet 21 includes face yarns 22, the face yarns 22 tufted into a mesh, woven or spunbond fabric, referred to as a primary backing 25. The primary backing 25 has tufted pile yarns 22 extending outwardly from one surface, a primary backcoat or precoat 23 on the opposite surface, and at least one secondary backcoat or primary coating (commonly referred to as a skip coat) 24. Other layers may also be associated with the carpet 1.

The primary backcoat or precoat 23 typically includes carboxylated latex (e.g., styrene-butadiene based latex), PVC (polyvinyl chloride), EVA (ethylene vinyl acetate), or other polymer-based materials, and the secondary backcoat 24 may also include these same polymers. The primary and/or secondary backcoatings may be foamed polymers. In one embodiment, the primary and/or secondary backcoating is a foam that is not an adhesive. One or both of primary backcoat 23 and secondary backcoat 24 may include a filler material. The most common filler is a mineral filler such as calcium carbonate, although other fillers such as alumina trihydrate, bauxite, magnesium hydroxide, and the like may also be used. In some cases, calcium carbonate may be used with other common materials (e.g., metal salts). Carpet 1 may be produced using filler in one or both of primary backcoating 23 and secondary backcoating 24 that includes waste carpet as all or part of the filler. Alternatively, only a single back coating may be provided, rather than the primary and secondary back coatings. This single back coating, like the primary back coating in the first alternative, also anchors the pile yarns in the primary backing. The single backcoating may be composed of the same materials as described for the primary and secondary backcoatings.

Typically, in the manufacture of carpet 1, the fiber tufts are tufted through a woven or nonwoven face fabric, which is a primary backing 25. The tufted portions on the exposed surface of the mat comprise face fibres or yarns 2. A back coating 23 is applied to the back of the tufted structure to lock the tufts. Next, a woven or non-woven secondary backing 24 is laminated to the back of the primary backing 25 to impart increased dimensional stability to the mat.

The primary backing is a supporting scrim (scrim) through which the fabric is tufted by tufting, typically a polyolefin such as polyethylene or polypropylene; however, other materials such as polyester (including, for example, PET) may be used. For example, a slit tape made of PET may be used. The secondary backing is a fabric adhered behind the primary backing with the back of the tufts sandwiched by an adhesive material. The secondary backing is typically made of polypropylene; however, other base fabric types may be used, such as jute, PVC (polyvinyl chloride), polyurethane and PET. The secondary backing may be a nonwoven fabric including, but not limited to, spunbond, wet-laid, meltblown, and air-entangled.

Filler materials such as calcium carbonate and binder materials are typically applied to the back of the tufted carpet backing in the form of slurries of various concentrations. There is almost always more filler than binder material. For example, a representative filler to adhesive ratio may include about 80 weight percent ("wt%" or "%") calcium carbonate relative to about 20 wt% adhesive. Although calcium carbonate is one of the most commonly used filler materials, one skilled in the art to which this disclosure pertains will recognize that carpets containing other filler materials may be used in the methods described herein.

The binder material serves to bind the tufts together with the backing. The binder material may include latex, for example, carboxy-styrene-butadiene rubber, styrene-butadiene rubber (SBR), natural rubber latex, vinyl acetate ethylene copolymer (VAE or EVA), other natural or synthetic rubbers, polyurethane, or polymers such as PET. Although latex is one of the most commonly used binder materials for retaining tufts on a carpet backing, one skilled in the art to which this disclosure pertains will recognize that carpets containing other binders may be used in the methods described herein.

A variety of different polyesters may be used in the yarn. For example, the polyester may comprise a PET polymer, e.g.

PET (available from DAK America), NAN

PET (Nan Ya Plastics Corporation, America), other PET polymers, or combinations thereof. PET can be produced, for example, by the transesterification of dimethyl terephthalate with ethylene glycol or by the esterification of terephthalic acid with ethylene glycol. PET can be provided from virgin resin and recycled resin. In one embodiment, the PET comprises recycled PET recovered from soda water and water bottles. In any of the embodiments described herein, the PET may be in the form of flakes or pellets. In addition, a single polyester or a blend of two or more polyesters may be used. Unless otherwise specified, the polyesters used in any embodiment of the present invention may be virgin, recycled, or blends thereof.

The fibers may be formed from the polymer by any method known in the art to produce fibers from a single polyester or from a blend. The polymer may be extruded to have any shape or size suitable for polymer carpet fibers. In addition, the carpet fibers may be subjected to any post-spinning process that is generally recognized as useful for making polymeric carpet fibers. The fibers may be as-spun or heat-set. By "fiber" is meant what is considered in the art to be a fiber, such as a continuous filament, a monofilament, a staple fiber, and the like. The fibers may be round or have other shapes, such as octalobal, triangular, sunburst (also called sol), scalloped, trilobal, four-channel (also called quatra-channel), scalloped ribbon, starburst, and the like. The fibers may also be solid, hollow or multi-hollow. Fibers can be used to make yarns, and fibers or yarns can be used to make a wide variety of materials, particularly carpets, mats, and the like.

The fibers of the present invention may further comprise other components such as, but not limited to, finishes, delusterants, tackifiers, fluorescent brighteners, delustrants (e.g., titanium oxide), thermal stabilizers (e.g., phosphorus compounds), antioxidants (e.g., hindered phenols), antistatic agents, pigments, uv blockers, and combinations thereof. In one embodiment, the fibers do not contain at least one component selected from the group consisting of finishes, delusterants, tackifiers, fluorescent brighteners, delusterants, heat stabilizers, antioxidants, antistatic agents, pigments, and uv stabilizers.

Accordingly, the yarn may be prepared according to any method of preparing yarn recognized as useful in the art. For example, the yarns of the present invention may be partially oriented yarns, spun drawn yarns, textured yarns, friction false twisted yarns, and bulked continuous filament ("BCF") yarns. Preferred steps for preparing BCF yarn include spinning (e.g., extruding, cooling, and coating filaments) at defined temperatures and draw ratios, single or multiple stage drawing (e.g., using heated rolls, heated needles, or hot fluid assistance), annealing, expanding, entangling, optionally relaxing, and winding the filaments on a package for later use.

Discussion and examples

One improvement for reducing the time and energy required to properly dye polyester fibers is to incorporate a modifier into the polymer of the fiber prior to fiber manufacture (e.g., during extrusion). One such modifier is polybutylene adipate terephthalate (PBAT) (available under the trademark BASF SE, Ludwigshafen, Germany

Obtained). One suitable modifier genus is a branched polyester modifier.

PBAT modifiers function by adding amorphous regions in the fiber structure. Generally, fibers with reduced crystallinity and therefore more amorphous regions will exhibit higher dyeability than fibers with higher crystallinity, even if the fibers are otherwise identical. The amorphous regions provide more sites in the fiber for the dye to be absorbed. Although these amorphous regions reduce crystallinity and thus fiber tenacity, this disadvantage is offset by the increased dye uptake by the fiber. By using modifiers and increasing the dye uptake by the fiber (i.e., increasing the dyeability of the fiber), the desired color gradient can be achieved to occur more quickly and less dye is required in the vat, or less time and machine energy is required to dye the fiber. As a result, the fibers (or mats containing the fibers) can spend less time in the vat dye. In cushioned mats, this results in less dye being absorbed by the substrate and less dye must be removed from the substrate before being provided to the consumer.

Advantageously, a washing process for removing excess dye from a vat-dyed PET washable mat after dyeing has been completed. The cleaning process involves immersing the dyed mat in a bath of caustic chemicals (such as soda ash or sodium hydroxide) which act to remove excess dye from the fibers. The cleaning process can be improved by adding a dispersant chemical (such as naphthalene sulfonate) to the cylinder.

The present inventors have discovered that by using a modifier in the PET fibers which allows for less dye to be used in the vat or allows for faster dyeing, thereby reducing the amount of dye absorbed by the substrate, in combination with a scouring process using caustic and dispersant chemicals to remove excess dye, a mat made with PET fibers can be vat dyed without undesirably staining the substrate or causing the dye to discolor or transfer to the floor. Additionally, the floor mat may be laundered by the consumer. The inventors were the first to use caustic and dispersant chemicals to combine the pre-dye fiber modifier with the post-dye cleaning process. By reducing the amount of dye required for the dyeing step and then removing excess dye after the dyeing step, the present inventors have invented a vat-dyed PET floor mat, and a method of making the same, that is colorfast and washable. The following method describes the process of making a cushioned floor mat using PET yarns and PBAT modifiers; one skilled in the art will readily recognize that the process can be practiced with different polyesters and modifiers.

One method of producing the fibers of the present invention using recycled polyester bottles is via a multi-rotating screw (MRS) extruder, as described in U.S. patent No. 8,597,553, the entire contents of which are incorporated herein by reference. This process produces Bulked Continuous Filaments (BCF).

According to a particular embodiment, the BCF (bulked continuous filament) manufacturing process can be generally divided into four steps: (1) preparing polyester polymer flakes from post-consumer bottles for use in the process; (2) passing the flakes through an extruder which melts the flakes and purifies the resulting polymer; (3) feeding the polyester polymer to a spinning machine, and (4) adding the modifying agent in the spinning machine, wherein the spinning machine converts the polyester polymer (and modifying agent to filaments or fibers, yarns for making carpets and mats).

As can be appreciated from fig. 3, in certain embodiments, the MRS extruder includes a first single screw extruder section 410 for feeding material to an MRS section 420; and a second single screw extruder section 440 is used to transport material away from the MRS section.

In a particular embodiment, after the PET polymer is extruded and purified by the extrusion process described above, the molten polymer is cooled into pellets. These pellets were then melted and fed into a BCF (or "spinning") machine. PBAT is also added to the spinning machine, which is configured to convert the molten polymer and PBAT into bulked continuous filaments. If virgin polymer (e.g., virgin PET) is used, no purification step will be performed, and pellets of virgin polymer are added directly to the spinning machine.

In a particular embodiment, the modifier is combined with the PET at a loading percentage of 1-16%. In another embodiment, the modifier is combined with the PET at a loading percentage of 8%.

The spinning machine extrudes molten polymer through small holes in a spinneret to produce yarn filaments from the polymer. After exiting the spinneret, the molten polymer was cooled. The yarn is then absorbed by a roll and ultimately converted into filaments for use in the production of carpets and mats. In various embodiments, the yarn produced by the spinning machine may have a tenacity between about 2 grams force per unit denier (gf/den) and about 9 gf/den. In a particular embodiment, the resulting yarn has a tenacity of at least about 2 gf/den. In a particular embodiment, spinning is carried out at a temperature in the range of 220 ℃ to 350 ℃. In another embodiment, spinning is performed at 280 ℃.

And 5: preparation of buffer floor mat

The yarns are tufted into a primary backing to form a "face fabric". Tufted carpet is fed to an applicator where a liquid foam or adhesive material is pumped directly to the back of the carpet. As the carpet moves under the applicator roll, the backing material may be scratched or measured to a desired thickness. The mat may be passed through a pre-heated oven to allow the pattern to be embossed into the scrim material. The material is then passed through a heated oven or alternative energy source to cure the foam or adhesive to form a cushioned mat.

Step 6: cylinder dyeing

The cushion mat is then cut and sewn and placed in a batch size suitable for vat dyeing in a vat of disperse dye. The batch size depends on the capacity of the vat dyeing machine. The floor mat is loaded into the staining jar and the desired ambient water level is added. The moisture content is in the range of 3/1 to 20/1 proportions relative to the weight of the mat. Disperse dye is then added to the dyeing vat. The dye vat water was then heated to 212 ° F at a controlled rate to adhere the dye to the fiber. The mat is circulated through the dyeing tank until the dye is uniformly distributed on the fibers. The dye water is drained and the dye vat is refilled with water for a rinse cycle. Then, the rinse water was drained. The rinse cycle may be repeated as desired. If the mat needs to be flushed, the dye vat will be filled again with water to start the flushing cycle. If the mat does not require washing, the mat will move to a drying process.

And 7: cleaning of

After the vat dyeing, the cushion mat may be washed, if necessary, to remove excess dye. After the dyeing and rinsing process, the dyeing vat will be filled again with water. Lye, for example a liquid containing soda ash or sodium hydroxide, is added to the staining jar. The lye may comprise a dispersant. In one embodiment, the dispersant is a naphthalene sulfonate. In one embodiment, the pH of the lye is between 7.5 and 11. The mat was circulated in the dyeing tank at ambient to 212 ° F water temperature. The wash water is then drained and the dye vat is returned to the rinse mode before the mat is moved to the drying process.

It is well known that trace amounts of dye may cause spotting when the mat is in use, particularly in a wet environment. Washing with lye and dispersant may allow removal, even complete removal, of such excess residual trace dyes, the washing step itself constituting a separate independent aspect of the present invention.

In alternative embodiments, the pH of the lye is about 7.5, 8, 8.5, 9, 9.5, 10, 10.5 or 11. In the alternative, the pH of the lye is greater than or less than about 7.5, 8, 8.5, 9, 9.5, 10, 10.5 or 11.

Alternative embodiments

non-MRS extrusion system

In particular embodiments, the process may utilize a polymer stream extrusion system other than the MRS extruder described above. Alternative extrusion systems may include, for example, twin screw extruders, multiple screw extruders, planetary extruders, or any other suitable extrusion system. The method can include any number of any combination of any suitable conical screw extruders (e.g., four twin screw extruders, three multi-screw extruders, etc.).

Variations on the mixing of polyester polymers and modifiers

In some alternative embodiments, there is no step of cooling the purified, molten PET into pellets. In this alternative embodiment, the molten components can be fed directly into a suitable spinning machine to be combined with the modifying agent and converted into fibers. The PET flakes were then fed from one feeder into the extruder and the modifier was fed from the other feeder into the extruder.

In an alternative embodiment, the recycled PET pellets are fed into the extruder from one feeder and the modifier is fed into the extruder from another feeder.

In an alternative embodiment, the raw PET pellets are fed into the extruder from one feeder and the modifier is fed into the extruder from another feeder.

In an alternative embodiment, the recycled PET pellets and the modifier are mixed together in a single feeder prior to melting and the pellet mixture is fed into an extruder.

In an alternative embodiment, the virgin PET pellets and the modifier are mixed together in one feeder prior to melting, and the pellet mixture is fed into an extruder.

In an alternative embodiment, the recycled PET pellets are mixed with virgin PET pellets and fed into the extruder from one feeder and the modifier is fed into the extruder from another feeder.

In an alternative embodiment, the recycled PET pellets, virgin PET pellets and modifier are mixed together in one feeder prior to melting and the pellet mixture is fed into an extruder.

In all of these variations, other additives may be used, such as delusterants, colorants, stabilizers, and the like, as previously discussed.

Conclusion

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the present disclosure. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A floor mat comprises

b) a backing layer secured to said textile fabric.

2. A floor mat as claimed in claim 1, in which the fibres or filaments of polyester comprise polyethylene terephthalate (PET).

3. A floor mat as claimed in claim 1 or claim 2, in which the backing layer comprises foam having a density in the range of about 2 ounces per square yard to about 50 ounces per square yard.

4. A floor mat as claimed in claim 3, in which the backing layer comprises polyurethane foam.

5. A floor mat as claimed in claim 1 or claim 2, in which the backing layer comprises an adhesive.

6. The floor mat of claim 4, wherein the adhesive is a foam adhesive.

7. A floor mat as claimed in any of claims 1 to 6, in which the fibres or filaments of the polyester comprise the modifying agent in an amount of from about 0.5% to about 16% by weight.

8. Ground mat according to any one of claims 1 to 7, wherein the modifying agent is a branched polyester.

9. A floor mat as claimed in any of claims 1 to 7, in which the modifier is polybutylene adipate terephthalate (PBAT).

10. A floor mat as claimed in any of claims 1 to 9, in which the polyester yarns comprise continuous filaments.

11. A floor mat as claimed in claim 10, in which the continuous filaments are lofted continuous filaments.

12. A floor mat according to any of claims 1 to 11, wherein the polyester yarn exhibits increased dyeability as compared to a polyester yarn comprising fibres or filaments of polyester having the same degree of crystallinity but lacking the modifier.

13. A floor mat according to claim 12, wherein the dyeability increase is at least about 1% to at least about 300%.

14. A floor mat as claimed in claim 13, in which the increase is from at least 1% to at least 25%.

15. A floor mat as claimed in any of claims 1 to 14, in which the fibres or filaments of polyester comprise recycled polyester.

16. A floor mat as claimed in claim 15, in which the recycled polyester is recycled PET.

17. A floor mat as claimed in claim 16, in which the recycled PET is recycled from carpet waste or plastic bottles.

18. A floor mat as claimed in any of claims 1 to 17, in which the fibres or filaments of the polyester comprise recycled PET and virgin PET, and in which the ratio of recycled PET to virgin PET is from about 99:1 to about 1: 99.

19. A floor mat as claimed in any of claims 1 to 18, in which the mat is vat dyed.

20. A floor mat as claimed in claim 19, in which the textile fabric and the backing layer are dyed simultaneously.

21. A floor mat as claimed in any of claims 1 to 20, further comprising at least one component selected from the group consisting of: finishing agents, delusterants, viscosity modifiers, fluorescent brighteners, delusterants, heat stabilizers, antioxidants, antistatic agents, pigments, and ultraviolet stabilizers.

22. A method of manufacturing a cushioned floor mat, the method comprising:

a) providing a greige goods fabric comprising polyester yarns, said polyester yarns comprising fibers or filaments of polyester, said fibers or filaments having a percent crystallinity of less than about 30%, and said fibers or filaments comprising a crystallinity-reducing modifier;

b) fixing a lining layer on the grey fabric to form an intermediate ground mat;

c) carrying out vat dyeing on the intermediate ground mat by using a disperse dye to form a dyed ground mat; and

d) the dyed floor mat was scoured with an alkaline solution.

23. The method of claim 22, wherein the lye comprises a dispersant.

24. The method of claim 23, wherein the dispersant is a naphthalene sulfonate.

25. The method of any one of claims 22-24, wherein the fibers or filaments of polyester are fibers or filaments comprising polyethylene terephthalate (PET) yarns.

26. The method of any of claims 22-25 wherein the backing layer comprises foam having a density in a range of about 2 ounces per square yard to about 50 ounces per square yard.

27. The method of claim 26, wherein the backing layer comprises polyurethane foam.

28. The method of any of claims 22-25, wherein the backing layer comprises an adhesive.

29. The method of claim 28, wherein the adhesive is a foam adhesive.

30. The method of any one of claims 22-29, wherein the fibers or filaments of the polyester comprise the modifier in an amount of about 1% to about 16% by weight.

31. The method of any one of claims 22-30, wherein the modifier is a branched polyester.

32. The method of any one of claims 22-30, wherein the modifier is polybutylene adipate terephthalate (PBAT).

33. The method of any one of claims 22-32, wherein the polyester yarn comprises continuous filaments.

34. The method of claim 33, wherein the continuous filaments are lofted continuous filaments.

35. The process of any one of claims 22-34, further comprising the step of providing the polyester yarn, wherein the fibers or filaments of the polyester are extruded fibers or filaments obtained by melt extruding a molten polymer comprising the crystallinity-reducing modifier, and stretching the extruded filaments to obtain a crystallinity of less than 30%.

36. The method of any one of claims 22-35, wherein the polyester yarn exhibits increased dyeability as compared to a polyester yarn comprising fibers or filaments of polyester having the same degree of crystallinity but lacking a modifier.

37. The method of claim 36 wherein the increase in dyeability is at least about 1% to at least about 300%.

38. The method of claim 37, wherein the increase is at least 1% to at least 25%.

39. The method of any one of claims 22-38, wherein the fibers or filaments of polyester comprise recycled polyester.

40. The method of claim 39, wherein the recycled polyester is recycled PET.

41. The method of claim 40, wherein the recycled PET is recycled from carpet waste or plastic bottles.

42. The method of any one of claims 22-41, wherein the fibers or filaments of polyester comprise recycled PET and virgin PET, and wherein the recycled PET: the raw PET ranges from about 99:1 to about 1: 99.

43. A cushioned floor mat made by the process of any one of claims 22-42.