Polyester Yarn Cushioned Rugs and Methods of Manufacturing Same

Abstract

The invention relates to cushioned rugs comprising polyester yarn, particularly polyethylene terephthalate (PET) yarn, comprising a crystallinity-reducing modifier in the polyester yarn, such as a branched polyester modifier. The invention further relates to methods of preparing such cushioned rugs.

1 - 43 . (canceled) 
     
     
         44 . A rug, comprising
 a) a textile face fabric comprising a polyester yarn, said polyester yarn comprising polyester fibers or filaments, 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 face fabric.   
     
     
         45 . The rug of  claim 44 , wherein said polyester fibers or filaments comprise polyethylene terephthalate (PET). 
     
     
         46 . The rug of  claim 44 , wherein said backing layer comprises foam, said foam having a density ranging from about 2 oz per square yard to about 50 oz per square yard. 
     
     
         47 . The rug of  claim 44 , wherein the polyester fiber or filament comprises the modifier in an amount from about 0.5% to about 16% by weight. 
     
     
         48 . The rug of  claim 44 , wherein the modifier is polybutylene adipate terephthalate (PBAT). 
     
     
         49 . The rug of  claim 44 , wherein the polyester yarn comprises bulked continuous filaments. 
     
     
         50 . The rug of  claim 44 , wherein the polyester yarn exhibits increased dyeability compared to a polyester yarn comprising polyester fibers or filaments that have the same degree of crystallinity but lack the modifier. 
     
     
         51 . The rug of  claim 44 , wherein the polyester fibers or filaments 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. 
     
     
         52 . The rug of  claim 44 , wherein the rug is beck-dyed. 
     
     
         53 . The rug of  claim 52 , wherein the textile face fabric and the backing layer have been dyed simultaneously. 
     
     
         54 . A method of manufacturing a cushioned rug, said method comprising:
 (a) providing a greige fabric comprising polyester yarn, said polyester yarn comprising polyester fibers or filaments, said fibers or filaments having a percent crystallinity of less than about 30%, and said fibers or filaments comprising a crystallinity-reducing modifier;   (b) securing a backing layer to the greige fabric, so as to form an intermediate rug;   (c) beck-dyeing the intermediate rug with disperse dye, so as to form a dyed rug; and   (d) scouring the dyed rug with a caustic liquid.   
     
     
         55 . The method of  claim 54 , wherein said polyester fibers or filaments are fibers or filaments comprising polyethylene terephthalate (PET) yarn. 
     
     
         56 . The method of  claim 54 , wherein said backing layer comprises foam, said foam having a density ranging from about 2 oz per square yard to about 50 oz per square yard. 
     
     
         57 . The method of  claim 54 , wherein the polyester fibers or filaments comprise the modifier in an amount from about 1% to about 16% by weight. 
     
     
         58 . The method of  claim 54 , wherein the modifier is polybutylene adipate terephthalate (PBAT). 
     
     
         59 . The method of  claim 54 , wherein the polyester yarn comprises bulked continuous filaments. 
     
     
         60 . The method of  claim 54 , further comprising the step of providing said polyester yarn, wherein said polyester fibers or filaments are extruded fibers or filaments obtained by melt extrusion of a molten polymer, said polymer comprising said crystallinity-reducing modifier, and drawing said extruded filaments so as to obtain a crystallinity of less than 30%. 
     
     
         61 . The method of  claim 54 , wherein the polyester yarn exhibits increased dyeability compared to a polyester yarn comprising polyester fibers or filaments that have the same degree of crystallinity, but lack a modifier. 
     
     
         62 . The method of  claim 54 , wherein the polyester fibers or filaments comprise the modifier in an amount from about 1% to about 16% by weight. 
     
     
         63 . A rug, comprising
 a) a textile face fabric comprising a polyester yarn, said polyester yarn comprising polyester fibers or filaments, 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 face fabric, wherein the polyester fibers or filaments comprise recycled PET recovered from carpet waste or plastic bottles, wherein the polyester yarn comprises bulked continuous filaments, wherein the modifier is polybutylene adipate terephthalate (PBAT) in an amount from about 0.5% to about 16% by weight, and wherein the rug is beck-dyed.