Tufted Carpet for Automotive Applications

Abstract

Embodiments of the present invention relate to a tufted carpet. The carpet may include a pile layer having a bulked continuous filament (BCF) yarn. The BCF yarn may include a polypropylene (PP) yarn with a tenacity between about 2.6 cN/dtex and about 3.2 cN/dtex at an elongation of about 50% to about 70%. Alternatively, the BCF yarn may include a polyethylene terephthalate (PET) with a tenacity between about 2.6 cN/dtex to about 3.4 cN/dtex at an elongation of about 20% to about 40%.

1 - 15 . (canceled) 
     
     
         16 . A tufted carpet used for sound attenuation in a passenger cabin of a vehicle, the tufted carpet comprising:
 a pile layer configured to be coupled to the cabin via one or more other layers, the a pile layer having a bulked continuous filament (BCF) yarn;   wherein the BCF yarn includes at least one yarn material chosen from (i) polypropylene (PP) yarn material with a tenacity between about 2.6 cN/dtex and about 3.2 cN/dtex at an elongation of about 50% to about 70%, and (ii) a polyethylene terephthalate (PET) yarn material with a tenacity between about 2.6 cN/dtex to about 3.4 cN/dtex at an elongation of about 20% to about 40%.   
     
     
         17 . The carpet of  claim 16 , wherein the BCF yarn includes a predetermined number of filaments, wherein each of the predetermined number of filaments has a predetermined diameter of about 5 to about 20 dpf. 
     
     
         18 . The carpet of  claim 17 , wherein the predetermined number of filaments is between about 70 to about 150 filaments. 
     
     
         19 . The carpet of  claim 18 , wherein the BCF yarn includes PP yarn material having between about 120 to about 150 filaments. 
     
     
         20 . The carpet of  claim 18 , wherein the BCF yarn includes PET yarn material having between about 70 to about 100 filaments. 
     
     
         21 . The carpet of  claim 16 , wherein the BCF yarn includes trilobal filaments. 
     
     
         22 . The carpet of  claim 16 , wherein the pile layer has a pile weight between about 200 gsm and about 750 gsm. 
     
     
         23 . The carpet of  claim 16 , wherein the carpet is a piece dyed carpet. 
     
     
         24 . The carpet of  claim 16 , wherein the BCF yarn is a solution dyed BCF yarn. 
     
     
         25 . The carpet of  claim 16 , wherein the at least one primary backing layer and the BCF yarn either both include a PP material or both include a PET material. 
     
     
         26 . The carpet of  claim 25 , further comprising:
 one or more additional layers, wherein each of the one or more additional layers includes the same material as the BCF yarn and the at least one primary backing layer, and is attached to an underside of the carpet.   
     
     
         27 . A method of producing a tufted carpet, comprising:
 tufting a Bulk Continuous Filament (BCF) yarn to form tufts, the BCF yarn including at least one yarn material chosen from (i) polypropylene (PP) yarn material with a tenacity between about 2.6 cN/dtex and about 3.2 cN/dtex at an elongation of about 50% to about 70%, and (ii) a polyethylene terephthalate (PET) yarn material with a tenacity between about 2.6 cN/dtex to about 3.4 cN/dtex at an elongation of about 20% to about 40%;   wherein the tufting includes tufting at a gauge of 5/64th inch onto a primary backing layer; and   applying a back coating to the tufted carpet via an extrusion, a latex application, or a thermal process to secure the tufted yarn to the primary backing layer.   
     
     
         28 . The method of  claim 27 , further including piece dying the tufted carpet. 
     
     
         29 . The method of  claim 27 , wherein applying the back coating includes applying a back coating comprised of the same material as the tufts. 
     
     
         30 . The method  claim 27 , wherein the BCF yarn and the back coating are each comprised of about 20% to about 80% recycled postindustrial waste. 
     
     
         31 . A tufted carpet, comprising:
 a Bulk Continued Filament (BCF) yarn, the BCF yarn including a plurality of filaments and a yarn material, wherein the material is at least one of (i) a polypropylene (PP) yarn material with a tenacity between about 2.6 cN/dtex and about 3.2 cN/dtex at an elongation of about 50% to about 70% and having about 120 to about 150 filaments, and (ii) a polyethylene terephthalate (PET) yarn material with a tenacity between about 2.6 cN/dtex to about 3.4 cN/dtex at an elongation of about 20% to about 40% and about 70 to about 100 filaments.   
     
     
         32 . The carpet of  claim 31 , wherein each of the plurality of filaments includes a diameter of about 5 to about 20 dpf. 
     
     
         33 . The carpet of  claim 31 , wherein the plurality of filaments include trilobal filaments. 
     
     
         34 . The carpet of  claim 31 , wherein the BCF yarn includes a weight between about 200 gsm and about 750 gsm. 
     
     
         35 . The carpet of  claim 31 , wherein the carpet is a piece dyed carpet.