Patterned bonded carpet and method
AssigneeMilliken & Company
InventorsN. David Sellman, Jr., Kyle T. Veatch
Life of this patent
Estimating the term…
Abstract
Color, pattern, design, and/or the like is applied by means of a jet dye process, or any other secondary or post pattern application process, including but not exclusively, silk screen printing, rotary printing, etc., to a bonded carpet, where the yarn in the carpet is all white (no dye applied) or light colored or where the yarn is pre-dyed with a single or multiple colors or where the yarn is treated chemically. The bonded carpet preferably has a low face weight and flat, short, dense, vertical cut pile.
Claims18
A method of producing bonded flooring, comprising the steps of:
- bonding a carpet substrate with a carpet yarn using a water based latex adhesive, wherein the carpet yarn is at least one of all white, light colored, pre-dyed with a single color, pre-dyed with multiple colors, naturally colored, and chemically treated to absorb dyes differently in arbitrary areas of the carpet to form a cut pile, fusion bonded carpet having a pile height of about 0.190-0.220 inches and a yarn density of about 9-15 folds per inch and 10-20 ends per inch,
- jet dyeing at least one of a background color, design, pattern, or border, on the fusion bonded carpet by applying liquid dye at a DPI greater than the DPI of the bonded carpet such that the applied dye migrates from terminal ends of the carpet yarn to the water based latex,
- and cutting or forming the jet dyed fusion bonded carpet into a completed item or product selected from the group consisting of carpet tiles, area rugs, runners, carpets, rugs, broadloom, and wall to wall carpet.
A method of producing bonded flooring, comprising the steps of:
- bonding a carpet substrate with a carpet yarn with a water based latex adhesive wherein the carpet yarn is all white to form a fusion bonded carpet having a face weight of less than 28 oz/yd2 and a pile height of about 0.190-0.220 inches and a yarn density of about 9-15 folds per inch and about 10-20 ends per inch;
- jet dyeing at least one of a background color, design, pattern, or border, on the fusion bonded carpet by application of a plurality of liquid dye droplets to the carpet yarn at a DPI greater than the DPI of the bonded carpet such that the applied dye migrates from terminal ends of the carpet yam to the water based latex;
- and cutting or forming the jet dyed fusion bonded carpet into a completed item or product selected from the group consisting of carpet tiles, area rugs, runners, carpets, rugs, broadloom, and wall to wall carpet.
Dependencies are inferred from the claim text.