Carpet made from self-bulking ptt-containing bicomponent fibers

Abstract

Disclosed herein are carpets whose face fiber comprises a bicomponent fiber comprising one component of poly(ethylene terephthalate) homopolymer or poly(ethylene terephthalate) copolymer and a second component of poly(trimethylene terephthalate) polymer or a blend of poly(trimethylene terephthalate) with poly(ethylene terephthalate) homopolymer or poly(ethylene terephthalate) copolymer, wherein the bicomponent fiber is self-bulking due to differential shrinkage. Also disclosed is an improved process for making a yarn to produce a carpet whose face fiber comprises a self-bulking bicomponent fiber comprising one component of poly(ethylene terephthalate) homopolymer or poly(ethylene terephthalate) copolymer and a second component of poly(trimethylene terephthalate) or a blend of poly(trimethylene terephthalate) with poly(ethylene terephthalate) homopolymer or poly(ethylene terephthalate) copolymer.

What is claimed is: 
     
         1 . A carpet whose face fiber comprises a bicomponent fiber comprising one component of poly(ethylene terephthalate) homopolymer or poly(ethylene terephthalate) copolymer and a second component of poly(trimethylene terephthalate) or a blend of poly(trimethylene terephthalate) with poly(ethylene terephthalate) homopolymer or poly(ethylene terephthalate) copolymer, wherein the bicomponent fiber is self-bulking due to differential shrinkage, in contrast to carpet whose face fiber is made from bulk continuous homofilament that is mechanically bulked. 
     
     
         2 . The carpet of  claim 1 , wherein the bicomponent fiber can be in a side-by-side configuration or an eccentric sheath core configuration. 
     
     
         3 . The carpet of  claim 1  or  claim 2 , wherein the first and second components of the bicomponent fiber are present in a weight ratio ranging from 80:20 to 20:80. 
     
     
         4 . The carpet of  claim 1  or  claim 2 , wherein the crimp contraction after heating of the bicomponent fiber is equal to or less than 30% as determined according to the Crimp Contraction Method. 
     
     
         5 . The carpet of  claim 3 , wherein the crimp contraction after heating of the bicomponent fiber is equal to or less that 30% as determined according to the Crimp Contraction Method. 
     
     
         6 . The carpet of  claim 1 , wherein the face fiber further comprises at least one additional fiber selected from bulked continuous filament, synthetic staple fiber, and natural fiber. 
     
     
         7 . The carpet of  claim 6 , wherein the at least one additional fiber is bulked continuous filament, and the bulked continuous filament comprises nylon, polypropylene, or polyester. 
     
     
         8 . The carpet of  claim 6 , wherein the at least one additional fiber is synthetic staple fiber, and the synthetic staple fiber comprises nylon or polyester. 
     
     
         9 . The carpet of  claim 6 , wherein the at least one additional fiber is natural fiber, and the natural fiber comprises wool, silk, or cotton. 
     
     
         10 . An improved process for making a yarn to produce a carpet whose face fiber comprises a self-bulking bicomponent fiber comprising one component of poly(ethylene terephthalate) homopolymer or poly(ethylene terephthalate) copolymer and a second component of poly(trimethylene terephthalate) or a blend of poly(trimethylene terephthalate) with poly(ethylene terephthalate) homopolymer or poly(ethylene terephthalate) copolymer, said process comprising:
 a) extruding the two components on a spinning machine capable of producing two or more independent melt streams;   b) combining the melt streams in a spinneret suited for making bicomponent fibers;   c) quenching in air the self-bulking bicomponent fibers produced in step (b);   d) drawing and heat setting the self-bulking bicomponent fibers; and   e) winding up the self-bulking bicomponent fibers by suitable means for subsequent processing into carpet, wherein the self-bulking bicomponent fibers eliminate the need for a mechanical bulking step.   
     
     
         11 . The improved process of  claim 10 , wherein the bicomponent fiber can be in a side-by-side configuration or an eccentric sheath core configuration. 
     
     
         12 . The improved process of  claim 10  or  11 , wherein the first and second components of the bicomponent fiber are present in a weight ratio ranging from 80:20 to 20:80. 
     
     
         13 . The improved process of  claim 10  or  claim 11 , wherein the crimp contraction after heating of the bicomponent fiber is equal to or less that 30% as determined according to the Crimp Contraction Method. 
     
     
         14 . The improved process of  claim 12 , wherein the crimp contraction after heating of the bicomponent fiber is equal to or less that 30% as determined according to the Crimp Contraction Method.