Multicolor polyester fabric and methods of manufacturing same

Abstract

The invention relates to carpets comprising a cationically-dyeable polyester effect yarn, dyed with a basic dye, and a background polyester or polyamide yarn, not dyed with a basic dye, and wherein the carpet has been overdyed with a disperse dye or an acid dye. The invention further relates to methods of preparing such overdyed carpets.

1 . A carpet comprising pile, said pile comprising a first yarn and a second yarn, said pile being tufted into a primary backing;
 wherein said first yarn comprises sulfonated entities and a cationically-dyeable polyester yarn; and   wherein said second yarn comprises a polymer selected from the group consisting of a polyester and a polyamide.   
     
     
         2 .- 31 . (canceled) 
     
     
         32 . The carpet of  claim 1 , wherein said first yarn has been dyed with a basic dye; and wherein said second yarn has been dyed with a second dye, or is undyed. 
     
     
         33 . The carpet of  claim 32 , wherein said carpet has been overdyed with a disperse dye. 
     
     
         34 . The carpet of  claim 33 , wherein said first yarn has been space dyed. 
     
     
         35 . The carpet of  claim 34 , wherein said first yarn comprises cationically-dyeable polyethylene terephthalate (PET) or cationically-dyeable polytrimethylene terephthalate (PTT). 
     
     
         36 . The carpet of  claim 35 , wherein said first yarn comprises sulfur in a concentration of at least 1000 ppm by weight. 
     
     
         37 . The carpet of  claim 36 , having at least one additional cationically-dyeable polyester yarn. 
     
     
         38 . The carpet of  claim 37 , having at least one additional polyester or polyamide yarn. 
     
     
         39 . The carpet of  claim 38 , wherein said first yarn is comprised of bulked continuous filaments. 
     
     
         40 . A carpet comprising a woven facecloth, said woven facecloth comprising a first yarn and a second yarn, said first yarn being interwoven with said second yarn;
 wherein said first yarn comprises sulfur in a concentration of at least 1000 ppm by weight and a cationically-dyeable polyester yarn;   wherein said second yarn comprises a polyamide; and wherein said carpet has been overdyed with an acid dye.   
     
     
         41 . The carpet of  claim 40 , wherein said first yarn has been space-dyed. 
     
     
         42 . The carpet of  claim 41 , wherein said first yarn comprises cationically-dyeable polyethylene terephthalate (PET) or cationically-dyeable polytrimethylene terephthalate (PTT). 
     
     
         43 . The carpet of  claim 42 , wherein at least one of said first yarn and said second yarn comprises continuous filaments. 
     
     
         44 . The carpet of  claim 43 , wherein said continuous filaments are bulked continuous filaments. 
     
     
         45 . The carpet of  claim 44 , having at least one additional cationically-dyeable polyester yarn. 
     
     
         46 . The carpet of  claim 45 , having at least one additional polyamide yarn. 
     
     
         47 . A woven fabric comprising a first yarn interwoven with a second yarn;
 wherein said first yarn comprises sulfur in a concentration of at least 1000 ppm by weight and a cationically-dyeable polyester yarn which has been dyed with a basic dye prior to being interwoven with the second yarn; and   wherein said second yarn comprises a polymer selected from the group consisting of a polyester and a polyamide, and is undyed, or dyed with a different dye, prior to being interwoven with the first yarn.   
     
     
         48 . The woven fabric of  claim 47 , wherein said second yarn comprises a polyester, and said fabric has been overdyed with a disperse dye. 
     
     
         49 . The woven fabric of  claim 47 , wherein said second yarn comprises a polyamide, and said fabric has been overdyed with a disperse dye or an acid dye. 
     
     
         50 . A carpet comprising the woven fabric of  claim 48 .