Antisoiling carpet and method for making an antisoiling carpet

Abstract

Oils, such as spin finishing oils, along with some other topicals are applied to filaments that are used in making yarns for carpets. These oils and some other topicals attract and retain soilants, such as dust and dirt, to the finished carpet. Similarly, oils and some other topicals may be tracked in on the soles of shoes, which will adhere to the yarn in a carpet thereby attracting and retaining more soilants. The present invention relates to a carpet that actively prevents soiling by removing topicals, and by continuing to eliminate compounds that attract carpet soilants through the application of microbes.

Description

[0001] Anti soiling carpet and method for making an anti soiling carpet

[0002] The present invention relates to a carpet that actively prevents soiling by removing processing aids that are used in creating the carpet, and by continuing to eliminate compounds that attract carpet soilants through the application of microbes.

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004] The present application claims the benefit of priority of U.S. Patent Application 63 / 570,263, filed on March 27, 2024, the contents of which are hereby incorporated by reference for all purposes.

[0005] BACKGROUND

[0006] Polymer yarns made for carpets are usually made with at least one processing aid on them. In many cases, the processing aid is a lubricant. This processing aid lubricant, which is usually an oil or an oil-based emulsion, is usually applied during extrusion but may be applied after. This processing aid lubricant, sometimes known as a “spin finish”, provides a coating for the filaments that aids in the processing steps, which provides elongation, crimps, and twists so that the yam obtains a desired bulk. That is to say that a spin finish aids in the processing of the filaments as they are being drawn and textured.

[0007] From that, a spin finish has been widely regarded as an essential component in the production of carpets, such as woven and tufted carpets, carpet tiles, mgs, mats, and other soft surfaces. However, the filaments, and therefore the yam, retains the spin finish after production has been completed, and even through the installation and well into the life of the carpet, if not all the way through the life of the carpet.

[0008] After installation, any type of oil on a carpet is seen as an attractant of soilants. In one example, specks of dust would normally slide off of a surface of a filament in a yarn. In that case, the specks of dust would easily be extracted from a carpet through vacuuming and / or washing. However, with a coating of a spin finish or any other type of hydrocarbon on the yam, some specks of dust will adhere to the hydrocarbon and will resist attempts of removing them through normal cleaning methods.

[0009] This is not to say that all dust, dirt, and other soilants will be eternally retained by the spin finish on yarn filaments. Since the spin finish is usually applied in very small amounts, only some of the soilants will adhere to the yarn to a degree that they will continue to adhere through normal cleaning methods, such as vacuuming.

[0010] More aggressive cleaning methods, such as steam cleaning and cleaning with detergents, will remove more soilants as well as some of the spin finish and other deposited hydrocarbons. However, it may be impractical to frequently use more aggressive cleaning methods. Indeed, those methods are usually only deployed when a stain or an accumulation of soilants becomes noticeable in spots or well-used pathways across the carpet.

[0011] As noted, other hydrocarbons and soilant-attracting compounds may be brought into the yam of the carpet by spills, clothing, footwear, skin, and animal fur. For example, most animals have minute amounts of oils secreted from their skins which may be rubbed off onto the pile or weave of a carpet through contact between the soft surface article and the fur of the animal. Similarly, coffee, tea, and wine contain very small amounts of oils, which may be retained by a carpet yam long after the water from those drinks has been wiped away and / or evaporated. As another example, a shoe may step into some drops of oil in a parking lot and deposit those drops, in large or small portions, across a carpet along the pathway of the wearer. As another example, a soap or other detergent may be applied to a carpet in an attempt to clean a stain. Some portion of the soap and / or detergent, which are hydrocarbons, may be left as a residue. This residue is also a soilant-attractor since some dust, dirt, and other particles will stick to it as it sticks to the filaments of the carpet yam.

[0012] When accumulated, the combination of soilants and soilant-attracting compounds can make a carpet appear soiled and unclean even after ordinary cleaning methods have been deployed. From this, there is a need to remove soilant-attracting compounds from soft surface articles such as a carpet, a carpet tile, a mg, and a mat so that soilants may be more easily removed with normal cleaning methods. Some background publications include the following:

[0013] U.S. Patent No. 3,041,288 A discloses: “This invention relates to improvements in making microscopic capsules of gelled hydrophilic colloid material, each of which capsules contains within its walls a single drop of water-immiscible liquid material.”

[0014] U.S. Patent No. 3,338,830 A discloses: “This invention relates to a new composition of matter and articles produced therewith. More particularly, this invention concerns textile-lubricating compositions suitable for use in producing a synthetic, continuous- filament, false-twist, textured yarn as well as other yarns.”

[0015] U.S. Patent No. 3,415,758 A discloses: “This invention relates to a process of manufacturing minute capsules en masse in a liquid manufacturing vehicle and to the capsule product, each capsule comprising a core and a seamless protecting wall surrounding the core. By minute capsules are meant capsules from a few microns to several thousand microns and possibly somewhat larger in average size.”

[0016] U.S. Patent No. 3,781,202 A discloses: “A spin finish composition for nylon feeder yarn to be processed at high temperature into carpet yarn, such as by steam jet texturing, comprising coconut oil, sulfonated natural petroleum product and other essential components results in improved processing and better quality yarn.”

[0017] U.S. Patent No. 3,843,517 A discloses: “In a preferred mode, cultures containing hydrocarbon and oil consuming microorganisms with or without nutrients are adsorbed in a carrier such as clays, vermiculites, silica gels, perlites and similar materials and freeze-dried to form useful compositions. These compositions are placed on oil films or layers which are on fresh or salt water, or on beaches or river banks, or in storage tanks, ships tanks and so on. The carrier adsorbs and concentrates the oil in the presence of the microorganisms and the microorganisms consume the oil. The microorganisms remain viable in these compositions even after long storage periods. In an alternative composition, the microorganisms may be freeze-dried and then admixed with a carrier such as clays, vermiculites, perlites, silica gels or so on.”

[0018] U.S. Patent No. 3,870,542 A discloses: “A fibrous article such as yarn, woven and knitted fabric and non-woven fabric is treated with hydrophobic treating agent by applying microcapsules composed of a core constitutent consisting of a non-aqueous solvent solution of the hydrophobic treating agent and a wall constituent containing the core constituent and made up of a thin synthetic resin shell and having a low tenacity at break of at most 100 g / cm2, and then by breaking the applied microcapsules at a breaking force of at least 100 g / cm2 so as to impregnate the fibrous article with the non-aqueous solvent solution which flows out from the broken microcapsules.”

[0019] U.S. Patent No. 10,479,963 B2 discloses: “Microcapsules for delivery of a liquid onto a surface such as a hard surface or a textile, such as mattress ticking, are disclosed. The microcapsules have a shell with an outer face and an inner face, the inner face encapsulating the liquid, and the liquid contains a microorganism such as a beneficial microorganism in a dormant state. The outer face of the microcapsules may comprise reactive functional groups whereby the outer face is chemically bondable, for instance covalently bondable to said surface. - The microcapsules provide a beneficial microflora on said surface by rupture of the capsules deposited onto said surface to release the microorganism onto said surface. This may reduce or obviate the need for chemical antimicrobial agents to clean said surface. For surfaces which are fabrics or textiles, rupture and release may occur during use of the fabric or textile.”

[0020] These publications are hereby incorporated by reference for all purposes.

[0021] BRIEF SUMMARY

[0022] Applicant has devised methods to apply microbes to carpets during the manufacturing process, such that the microbes will consume and remove oils and other soilant-attracting compounds from the carpets. With less soilant-attracting compounds on the carpets, normal cleaning methods will remove greater amounts of soilants from the carpets. Among other benefits, the greater removal of soilants from carpets will make each carpet appear cleaner.

[0023] Another way of stating a problem that the inventions disclosed and taught herein will address is that with less or no soilant-attractors on carpets, soilants such as dust, dirt, and other particulate matter will become vacuumable or removable to a greater extent. This means that ordinary cleaning of carpets will produce cleaner carpets, and that the need for extraordinary cleaning processes may be reduced.

[0024] In a first independent aspect, the invention relates to a section of a carpet comprising: a yarn comprising a plurality of filaments, wherein at least a first portion of the plurality of filaments is coated with at least one soilant-attractor; and microbes that are encapsulated in friable capsules; wherein the friable capsules are retained on filaments of the yarn and are configured to break open to release the microbes; and wherein at least a portion of the microbes are configured to consume the at least one soilant-attractor.

[0025] In a second independent aspect, the invention relates to a method of making a carpet, comprising: providing an unfinished carpet; wherein the unfinished carpet comprises at least one yarn comprising a plurality of filaments, wherein at least a first portion of the plurality of filaments is coated with a soilant-attractor; providing a plurality of microbes; wherein at least a portion of the plurality of microbes are configured to consume the soilant-attractor; encapsulating the plurality of microbes into a plurality of friable capsules; embedding a first portion of the plurality of capsules into the at least one yarn.

[0026] In a third independent aspect, the invention relates to a method of cleaning a carpet, comprising: providing a carpet comprising a plurality of microbes; wherein the carpet comprises at least one yam comprising a plurality of filaments, wherein at least a first portion of the plurality of filaments is coated with a soilant-attractor; wherein at least a portion of the plurality of microbes are configured to consume the soilant-attractor, are encapsulated into a plurality of friable capsules, and are embedded into the at least one yam; and vacuuming the carpet.

[0027] In a fourth independent aspect, the invention relates to a method of making a carpet, comprising: providing an unfinished carpet; wherein the unfinished carpet comprises at least one yarn comprising a plurality of filaments, wherein at least a first portion of the plurality of filaments is coated with a soilant-attractor; providing a plurality of microbes; wherein at least a portion of the plurality of microbes are configured to consume the soilant-attractor; encapsulating the plurality of microbes into a plurality of friable capsules; wherein the friable capsules are coated with a binding agent or a bonding agent configured to adhere to the plurality of filaments; forming a solution containing a carrier and the plurality of binding or bonding-agent coated friable capsules; applying the plurality of binding or bonding-agent coated friable capsules onto the unfinished carpet; and evaporating the carrier from the unfinished carpet.

[0028] Descriptions of these inventions will be defined in the appended independent claims, while preferred embodiments are defined in the dependent claims.

[0029] BRIEF DESCRIPTION OF THE DRAWINGS

[0030] With the intention of better showing the characteristics of the invention, hereinafter, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:

[0031] Figure 1 illustrates a flow chart of one method of continually cleaning a carpet using the inventions disclosed herein.

[0032] DETAILED DESCRIPTION

[0033] Applicant has devised methods to apply microbes to carpets during the manufacturing process, such that the microbes will consume and remove hydrocarbons, such as oils, and other soilant-attracting compounds from the carpets. With less soilant-attracting compounds on the carpets, normal cleaning methods will remove greater amounts of soilants from the carpets.

[0034] Throughout this specification, the term microbes will be used to encompass types of microbiological life forms, such as bacteria and fungi, that are capable of consuming hydrocarbons.

[0035] Also, throughout this specification, the term consuming will encompass any process whereby a microbe derives nutrition by chemically altering a substance. As an example, bacterial genera, namely, Bacillus, Gordonia, Brevibacterium, Aeromicrobium, Dielzia, Burkholderia, Mycobacterium, and Sphingomonas utilize enzymes to degrade and utilize different types of hydrocarbons as sources of carbon and energy. Similarly, fungal genera, namely, Amorphoteca, Neosartorya, Talaromyces, and Graphium and yeast genera, namely, Candida, Yarrowia, and Pichia also utilize enzymes to degrade and utilize different types of hydrocarbons as sources of carbon and energy.

[0036] For the purposes of removing soilant-attractors from living spaces, terrestrial microbes will be preferred over marine microbes. For example, the genera Bacillus, Nocardioides (especially N. deserti), Dietzia (especially D. papillomatosis'), Microbacterium, Micrococcus, Arthrobacter, Pseudomonas, Cellulomonas, Gordonia and other terrestrial bacterial that have shown a high propensity towards consuming oil contamination in soil. However, in certain environmental conditions, marine microbes may be utilized in the same way as terrestrial microbes as disclosed and taught herein without departing from the spirit of the inventions disclosed, taught, and claimed.

[0037] Similarly, microbes configured to remove soilant-attractants in living spaces must be benign to people, pets, and plants. As such, microbes that improve living spaces in ways disclosed and taught herein may be termed probiotics.

[0038] From this, the microbes that meet these criteria may be called soilant-attractant- consuming microbes. As noted, there may be a plethora of microbiological life forms that meet these requirements. Therefore, when a soilant-attractant-consuming microbe is referenced in this specification, it may be any such microbiological life form suitable for these purposes, or it may be a combination of microbiological life forms that produce the desired results.

[0039] Along those lines, the inventions disclosed and taught herein are not limited to the singular use of a biological life form - or a group of them - that consumes soilantattractors. Soilant-attractor-consuming microbes may be combined with other microbiological life forms (e.g., other probiotics) chosen to perform other activities. For example, and without limitation, soilant-attractor-consuming microbes may be deployed along with odor-consuming microbes and / or with allergen-consuming microbes. Having explained and exemplified the types and requirements for microbes that are useful for the inventions taught and disclosed herein, attention will now be turned towards exemplary, but non-limiting embodiments.

[0040] Figure 1 illustrates one embodiment of many for applying microbes (e.g., probiotics) to keep a carpet clean. This process 100 starts with Step 101, where a griege product has been produced that will be made into a carpet, carpet tile, rug, or other soft surface product. This may be a tufted product or a woven product.

[0041] The griege product may be made of yams made of filaments of one or more polyamide; filaments of one or more polyester; filaments of one or more polyolefin; and / or staple fibers, such as cotton, wool, and jute. In any of these, a lubricant may have been placed upon the filaments, fibers and / or the yams to facilitate their tufting or weaving to make the griege product.

[0042] Step 110 includes other processes needed to make a griege product, such as applying a backing, trimming selvage, and binding a border. If the griege product does not require dyeing or any further processing to make it ready for use by a consumer, it is still considered to be a griege product in this step because it still has not been treated with the microbes as disclosed and taught herein.

[0043] One option 111 at this stage of preparing a carpet, carpet tile, mg, or other soft surface product for a consumer may be illustrated in optional Step 112. At this point, the yarn or yarns in the griege product will still have a spin finish on the surface of the yarn or yarns. Some amount of a soilant-attractor-consuming microbe may be applied directly onto the griege product. This may entail spraying, sprinkling, or dusting a dry or wetted soilant-attractor-consuming microbe onto the griege product and nurturing the soilant-attractor-consuming microbe in a suitable environment. Examples of environmental conditions to nurture the microbes may include a humidity and a temperature that promotes the growth and sustains the soilantattractor-consuming microbe. Another example of an environmental condition to nurture the microbes may include a type of light, wherein the intensity of the light and frequency of the light wavelengths may be configured to produce suitable conditions for the soilant-attractor-consuming microbes. This step is designed to remove at least a portion of the spin finish that is retained on the filaments, fibers, and yam. When the soilant-attractor-consuming microbe has consumed some amount of the spin finish, the carpet, carpet tile, rug, or other soft surface article may be vacuumed to remove any vacuumable metabolites.

[0044] It may be impractical for a manufacturer of a carpet to hold a product for that length of time and / or to provide a suitable environment for fostering the soilant-attractorconsuming microbes for a length of time for them to completely consume all of the spin finish in the carpet.

[0045] Step 120 illustrates that soilant-attractor-consuming microbes may be prepared for use. This may include encapsulating them. This Step 120 may be performed prior to Step 110 if the soilant-attractor-consuming microbes are to be stored until the process 100 requires them. In another embodiment, Step 120 may be performed contemporaneously with Step 110.

[0046] The soilant-attractor-consuming microbes may be encapsulated in friable shells in ways that have been referenced above or in ways known to those of ordinary skill in the art. While any composition for a friable shell may be used, a composition that will break into vacuumable particles is preferred. While the shells may be described as friable, they may also be frangible.

[0047] The composition of the shells need not be uniform. As will be explained, it may be preferable to have a first portion of the soilant-attractor-consuming microbes encapsulated in shells of one composition and a second portion encapsulated in shells of another composition.

[0048] In some embodiments, the microcapsules may have diameters from about 1pm to about 500pm. In a preferred embodiment, the microcapsules may have diameters from about 2pm to about 100pm, while in a more preferred embodiment, the microcapsules may have diameters from about 2pm to about 50pm.

[0049] In some embodiments, the microcapsules may have a ratio of the mass of the friable shell to the mass of the soilant-attractor-consuming microbes, including any fluid they may be kept in, within a range of between about 1 : 100 to about 1 : 15,000. In this, a range of between about 1 :500 and 1 :5,000 will provide friable shells that will break over time. This will prevent the soilant-attractor-consuming microbes from being released all at once when the carpet is disrupted by being trod upon.

[0050] However, in some embodiments, it may be preferable to have some portion of the encapsulated soilant-attractor-consuming microbes break open relatively quickly after application. This may occur as the carpet is being prepared for shipment, such as by rolling it. This may be a preferred embodiment when a fully prepared carpet, carpet tile, rug, or other soft surface product is waiting to be sold and / or installed and a manufacturer and / or consumer may wish that the soilant-attractor-consuming microbes be given an uninterrupted period of time to consume the spin finish before installation. If this is desired, then a portion of the soilant-attractor-consuming microbes may be provided in shells that have a ratio of the mass of the friable shell to the mass of the soilant-attractor-consuming microbes, including any fluid they may be kept in, within a range of between about 1 :5,000 to about 1 : 15,000. This portion of the soilant-attractor-consuming microbes may have shell diameters in the range of between about 200pm to about 500pm such that a large amount of the soilantattractor-consuming microbes are spread while the carpet is in transport or is being stored awaiting sale or installation. With this ratio of the mass of the friable shell to the mass of the soilant-attractor-consuming microbes, including any fluid they may be kept in, the shells are very fragile and will break open to release the soilantattractor-consuming microbes with a very small force.

[0051] Many people prefer that a carpet be vacuumed after installation. That process would remove any broken friable shell pieces, some of the live soilant-attractor-consuming microbes, and other particulate matter including particulate metabolites. That process would also break unbroken shells that have a ratio of the mass of the friable shell to the mass of the soilant-attractor-consuming microbes, including any fluid they may be kept in, within a range of between about 1:500 to about 1 :5,000 thereby releasing fresh soilant-attractor-consuming microbes.

[0052] Once the soilant-attractor-consuming microbes are encapsulated, they must still be prepared for application. This may be done by coating the encapsulated soilantattractor-consuming microbes in a binding agent or a bonding agent as may be known to those of skill in the art. In this, it is preferable to have a binding or bonding agent that will have a preference to binding or bonding with the components of the carpet.

[0053] In one exemplary embodiment, a carpet yarn may be made of a polyamide, such as nylon 6. From that, it would be preferable to use a binding or bonding agent that would have an affinity to bind and / or bond the shells to the polyamide. This may be done so that when the fibers of the yarn are walked upon or otherwise disturbed, the shells on the polyamide fibers will be subject to that stress, and some of them will break apart releasing the encapsulated soilant-attractor-consuming microbes.

[0054] The affinity of the binding and / or bonding agent need not be limited to the yam. For example, some portion of the encapsulated soilant-attractor-consuming microbes may be applied with a binding and / or bonding agent with an affinity towards the yarn with another portion applied with a binding and / or bonding agent with an affinity towards the primary backing of a tufted carpet. In another exemplary and nonlimiting embodiment, if it is known that a first shell composition will have an affinity to adhere to a polyamide filament when applied with a first bonding agent, then a first portion of the soilant-attractor-consuming microbes may be encapsulated in shells of the first shell composition and applied with the first bonding agent to the yarn of the tufted carpet. Also, if it is known that a second shell composition will have an affinity towards a polyolefin primary backing when applied with a second binding agent, then a second portion of the soilant-attractor-consuming microbes may be encapsulated in shells of the second shell composition and applied with the second binding agent.

[0055] The selection of shell compositions and binding and / or bonding agents in relationship to the composition of the carpet, carpet tile, mg, or other soft surface product may be cojoined with a selection of shell diameters. For example, a carpet may be made from a double-woven cloth, such that two products are woven face-to-face with polypropylene warp and weft yams for each face, and a polyamide yarn picked between the faces to form the pile, with all of the yarns having a spin finish on them. When trod upon the pile yarns will deform much more than the face yarns. If the shells have uniform sizes, then the encapsulated soilant-attractor-consuming microbe shells adhering to the pile yarns will be broken open much more quickly than the encapsulated soilant-attractor-consuming microbe shells adhering to the face yams. From that, the soilant-attractor-consuming microbe shells that were initially adhered to the pile yarns will be depleted at a rate much faster than the encapsulated soilantattractor-consuming microbe shells that were initially adhered to the face yarns. From this, there may be an initial fast rate of release of some of the soilant-attractorconsuming microbes, until the shells on the pile yam are depleted, then a much slower rate of release of the rest of the soilant-attractor-consuming microbes, which are in the face yarns.

[0056] To counter this, shells that are more fragile may be configured from a shell composition and applied with a binding and / or bonding agent so that they will have an affinity to the face yarns, while shells that are less fragile may be configured from a shell composition and applied with a binding and / or bonding agent so they will have an affinity to the pile yarns. With that configuration, it will be harder to break open the shells on the pile yarns and easier to break open the shells on the face yam, resulting in a much more even release of the soilant-attractor-consuming microbes over time.

[0057] On the other hand, it may be preferable to have more fragile shells on the pile yam and less fragile shells on the face yams. This would act to quickly release enough soilant-attractor-consuming microbes to remove the spin finish on the yarns, and then slowly release more soilant-attractor-consuming microbes to continually consume any newly acquired soilant-attractors that are deposited on the carpet.

[0058] In an envisioned embodiment, the shells of the encapsulated soilant-attractorconsuming microbes may be electrically conductive. In this embodiment, the shells may aid in dissipating any static charges that may build up in the soft surface article.

[0059] In another aspect of the inventions disclosed and taught herein, the composition of a first portion of the applied encapsulated soilant-attractor-consuming microbes may be of a first type while a second portion may be of a second type. For example, a first portion of the applied encapsulated soilant-attractor-consuming microbes may have shells made of a composition that adheres, with or without a binding or bonding agent, to the filaments and / or yarn whether it has spin finish on it or not. In addition, a second portion of the applied encapsulated soilant-attractor-consuming microbes may have shells that adhere to and be weakened by the spin finish regardless of where it is in the carpet. That is to say that the shells of the second portion may be made of a composition that reacts with the spin finish so as to weaken and / or dissolve the shell, thereby releasing the encapsulated soilant-attractor-consuming microbes so that the released soilant-attractor-consuming microbes are immediately contacted by and quickly consume the spin finish.

[0060] A non-limiting exemplary illustration of the application of shells with different properties may be exemplified in an embodiment where a first portion of encapsulated soilant-attractor-consuming microbes are encapsulated in shells that react with soilant-attractors, while a second portion of encapsulated soilant-attractorconsuming microbes are encapsulated in shells that are inert to soilant-attractors. This may be associated with the ratio of the mass of the friable shell to the mass of the soilant-attractor-consuming microbes. For example, in this illustrative embodiment, the shells that react with soilant-attractors may have a ratio of the mass of the friable shell to the mass of the soilant-attractor-consuming microbes in the range of about 1 : 100 to about 1 :500. Under normal use of the carpet, these shells in the first portion will not crush or open to release the soilant-attractor-consuming microbes. With a ratio in that range, it may be that the amounts of spin-finish may not weaken the shells to an extent that they may be broken open. However, at some point in the life of the carpet, an amount of a soilant-attractor may be deposited on a section of the carpet. When that happens, the shells will react with the soilant-attractor such that the soilant-attractor-consuming microbes are released and will consume the deposited soilant-attractor.

[0061] Once the soilant-attractor-consuming microbes have been prepared in Step 120, the process 100 may proceed to Step 130 where the encapsulated soilant-attractorconsuming microbes are applied to the carpet, carpet tile, rug, or other soft surface article.

[0062] The soilant-attractor-consuming microbes may be applied with or without a bonding and / or binding agent as disclosed herein. The soilant-attractor-consuming microbes may be applied to the pile and / or to the primary backing. In one embodiment, the encapsulated soilant-attractor-consuming microbes may be applied to the primary backing before the pile yam is tufted into it. In another embodiment, the encapsulated soilant-attractor-consuming microbes may be applied to the yarn before it is tufted into the primary backing, or before it is woven. The encapsulated soilant-attractor-consuming microbes may be applied to the yarns and / or backings, and / or may be mixed with a dye or colorant and applied during a dyeing process, such as but not limited to space dyeing, continuous dyeing, piece dyeing, beck dyeing, and other dyeing methods known to those ordinarily skilled in the art. As those ordinarily skilled in the art of dyeing fabrics will be aware, the encapsulated soilant-attractor-consuming microbes may be applied to the yarns and / or backings through exhaustion, padding, spraying, and combinations of those during dyeing or at other points in the process of creating a soft surface article.

[0063] In these embodiments, the encapsulated soilant-attractor-consuming microbes may be mixed with a carrier and applied to the backing, the yarn, and / or the griege or finished product. In one embodiment, the encapsulated soilant-attractor-consuming microbes may be mixed with water or a water-based carrier and sprayed on. In another embodiment, the encapsulated soilant-attractor-consuming microbes may be mixed with a foaming agent and applied in a foam. When there is a liquid-based carrier carrying the encapsulated soilant-attractor-consuming microbes, it may be desirable to evaporate the carrier from the soft surface product. This may be done with an application of heat and / or an application of light configured to evaporate the carrier. When the carrier is a gas, such as but not limited to carbon-dioxide, nitrogen, or air, then the gaseous carrier will normally dissipate leaving the encapsulated soilant-attractor-consuming microbes on the soft surface product. As disclosed herein, the shells of the encapsulated soilant-attractor-consuming microbes may be pre-reacted with a binding agent and / or a bonding agent so that they may be retained on the surfaces of the soft surface product.

[0064] If the encapsulated soilant-attractor-consuming microbes are applied before a latex and / or hot melt adhesive is applied, the treatment of the griege product to cure those may apply sufficient energy to drive off a liquid-based carrier. This will leave the encapsulated soilant-attractor-consuming microbes adhering to the yarns and backing of the carpet, carpet tile, rug, or other soft surface article. An option 131 after making the carpet in Step 130 may be to provide the carpet with an environment conducive to the growth of the soilant-attractor-consuming microbes. This may be by placing the carpet, carpet tiles, rug, or other soft surface article in a chamber where temperature, humidity, and levels and types of light are controlled to provide a suitable environment to, for example, allow a portion of the soilantattractor-consuming microbes to consume at least a portion of the spin finish from the yams and / or filaments.

[0065] Additionally, some amount of unencapsulated soilant-attractor-consuming microbes may be added to the soft surface product in optional Step 132. This will allow for more of the spin finish to be removed prior to installation.

[0066] The carpet, carpet tile, rug, or other soft surface article may be installed in Step 140. If the soft surface article is a carpet or rug, it may be unrolled and stretched. These operations will break open some of the shells of the encapsulated soilant-attractorconsuming microbes, thereby releasing more soilant-attractor-consuming microbes to continue to consume the spin finish. The Step 140 of installing the soft surface article will also likely include an initial vacuuming of the article to remove any fuzz, lint, or unattached segments of yarn. The act of vacuuming, with or without a beater, will move the yarn to an extent that some portion of the shells of the encapsulated soilant-attractor-consuming microbes will be broken thereby releasing more of the soilant-attractor-consuming microbes.

[0067] In one embodiment, the room in which the soft surface article has been installed may be left alone for a period to allow the soilant-attractor-consuming microbes to consume additional amounts of the spin finish. If this can be managed, it may be preferable to create an environment conducive to the growth of the soilant-attractorconsuming microbes. This may be done by setting a temperature, humidity, and light level that will support the growth and functions of the soilant-attractor-consuming microbes. In some embodiments, it may be preferable to apply a mist of water, or highly humid air to the soft surface article to provide free water on and within the soft surface article.

[0068] It may be noted here that it is preferred that all or some portions of the broken shells will become vacuumable while the unbroken shells will remain adhered to the yams and / or the backing of the soft surface article. It may also be noted that some of the soilant-attractor-consuming microbes may be vacuumable when their shells are broken. However, a majority of the soilant-attractor-consuming microbes released from the breaking of the shells will themselves adhere to the yarns and / or the backing of the soft surface articles due to the adhesive nature of the fluid that the soilantattractor-consuming microbes are borne in within the shells. For example, if the bearing fluid is an organic oil, a silicone oil, a fluorocarbon, or a mixture thereof, the soilant-attractor-consuming microbes will retain some of those fluids as they are released which will act as an adhesive to adhere the soilant-attractor-consuming microbes to carpet fibers such as the yams and / or the filaments before the soilantattractor-consuming microbes are swept away by the action of the vacuum.

[0069] Step 150 is the normal life of the carpet, carpet tile, rug, or other soft surface article. During this lifetime, the carpet will be used and cleaned with ordinary cleaning methods. The use of the carpet may include any or all of the following: walking upon the carpet; laying on the carpet; playing games on the carpet; having pets walk upon, lay upon, and play on the carpet; placing objects on the carpet; moving objects placed on the carpet by sliding them across the carpet; rolling objects across the carpet; and otherwise using the carpet in normal household and / or office uses.

[0070] Normal use of the carpet will also likely include unintentional soiling of the carpet. This may happen through spills; accidental transfer of fluids such as by dropping a marker or other writing utensil on the carpet; unwanted defecation and urination on the carpet; transfer of oils found naturally on humans and pets to the carpet by contact; and transferring particulate matter, fluids, and fluid-suspended particulate matter to the carpet from soiled shoes and other objects contacting the carpet.

[0071] Normal cleaning methods may include vacuuming; sweeping with a broom or a carpet sweeper; brushing the carpet; applying soap and water or other detergents in aqueous media, along with scrubbing and then absorbing the water. The last two of that list may be performed with a suction apparatus to forcefully withdraw any remaining liquid water from the soft surface article.

[0072] More aggressive cleaning methods may include steam cleaning; cleaning with harsh chemicals; and cleaning with a caustic wash. These methods may also include the use of an apparatus that forcefully suctions remaining fluids from the soft surface article.

[0073] Some of the shells of the encapsulated soilant-attractor-consuming microbes will break open upon normal use of the carpet as the filaments of the yarn are compressed and / or released from pressure being placed upon the carpet through normal use. When the shells are broken, the soilant-attractor-consuming microbes will be released and will seek out and consume any soilant-attractors.

[0074] As has been disclosed herein, many types of particulate matter may adhere or cling to soilant-attractors and may not be removable through normal cleaning methods. However, once the soilant-attractor-consuming microbes consume the soilantattractors, the particulate matter will not have a site to adhere to. Without a site to adhere to, the particulate matter will be cleanable under normal cleaning methods such as by vacuuming.

[0075] The normal life of the soft surface article may last for many years. The process of having deposits of soilant-attractors adhering particulate matter will normally make a carpet look dingey or dirty. However, continually removing the soilant-attractors will aid in the removal of particulate matter thereby making the carpet cleaner and thereby appearing clean.

[0076] The particulate matter that may be removed through normal cleaning methods will include: broken shells and / or portions of shells; waste metabolites; and particulate matter.

[0077] While some portions of the encapsulated soilant-attractor-consuming microbes will be released over time, an application of sufficient encapsulated soilant-attractorconsuming microbes during Step 130 will allow the soilant-attractor-consuming microbes to act upon the carpet for several years.

[0078] In a preferred embodiment where the life of the soft surface article is desired to be about 10 years, the encapsulated soilant-attractor-consuming microbes will be applied in such a way to last that lifetime. That is to say that the soilant-attractorconsuming microbes may still be active up to and including the tenth year of the life of the soft surface article. In some embodiments, this may be up to 1% of the weight of the face fibers. In a more preferred embodiment, the weight of the encapsulated soilant-attractor-consuming microbes may be applied to a griege product at a weight of 0.50% of the weight of the face fibers. In an even more preferred embodiment, the weight of the encapsulated soilant-attractor-consuming microbes may be applied to a griege product at a weight of 0.10% of the weight of the face fibers. In an even more preferred embodiment, the weight of the encapsulated soilant-attractorconsuming microbes may be applied to a griege product at a weight of between 0.15% and 0.05% of the weight of the face fibers.

[0079] Applicant has tested an encapsulated microbe on a carpet at a weight of 0.09% of the weight of the face fibers where the weight of the face fibers was 45 ounces per square yard (1,526 grams per square meter). The encapsulated microbe adhered to the carpet fibers. Tests were conducted after normal cleaning by using an upright vacuum cleaner with beater. After more than 10 normal cleanings, encapsulated microbes were still found to be adhering to the face fibers and microbes were still active in the carpet.

[0080] Applicant has also found that an application of encapsulated microbes in the range of between 0.15% and 0.05% of the weight of the face fibers provides satisfactory results for carpets having a face weight of between 35 and 60 ounces per square yard (1,187 and 2,034 grams per square meter).

[0081] Adjustments to the ratio of the mass of the friable shell to the mass of the soilantattractor-consuming microbes, including any fluid they may be kept in, may be made based upon the face weight of the fibers. For example, a ratio within a range of between about 1:500 to about 1 :5,000 may be preferred for a soft surface article having a face weight of between 35 and 60 ounces per square yard (1,187 and 2,034 grams per square meter). However, a ratio of between about 1 :500 to about 1 :3,500 may be preferred for a soft surface article having a face weight of below 35 ounces per square yard (1,187 grams per square meter). In a light face weight carpet, normal pressure from a footfall would break open more encapsulated microbes than would be broken open in a heavier weight carpet. Similar adjustments may be made for soft surface articles with heavier face weights. If a more aggressive cleaning method is deployed, such as steam cleaning, a large amount of encapsulated and released soilant-attractor-consuming microbes may be destroyed. In that case, more encapsulated soilant-attractor-consuming microbes may be applied. Some methods of applying more encapsulated soilant-attractor- consuming microbes may include: blowing encapsulated soilant-attractor-consuming microbes onto and into the soft surface article; spraying encapsulated soilantattractor-consuming microbes into the surface of the soft surface article and working them into the yarns by brushing; suspending encapsulated soilant-attractorconsuming microbes into a foamable composition, applying that, and working the foam into the soft surface article; and other methods of applying microcapsules as would be known to those ordinarily skilled in the art.

[0082] The present invention is in no way limited to the herein above-described embodiments. On the contrary many such flexible energy-activated formulations may be devised and applied according to various variations of the inventions disclosed and taught herein, without leaving the scope of the present invention.

Claims

Claims1. A section of a carpet comprising: a yarn comprising a plurality of filaments, wherein at least a first portion of the plurality of filaments is coated with at least one soilant-attractor; and microbes that are encapsulated in friable capsules; wherein the friable capsules are retained on filaments of the yarn and are configured to break open to release the microbes; and wherein at least a portion of the microbes are configured to consume the at least one soilant-attractor.

2. The section of carpet according to claim 1, wherein the at least one soilantattractor comprises a hydrocarbon that supplies a tackiness to the first portion of the plurality of filaments.

3. The section of carpet according to any preceding claim 1-2, further comprising a soilant, wherein the soilant is selected from a group consisting of dust, dirt, small particulate matter, and combinations thereof.

4. The section of carpet according to claim 3, wherein at least a first bevy of the soilant is adhered to the filaments in the first portion of the plurality of filaments by the at least one soilant-attractor.

5. The section of carpet according to claim 4, wherein at least a second bevy of the soilant is not adhered to the filaments of the first portion of the plurality of filaments.

6. The section of carpet according to claim 5, wherein a minority of the first bevy of soilants is removable from the section of carpet by vacuuming, and whereina majority of the second bevy of soilants is removable from the section of carpet by vacuuming.

7. The section of carpet according to claim 6, wherein the minority of the first bevy of soilants is less than 30% of the bevy of soilants.

8. The section of carpet according to claim 6 or 7, wherein the majority of the second bevy of soilants is greater than 65%.

9. The section of carpet according to claim 2, wherein the tackiness of the first portion of the plurality of filaments is reduced when the microbes consume the at least one soilant-attractor.

10. The section of carpet according to claim 2, wherein the at least one soilantattractor is a spin finish applied to the at least first portion of the plurality of filaments during extrusion.

11. The section of carpet according to claim 2, wherein the at least one soilantattractor is a soilant selected from the group consisting of a hydrocarbon from a spilled beverage, an oil transferred from a shoe, an oil from skin or fur, and combinations thereof.

12. A method of making a carpet, comprising: providing an unfinished carpet; wherein the unfinished carpet comprises at least one yarn comprising a plurality of filaments, wherein at least a first portion of the plurality of filaments is coated with a soilant-attractor; providing a plurality of microbes; wherein at least a portion of the plurality of microbes are configured to consume the soilant-attractor;encapsulating the plurality of microbes into a plurality of friable capsules; embedding a first portion of the plurality of capsules into the at least one yarn.

13. The section of carpet according to claim 12, wherein the soilant-attractor comprises a hydrocarbon that supplies a tackiness to the first portion of the plurality of filaments.

14. The section of carpet according to any preceding claim 12-13, further comprising a soilant, wherein the soilant is selected from a group consisting of dust, dirt, small particulate matter, and combinations thereof.

15. The section of carpet according to claim 14, wherein at least a first bevy of the soilant is adhered to the filaments in the first portion of the plurality of filaments by the soilant-attractor.

16. The section of carpet according to claim 15, wherein at least a second bevy of the soilant is not adhered to the filaments of the first portion of the plurality of filaments.

17. The section of carpet according to claim 16, wherein a minority of the first bevy of soilants is removable from the section of carpet by vacuuming, and wherein a majority of the second bevy of soilants is removable from the section of carpet by vacuuming.

18. The section of carpet according to claim 17, wherein the minority of the first bevy of soilants is less than 30% of the bevy of soilants.

19. The section of carpet according to claim 17 or 18, wherein the majority of the second bevy of soilants is greater than 65%.

20. The section of carpet according to claim 13, wherein the tackiness of the first portion of the plurality of filaments is reduced when the microbes consume the soilant-attractor.

21. The section of carpet according to claim 13, wherein the soilant-attractor is a spin finish applied to the at least first portion of the plurality of filaments during extrusion.

22. The section of carpet according to claim 13, wherein the soilant-attractor is a soilant selected from the group consisting of a hydrocarbon from a spilled beverage, an oil transferred from a shoe, an oil from skin or fur, and combinations thereof.

23. A method of cleaning a carpet, comprising: providing a carpet comprising a plurality of microbes; wherein the carpet comprises at least one yarn comprising a plurality of filaments, wherein at least a first portion of the plurality of filaments is coated with a soilant-attractor; wherein at least a portion of the plurality of microbes are configured to consume the soilant-attractor, are encapsulated into a plurality of friable capsules, and are embedded into the at least one yarn; and vacuuming the carpet.

24. The method of cleaning the carpet of claim 23, wherein the step of vacuuming the carpet breaks the friable capsules of a first portion of the plurality of friable capsules.

25. The method of cleaning the carpet of claim 24, wherein breaking the friable capsule releases the encapsulated microbes.

26. The method of cleaning the carpet of claim 25, wherein releasing the encapsulated microbes comprises spreading a portion of the encapsulated microbes that are configured to consume the soilant-attractor onto at least one filament of the first portion of the plurality of filaments coated with a soilant-attractor.

27. The section of carpet according to claim 26, wherein the soilant-attractor comprises a hydrocarbon that supplies a tackiness to the first portion of the plurality of filaments.

28. The section of carpet according to claim 27, further comprising a soilant, wherein the soilant is selected from a group consisting of dust, dirt, small particulate matter, and combinations thereof.

29. The section of carpet according to claim 28, wherein at least a first bevy of the soilant is adhered to the filaments in the first portion of the plurality of filaments by the soilant-attractor.

30. The section of carpet according to claim 29, wherein at least a second bevy of the soilant is not adhered to the filaments of the first portion of the plurality of filaments.

31. The section of carpet according to claim 30, wherein a minority of the first bevy of soilants is removable from the section of carpet by vacuuming, and wherein a majority of the second bevy of soilants is removable from the section of carpet by vacuuming.

32. The section of carpet according to claim 32, wherein the minority of the first bevy of soilants is less than 30% of the bevy of soilants.

33. The section of carpet according to claim 31 or 32, wherein the majority of the second bevy of soilants is greater than 65%.

34. The section of carpet according to claim 27, wherein the tackiness of the first portion of the plurality of filaments is reduced when the microbes consume the soilant-attractor.

35. The section of carpet according to claim 27, wherein the soilant-attractor is a spin finish applied to the at least first portion of the plurality of filaments during extrusion.

36. The section of carpet according to claim 27, wherein the soilant-attractor is a soilant selected from the group consisting of a hydrocarbon from a spilled beverage, an oil transferred from a shoe, an oil from skin or fur, and combinations thereof.

37. A method of making a carpet, comprising: providing an unfinished carpet; wherein the unfinished carpet comprises at least one yarn comprising a plurality of filaments, wherein at least a first portion of the plurality of filaments is coated with a soilant-attractor; providing a plurality of microbes; wherein at least a portion of the plurality of microbes are configured to consume the soilant-attractor; encapsulating the plurality of microbes into a plurality of friable capsules; wherein the friable capsules are coated with a binding agent or a bonding agent configured to adhere to the plurality of filaments; forming a solution containing a carrier and the plurality of binding or bonding-agent coated friable capsules; applying the plurality of binding or bonding-agent coated friable capsules onto the unfinished carpet; and evaporating the carrier from the unfinished carpet.

38. The method of making a carpet according to claim 37, wherein the soilantattractor comprises a hydrocarbon that supplies a tackiness to the first portion of the plurality of filaments.

39. The method of making a carpet according to any preceding claim 37-38, further comprising a soilant, wherein the soilant is selected from a group consisting of dust, dirt, small particulate matter, and combinations thereof.

40. The method of making a carpet according to claim 39, wherein at least a first bevy of the soilant is adhered to the filaments in the first portion of the plurality of filaments by the soilant-attractor.

41. The method of making a carpet according to claim 40, wherein at least a second bevy of the soilant is not adhered to the filaments of the first portion of the plurality of filaments.

42. The method of making a carpet according to claim 41, wherein a minority of the first bevy of soilants is removable from the section of carpet by vacuuming, and wherein a majority of the second bevy of soilants is removable from the section of carpet by vacuuming.

43. The method of making a carpet according to claim 42, wherein the minority of the first bevy of soilants is less than 30% of the bevy of soilants.

44. The method of making a carpet according to claim 42 or 43, wherein the majority of the second bevy of soilants is greater than 65%.

45. The method of making a carpet according to claim 38, wherein the tackiness of the first portion of the plurality of filaments is reduced when the microbes consume the soilant-attractor.

146. The method of making a carpet according to claim 38, wherein the soilantattractor is a spin finish applied to the at least first portion of the plurality of filaments during extrusion.

47. The method of making a carpet according to claim 38, wherein the soilantattractor is a soilant selected from the group consisting of a hydrocarbon from a spilled beverage, an oil transferred from a shoe, an oil from skin or fur, and combinations thereof.

48. The section of carpet of any preceding claim 1-11, the method of making a carpet of any preceding claim 12-22 and 37-47, and the method of cleaning a carpet of any preceding claim 23-36, wherein the microbes are encapsulated in friable capsules such that their weight within the carpet is less than 1.00% of the face weight of the fibers on the carpet.

49. The section of carpet of any preceding claim 1-11, the method of making a carpet of any preceding claim 12-22 and 37-47, and the method of cleaning a carpet of any preceding claim 23-36, wherein the microbes are encapsulated in friable capsules such that their weight within the carpet is less than 0.50% of the face weight of the fibers on the carpet.

50. The section of carpet of any preceding claim 1-11, the method of making a carpet of any preceding claim 12-22 and 37-47, and the method of cleaning a carpet of any preceding claim 23-36, wherein the microbes are encapsulated in friable capsules such that their weight within the carpet is between 0.15% and 0.05% of the face weight of the fibers on the carpet.

51. The carpet of any preceding claim 48-50, wherein, the capsules have a ratio of a mass of a friable shell to a mass of a soilant-attractor-consuming microbes, including any fluid they may be kept in, within a range of between about 1 : 100 to about 1 : 15,000.

52. The carpet of any preceding claim 48-50, wherein, the capsules have a ratio of a mass of a friable shell to a mass of a soilant-attractor-consuming microbes, including any fluid they may be kept in, within a range of between about 1 :500 to about 1 :5,000.

53. The carpet of any preceding claim 51-52, wherein the capsules have diameters from about 2pm to about 50pm.

54. The carpet of any preceding claim 52-53, wherein the capsules are pretreated with a binding agent and / or a bonding agent.

55. The carpet of claim 54, wherein the binding agent and / or bonding agent is configured to adhere to a soilant-attractor.

56. The carpet of claim 55, wherein the soilant-attractor is a spin finish.

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