PET Carpet With Additive

• US 20110177283A1
• Filed: 07/06/2010
• Published: 07/21/2011
• Est. Priority Date: 01/18/2010
• Status: Abandoned Application

• Current Assignee: Futuris Automotive Interiors Pty Limited (Elders Limited)
• Original Assignee: Futuris Automotive Interiors Pty Limited (Elders Limited)
• Inventors: Juriga, Duane M.
• Application Number:
  US12/830,761
• Publication Number:
  US 20110177283A1
• Time in Patent Office: Days
• US Class Current: 428/97
• CPC Class Codes: B29C 48/0018 combined with shaping by orienting, stretching or shrinking, e.g. film blowing B29C48/0017 takes precedence
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/272 of dies
• CPC Class Codes: B29C 48/285 Feeding the extrusion material to the extruder
• CPC Class Codes: B29C 48/287 Raw material pre-treatment while feeding B29C48/78 takes precedence
• CPC Class Codes: B29C 48/793 upstream of the plasticising zone, e.g. heating in the hopper
• CPC Class Codes: B29C 48/80 at the plasticising zone, e.g. by heating cylinders
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/006 PBT, i.e. polybutylene terephthalate
• CPC Class Codes: B29L 2031/731 Filamentary material, i.e. comprised of a single element, e.g. filaments, strands, threads, fibres cables B29L2031/707
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08J 2467/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds C08J2467/06 takes precedence
• CPC Class Codes: C08J 3/226 using a polymer as a carrier
• CPC Class Codes: C08L 2666/18 Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof
• CPC Class Codes: C08L 67/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds C08L67/06 takes precedence
• CPC Class Codes: D01D 1/00 Treatment of filament-forming or like material working of plastics or substances in a plastic state, in general B29
• CPC Class Codes: D01F 1/04 Pigments
• CPC Class Codes: D01F 1/06 Dyes
• CPC Class Codes: D01F 6/92 of polyesters
• CPC Class Codes: D06N 7/0065 : characterised by the pile
• CPC Class Codes: Y10T 428/23993 : Composition of pile or adhesive

Abstract

A method of forming PET fiber for carpet is disclosed. The method includes drying PET material so it has a water content of less than 50 ppm. Adding color to the PET material, heating the PET material to a temperature less than 330° C. so the PET has a viscosity between about 0.68 and 0.86, and extruding the PET through a spinneret to form fibers.

Claims

1. A method of producing a fiber comprising:

compounding PET with one of PBT or oligomers of PBT;

heating the compound to a temperature of less than about 310°

C.; and

extruding the compound through spinnerets to form carpet fibers.

2. The method according to claim 1 wherein compounding PET is compounding PET with one of between 0.1% and about 5% PBT or between 0.1% and about 5% oligomer of PBT and extruding the compound is extruding the compound though spinnerets in an oxygen reduced environment.

3. The method according to claim 1 wherein compounding PET is compounding PET with one of between about 2.0% to about 3.0 weight % PBT or oligomer of PBT.

4. The method according to claim 1 wherein the one of PBT or oligomers of PBT is compounded with PET so the compound has a viscosity of between about 0.68 and about 0.86 at temperatures between 280°

and 300°

C.

5. The method according to claim 1 further comprising crimping, bundling, and mating the carpet fibers to a carpet backing to form a PET/PBT carpet.

6. A method of forming PET fiber for carpet comprising:

drying PET material so it has a water content of less than 50 μ

m;

adding color to the PET material;

heating the PET material to a temperature less than 330°

C. so the PET has a viscosity between about 0.68 and 0.86; and

extruding the PET through a spinneret.

7. The method according to claim 6 further comprising mixing one of about 0.1 to about 5% PBT or about 0.1 to about 5% oligomers of PBT with the PET to form a compound;

heating the compound to a temperature where the viscosity is between 0.68 and 0.86 at a temperature less than 330°

C.; and

extruding the heated mixture at temperatures where there is no measurable amount of degradation of the PET.

8. The method according to claim 7 wherein the material is extruded in an atmosphere containing a reduced level of oxygen.

9. A method of forming PET fibers comprising:

compounding PET with one of a polymer or oligomer which reduces the viscosity of the compound between 5% to about 15% at processing temperatures between 250° and

330°

without degradation of the carpet fiber properties at room temperature.

10. The method according to claim 9 further comprising compounding the PET with between 0.1% and about 5% PBT.

11. The method according to claim 9 further comprising compounding the PET with one of between 2.0% and about 3.0% PBT or between 2.0% and about 3.0% oligomers of PBT.

12. A carpet comprising:

a plurality of crimped/bundled fibers having PET and between 0.1% and about 5.0 weight % of PBT.

13. The carpet according to claim 12 further comprising a backing material.

14. The carpet according to claim 12 wherein the fiber comprises between about 2.0% and about 3.0 weight % of PBT.

15. The carpet according to claim 12 comprising PET yarn having a diameter of between 1200 and 2400 denier.

16. The carpet according to claim 12 further comprising an underlayment layer.

17. The carpet according to claim 12 further having a face layer ranging from 9.0 oz per 1 sq yard to 50.0 oz per 1 sq yard.

18. The carpet according to claim 12 wherein the fibers comprise between 0.5 to about 3.0 weight % PBT.

19. The carpet according to claim 12 wherein the fibers comprise between 2.0 to about 3.0 weight % PBT.

20. The carpet according to claim 12 wherein the fiber is tufted into one of a ⅛

or 1/10 gauge.