WO2026009080A1 - Soft surface articles having a hydrophobic coating and methods to make them - Google Patents

Abstract

The present invention relates to a soft surface article, such as a carpet, a carpet tile, a rug, or a mat, that has a hydrophobic coating applied to the wear layer of the soft surface article. The soft surface article disclosed herein exhibits superior properties of anti-soiling, soil release, and cleaning.

Description

Soft surface articles having a hydrophobic coating and methods to make them

The present invention relates to a soft surface article, such as a carpet, a carpet tile, a rug, or a mat, that has a hydrophobic coating applied to the wear layer of the soft surface article.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority of U.S. Patent Application 63/666,269, filed on July 1, 2024, the contents of which are hereby incorporated by reference for all purposes.

BACKGROUND

Within the textile industry that produces soft surface articles, and particularly the carpet industry, consumers increasingly demand soft surface articles that have more robust characteristics and properties. Generally, carpets (as an exemplary, but nonlimiting soft surface article) are produced by tufting a plurality of fibers into the primary backing, or by weaving a plurality of fibers, and such forming a wear layer of the carpet.

Carpets are one of the most popular products used both in commercial and residential constructions. Carpets are often subjected to heavy foot traffic along with spills of various liquids and require frequent cleaning to ensure a healthy and hygienic environment. However, heavy foot traffic, spills, and frequent cleaning can affect the quality of the face fiber and the general appearance of the carpet.

Since carpets are usually long-term capital investments, carpets need to possess various important properties, including high wear and abrasion resistance. However, it is also important to produce such high wear and abrasion-resistant carpets without increasing the cost or environmental impact and without affecting the esthetic appearance of the carpet. Thus, there is a clear need for novel flooring products that can withstand high foot traffic, spills, frequent and harsh cleaning and still provide cradle-to-cradle or cradle- to-grave environmentally conscious solutions. Still further, there is a need for methods of manufacturing such products. These needs and other needs are at least partially satisfied by the present disclosure.

Some background publications include the following:

U.S. Patent Application Serial Nos. 18/304,476 and 18/304,487 disclose: “Soft surface articles may be treated during manufacture with treatment articles loaded with treatment chemicals while drying the soft surface articles. This eliminates a step of adding the treatment chemicals to a water bath containing the treatment chemicals. Eliminating this step reduces the amount of water used in the manufacture of the soft surface articles and also removes the requirement of having to process a vat of waste water.

WIPO Publication WO 2023/089436 Al discloses: “The present disclosure provides for a flooring product comprising a primary backing having a face side and a back side; a plurality of fibers tufted into the primary backing and extending from the face side to form a face fiber having a predetermined length, and a layer of a polyester- based material disposed at at least a portion of the face fiber, where the layer of the polyester-based material can at least partially encapsulate at least some of the plurality of fibers.”

The article “Less Is More In Applying Chemicals to Textiles” published in Textile World, March 1994, discloses: “New systems were especially developed to minimize wet pickup (WPU) of fabrics and carpets in chemical applicators of continuous lines.”

The publication “Molecular Simulation Study on the Wettability of a Surface Texturized with Hierarchical Pillars” in Molecules (https://doi.org/10.3390/molecules28114513) discloses: “By using molecular dynamics simulation, we investigate the wettability of a surface texturized with a periodic array of hierarchical pillars. By varying the height and spacing of the minor pillars on top of major pillars, we investigate the wetting transition from the Cassie- Baxter (CB) to Wenzel (WZ) states. We uncover the molecular structures and free energies of the transition and meta-stable states existing between the CB and WZ states. The relatively tall and dense minor pillars greatly enhance the hydrophobicity of a pillared surface, in that, the CB-to-WZ transition requires an increased activation energy and the contact angle of a water droplet on such a surface is significantly larger.”

WIPO Publication WO 2023/170577 Al discloses: “The use of a hydrophobic polymer, being for example a hydrophobic polyurethane or a hydrophobic acrylate polymer, for producing a coating (23) or treatment on one or more surfaces of decorative panels (1), wherein the hydrophobic polymer comprises an aliphatic hydrocarbon group, preferably with between 6 and 34 carbon atoms, method for the manufacture of decorative panels (1), decorative panels (1) and mixture.”

The foregoing publications are incorporated herein by reference for all purposes.

BRIEF SUMMARY

Applicant has created soft surface articles, such as carpets, carpet tiles, rugs, mats, and other textile articles, that have hydrophobic properties. That is to say that soft surface articles as disclosed and taught herein may repel water-based fluids and therefore have anti-soiling properties. Soft surface articles having this anti-soiling property will require less cleaning and will wear longer without showing as much soiling and wear than equivalent soft surface articles that do not have these antisoiling properties.

Applicant has also devised ways to apply hydrophobic coatings, also known as finishes, to the wear layer of soft surface articles.

In some embodiments, hydrophobic coatings may be applied to soft surface articles by flooding or foaming a solution containing a hydrophobic treatment chemical onto the soft surface articles while they are being made. In some embodiments, the solution may have a carrier that may need to be removed. In some embodiments, the carrier may be aqueous. In other embodiments, hydrophobic coatings may be applied to soft surface articles by spraying a solution containing a hydrophobic treatment chemical onto the soft surface articles while they are being made. In some of these embodiments, the solution may have a carrier that may need to be removed.

In the application of hydrophobic treatment chemicals, it is desirable to apply as little as possible to achieve desired results. Applying the least amount possible saves in the cost of obtaining the chemical, which thusly reduces the total cost to produce the soft surface article. Applying the least amount of a hydrophobic treatment chemical will still ensure that the soft surface article will still meet the expectations for resistance to soiling.

Articles made with a hydrophobic coating as disclosed and taught herein resist wear to a higher degree than soft surface articles that are equivalently made without hydrophobic coatings. In one way, this is because staining materials cannot adhere to the wear layer of soft surface articles. In this, any aqueous carrier for the stains and/or soilants is repelled by the wear layer and are easily removed.

One of several methods to measure the ability of fabrics to release oily stains during home laundering is described in the AATCC 130-2015 method using synthetic blood, simulated urine, coke, whole milk, black coffee, and grape juice. Since each of these has aqueous carriers, each will be repelled and not permitted below the wear layer to stain the fibers or backing in the soft surface article. Other methods may be used to test the adherence and removability of non-aqueous soilants.

In a first independent aspect, the invention relates to a soft surface article comprising: a wear surface secured to a backing, wherein the wear surface comprises a visible surface and a hydrophobic coating.

In a second independent aspect, the invention relates to a soft surface article comprising: a backing and a pile, wherein the soft surface article comprises a hydrophobic coating.

In a third aspect, the invention relates to a method of a method of making the soft surface article of the first or second aspect comprising: providing an unfinished product comprising woven fibers or tufts of fibers, wherein the woven fibers or tufts of fibers present an upper wear surface; applying a hydrophobic composition to at least the upper wear surface.

In a fourth aspect, the invention relates to a method for determining an amount of hydrophobic composition to be applied to a soft surface article, comprising: defining a pile configuration for the soft surface article; creating a first and a second griege product comprising a pile defined from the pile configuration; applying a hydrophobic composition to the pile of the first griege product at a first rate, and applying the hydrophobic composition to the pile of the second griege product at a second rate; cutting the first and second griege product into a plurality of test samples; placing at least a portion of the test samples from the first and second griege products in a water bath with the pile of all test samples facing a surface of the water bath for a time period; performing a statistical analysis on a number of test samples that float at the end of the time period; using a result of the statistical analysis to determine the amount of hydrophobic substance to be applied to the soft surface article.

If the degree of limits is not otherwise defined or ascertainable by a person of ordinary skill in the art, as used herein, the term “about” will represent the value with a margin of plus or minus five percent. For example, a length of about 1 inch (about 2.54 centimeters) may be interpreted to mean that the length may be between 1 inch less five percent of the one inch and 1 inch plus five percent of the one inch (between 2.54 centimeters less five percent of the 2.54 centimeters and 2.54 centimeters plus five percent of the 2.54 centimeters).

BRIEF DESCRIPTION OF THE DRAWINGS

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

Figure 1 illustrates a loop pile carpet.

Figure 1A illustrates a top portion of the loop pile carpet illustrated in Figure 1.

Figure 2 illustrates a shag carpet.

Figure 3 illustrates a multi-level loop carpet. Descriptions of these inventions will be defined in the appended independent claims, while preferred embodiments are defined in the dependent claims.

DETAILED DESCRIPTION

Applicant has created soft surface articles with hydrophobic coatings using minimal amounts of hydrophobic coating chemicals. Carpets, as a nonlimiting example of soft surface articles, having hydrophobic coatings repel the carriers of many soilants thus prevent the soilants from contacting the fibers that may otherwise be stained or soiled by the soilants.

The AATCC 130-2015 method of testing for soil release includes applying synthetic blood, simulated urine, coke, whole milk, black coffee, and grape juice as a soilant. Each of these has an aqueous carrier, which is repelled by the hydrophobic coating, thereby rendering the carpet to be anti-soiling.

Applicant has found other methods for testing the adherence of non-aqueous-based soilants that will be described herein.

When each of the soilants contacts a carpet having a hydrophobic coating as disclosed and taught herein, the aqueous carrier is repelled by the hydrophobic coating. Similarly, non-aqueous soilants do not readily adhere to the carpet. Those that do may be easily removed by ordinary cleaning processes.

In any embodiment, the wear layer of a carpet may be made with synthetic or natural fibers. That is to say that the fibers may be made of polyolefins, polyamides, polyesters, wool, cotton, flax, jute, other natural fibers, and combinations of any or all of these. The wear layer will have these fibers, usually in the form of yarns comprised of many fibers texturized and drawn together, exposed at the top of the carpet. These yarns may be exposed as a loop pile, a cut pile, a shag pile, a Saxony pile, a Berber pile, a Frieze pile, a twist pile, a tip sheared pile, a velvet or plush pile, or woven piles such as Axminster and Wilton. Each of these may present some portion of the yams upwards while other portions may not be visible to someone walking across them. For example, a shag pile may have some pile yams laying across other pile yarns such that the sides of some of the pile yams will be visible. On the other hand, a tight loop pile will present the tops of arcs of rows of pile yam. The sides of the yams will not be visible without pushing apart some of the loops. Similarly, a cut pile may present only ends of yam filaments at the surface of the carpet while the yarn ends below the surface are not visible without pushing apart some of the tufts.

In any style of pile, an upwards facing and visible surface will be presented, while some portion of the pile will be under the upwards facing surface such that it will not readily be visible. This may be illustrated in exemplary Figures 1-3.

Figure 1 illustrates a loop pile carpet 100 having a backing 110 and a plurality of loops 120. The loops 120 are spaced apart for clarity, but may be spaced closer together in actual embodiments. The loops 120 present an upper portion 130, which is visible to an observer looking at the loop pile carpet 100 from above. The loops 120 also have a lower portion 140 that is below the upper portion 130 that cannot normally be seen by an observer walking across the loop pile carpet 100.

Figure 2 illustrates similar structures in light of a shag carpet 200. In this, the ends 220 will have an upper surface 230 and a lower portion 240 that will not be observable while the ends 220 lay upon the backing 210 and each other. From that, when measuring a depth of the pile for a shag carpet or similar, the tufts 220 should be at their full extension, such as if the carpet were upside down and the tufts 220 falling away from the backing 210.

Figure 3 illustrates a similar structure in light of a multi-level loop carpet 300.

Figure 1A illustrates the upper portion 130 of a single loop 121 from Figure 1. In this, the ends of the yarn are seen as tight bundles 122 with some loose filaments 124 being distinct from the tight bundles 122 for portions of the single loop 121. This may be at locations where the yarn or the ends were not tacked together during texturizing so that they present more bulk.

The upward facing and visible surface will present a surface that may be described as having major bundles and multiple minor fibers associated with the major bundles. In the illustrative Figure 1A, the major bundles of the single loop 121 are the tight bundles 122 while the minor fibers are the loose filaments 124. In a preferred embodiment, a hydrophobic chemical may be mixed with a carrier, such as water as a nonlimiting example, along with any other treatment chemicals as long as they do not react together in any way that would be adverse to coating the yams of a soft surface article. That is to say that a hydrophobic treatment chemical must not reduce the effectiveness or desired properties of any other treatment chemical to be applied, and must not negatively impact any of the characteristics of the soft surface article.

In some embodiments, hydrophobic chemicals may be applied to soft surface articles by flooding or foaming a solution containing a hydrophobic treatment chemical onto the soft surface articles while they are being made. One way of doing this is with a chemical applicator, such as a Fluicon applicator made by Zima Corporation.

In other embodiments, hydrophobic coatings may be applied to soft surface articles by spraying a solution containing a hydrophobic treatment chemical onto the soft surface articles while they are being made. This may be performed in a coater.

In the embodiments of flooding, foaming, and spraying, the solution may contain other treatment chemicals that are to topically remain on the yam such as soilant resistors and protectors against harmful light such as ultraviolet light.

Also, with the embodiments of flooding, foaming, and spraying, a surfactant may be added to the solution to ensure that the solution is evenly distributed within the ends of the pile. That is to say that in some embodiments, it may be desirable for the hydrophobic treatment chemical to penetrate into the ends of the pile to contact each of the filaments in each end. To achieve this, a hydrophobic composition may comprise a carrier liquid, one or more hydrophobic agents, and potentially an adhering agent. An adhering agent may keep the hydrophobic agent adhered to the yarn or filaments after the carrier has been removed.

In some embodiments, the carrier, such as a solvent, for the hydrophobic coating should not change the characteristics of the carpet, carpet tile, rug, mat, or other soft surface. In this way, the product without the hydrophobic coating will have the same look and feel of a product having the hydrophobic coating. This is important in many cases so that the product that is ordered by a consumer will be the product that is delivered to that consumer. In other embodiments, if the characteristics of the carrier and/or other applied topicals will change the properties of the finished product in a very known and predictable way, they may be used so that when a consumer orders a product, a product having that look and feel (along with all other properties of the carpet) will be delivered. In this, an intermediate product may be different from a desired final product, but the addition of a hydrophobic coating along with other components, such as topicals, may be applied to the intermediate product in known ways and proportions to produce a final product having the desired properties, such as, but not limited to look and feel.

A hydrophobic composition containing a hydrophobic coating may be water-based, solvent based, or oil-based, or may be a combination of any or all of these. The hydrophobic coating may be radiation and/or heat curable. The water, solvent, and/or oil may function as a carrier liquid for one or more hydrophobic agents.

In some embodiments, non-aqueous solvents may include, but are not limited to: butylacetate, propyl acetate, such as 3-Mathoxy-3-Methyl-l-Butylacetate (MMB- AC) or 1-Mathoxy -Propyl acetate (MPA); a dibasic ester; a glycol di ether, such as dipropylene glycol dimethyl ether; a benzoate ester; a diphenylmethane or diphenylethane, such as butyl diphenyl methane and/or butyl diphenyl ethane; acetone; or a tetramathoxy ether. Preferably, the solvent has a flash point above 30°C, and even better of 60°C or above. In some embodiments, it may be preferable to use a hydrophobic solvent, such as propyl acetate, diphenylmethane or diphenylethane.

In some embodiments, a non-aqueous solvent may be made of an alkane, preferably with 10 to 20 carbon atoms, or of an alcohol with 1 to 6 carbon atoms, or of an ester such as acetate from an alcohol with 1 to 10 carbon atoms.

In some embodiments, an oil-based solvent may be used, such as but without limitation: turpentine; linseed oil; castor oil; soy oil; or other protein-based liquids. Alternatively, other solvents that exhibit hydrophobic properties and have a high flash point may be used.

When using non-aqueous carriers, some care must be taken on methods to remove the carrier entirely, or to such an extent that its presence is imperceptible to a consumer and/or to tests, such as tests for residual volatile organic compounds. Such residual carriers may be undesirable in a finished product. The hydrophobic composition may comprise a polymerizable substance, for example one or more monomers for forming a polymer or copolymer. For example, the polymerizable substance may comprise monomers for forming PET (polyethylene terephthalate), for example terephthalic acid and ethylene glycol. The polymerizable substance may function as adhering agent when polymerized. In this, the polymerizable substance may interact with the fibers of the pile to adhere themselves along with the hydrophobic coating to the pile.

The hydrophobic coating may comprise polymeric particles, for example particles of a polyester (such as PET and/or CoPET), a polyolefin (such as PP), or a polyamide (such as nylon). The polymeric particles may function as an adhering agent when applied. In applying these particles, the particles may be partially molten or in a suspension such as in a latex to become adhered to the yarn or filaments such that they also adhere all other hydrophobic coatings and any other desirable topicals.

The hydrophobic coating may comprise a resin that adheres to the yarn or filaments. Examples of such resins include, but are not limited to: an alkyd resin; a polyester resin; an MDI resin; a polyurethane resin; an acrylic resin; a polyurethane modified polyester resin; silanes; siloxanes; or mixtures thereof. The resin or resin composition may be heat settable, settable by drying or radiation curable. In the case of a radiation curable resin, use can for example be made of a UV curing polyurethane dispersion resin, or a UV curing acrylic or polyester resin.

The hydrophobic coating may comprise a fluorocopolymer as a hydrophobic agent. In some embodiments where a fluorocopolymer may adversely affect the look, feel, or other properties of the soft surface article, the hydrophobic coating may be fluorine free. For example, the hydrophobic coating may be any of the mixtures disclosed in WIPO publications WO 2023/170577 and WO 2023/170578, which are incorporated herein by reference in their entireties.

In some embodiments, the hydrophobic coating may be a mixture comprising a hydrophobic polymer, being for example: a hydrophobic polycarbodiimide; a hydrophobic polyurethane; or a hydrophobic acrylate polymer, wherein the hydrophobic polymer comprises an aliphatic hydrocarbon group preferably with 6 to 34 carbon atoms. Further the hydrophobic coating may comprise wax, for example and without limitation: a paraffin wax; a polyethylene wax; or a polypropylene wax.

Further the hydrophobic composition may comprise additives such as surface-active agents, coalescing agents, frost resisting agents, emulsifying agents, surfactants, or stabilizing agents. Examples of suitable additives can be found in US Patent No. 11,124,918 which is incorporated herein by reference in its entirety.

In some of these embodiments, the hydrophobic composition may have an aqueous or non-aqueous carrier that may need to be removed. In one embodiment, this may be done by having the soft surface article transported through an oven. In a preferred embodiment where a latex backing is applied to the unfinished product and needs to be cured, advancing the soft surface article through an oven may cure the latex and drive off the aqueous carrier of the treatment chemicals at the same time.

As noted herein, in some embodiments, it may be preferable to use as little of the hydrophobic coating as possible. In this, it may be preferable to only have the hydrophobic coating applied to a portion of the tuft, such as the tops of the tufts. This may provide sufficient coverage to repel soilants without the need to apply the hydrophobic coating to the entirety of the tufts, which may be more costly and may not provide any increase in anti-soiling and/or soil release properties. That is to say that having a hydrophobic coating applied to the visible surface of a carpet may repel water-based soilants, and not permit dry soilants to adhere such that they do not permeate carpet fibers to stain the carpet or its tufts. These may then be removed through ordinary cleaning methods.

As a nonlimiting example, other treatment chemicals, such as softeners; waxes; soilrelease agents; antimicrobial agents; fire retardants; odor eliminators; perfumes or other fragrances; anti-static agents; color fastness agents; lightfastness agents; UV absorbers; optical brighteners; leveling agents; and essential oils may be applied through foaming and/or flooding. In some embodiments, it may be desirable for these to fully permeate the fibers in the tufts or weave to provide full efficacy throughout the wear surface. Applying these through flooding or foaming will ensure their distribution throughout the pile or weave above the backing and may also permeate into the backing to some extent. While this may be preferable for other treatment chemicals, this may not be preferred in all embodiments of applying a hydrophobic coating where the efficacy is only needed at the top of the wear surface.

In some embodiments, it may be preferable to flood or foam those other treatment chemicals onto the carpet first, then apply the hydrophobic coating such that it is only, or primarily, retained on the top of the wear surface. In this, the hydrophobic coating will not be distributed deeper into the pile toward the backing. In a preferred embodiment, the hydrophobic coating will not be detectable in the backing.

One way of applying a hydrophobic coating such that it does not disperse into the pile is by spraying. This will apply the hydrophobic coating onto the top of the wear surface. One technique for applying a hydrophobic coating with this distribution is to spray it onto the top of the wear surface in solution and then drive off the solvent such that the hydrophobic coating remains and is concentrated at and near the top of the wear surface.

In this way, any soilant within an aqueous carrier will be repelled at the top of the wear surface such that it may be removed before the soilant can contact and interact with the fibers of the carpet. Similarly, any soilant will not be able to adhere and will be removable through ordinary cleaning means such as vacuuming and/or washing.

In one process of creating a tufted carpet, a primary backing is tufted such that the wear layer is facing downwards, and the back of the primary backing is facing upwards. Any secondary backings are then applied from above such that they contact the back of the primary backing with gravity aiding in the application. At this stage, it may be optimal to apply other treatment chemicals that are desired to permeate the fibers of the wear surface and perhaps even contact the backing or backings. This may be done through flooding or foaming as disclosed herein. This step may include partially removing any solvent used to carry the treatment chemicals. This may be done by squeezing the griege product through rollers, or by any other means known to those skilled in the art.

In a usual embodiment of creating a finished product, a latex, hot melt adhesive, or other backing may be applied at this point by adding those from above the carpet. This includes not only tufted products, but also woven products and all other soft surface articles. The product is then progressed through an oven that may be used to remove any remaining solvent, such as water, from the upper layers of the product, and to cure the latex if a latex backing had been added. If another type of backing had been added, the heat from the oven may be used to activate an adhesive or to anneal a layer.

However, in Applicant’s revised process, after the other treatment chemicals have been added and either before or while any additional backings are being applied, the hydrophobic coating may be applied by spraying, surface flooding, surface foaming, or any other technique that may apply a topical to the top of the wear surface. After that, the product may be advanced through an oven to accomplish the operations previously mentioned. This may be done while the unfinished carpet is still oriented with the wear surface facing downwards.

One way of applying the hydrophobic coating may be to spray it on from underneath. A spray aimed upwards will allow the hydrophobic coating in its carrier to reach the top of the wear surface. This spray should be propelled with sufficient force to reach the wear surface without penetrating between the tufts or weave to reach deeper into the tufts or weave. In this orientation, gravity will aid in keeping the hydrophobic composition in the portion of the tufts near the wear surface and not allow it to drain towards the backing. However, some wicking will aid in distributing the composition throughout each tuft and towards the backing to achieve a desirable distribution.

In a preferred embodiment the spray will apply a desired amount of hydrophobic coating to the top of the pile and will stay there without any of the carrier containing the hydrophobic coating dripping off. This will be dependent upon the concentration of the hydrophobic coating in the carrier. Applying a hydrophobic coating only to the tops of the pile may be illustrated with reference to Figures 1 and 1 A. In this, a spray of a hydrophobic composition may contact the upper portion 130 of the pile. This may be absorbed into the yarn and distributed therethrough within that portion of the tuft.

In this, it may be preferable to have the hydrophobic coating dispersed irregularly within the pile depth. For example, if the pile is measured from the top of the backing 110 to a level top of the tufts 120, then it may be preferable to have at least a majority of the hydrophobic coating within an upper portion of each tuft. For example, within the upper half of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%. As another example, within the upper 40% of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%. As another example, within the upper 30% of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%. As another example, within the upper 20% of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%. As another example, within the upper 10% of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%.

This may also be applied to other types of piles. In an illustrative and nonlimiting example, a shag pile, such as is illustrated in Figure 2, may be treated with the same proportions in the same manner as disclosed herein. In this, if an upper portion 230 of tuft 220 were to have a majority of hydrophobic coating adhering to the tufts 220, then, when the carpet is installed, the tufts 220 will lay atop each other such that the coated portion of each tuft is laying over the lower portions. Any soilant contacting the face of the carpet 200 would then only come in contact with the portions of the tufts that have been coated with a hydrophobic coating.

This is also similar to other types of piles that have irregularly shaped tufts, such as is exemplarily illustrated by a multi-level loop pile of Figure 3. In this, a level surface may be seen as going across the tops of the highest tufts as a plane that is parallel with the backing 310. While the visible surface may appear to be irregular, the portion that may contain a majority of the hydrophobic coating may still be seen as the portions of the tufts 320 that are above a distance from the backing 310. That is, again, there is an upper portion 330 of the tufts 320 of carpet 300, and a lower portion 340 that is below the upper portion 330. Another method of applying a hydrophobic coating to only the upper portion of a wear surface may be to dredge the carpet through a shallow bath of the hydrophobic coating in solution. The depth of the hydrophobic coating solution may be configured so that only the top of the wear surface is contacted by the solution. This is to say that while the carpet pile is still downward facing, the product may be dragged through a bath or shallow pool of the hydrophobic coating solution. In this way, the hydrophobic coating will disperse upwards, towards the backing and against gravity such as by wicking, such that a desired amount is retained on the upper portion of the wear surface. As may be envisioned and understood by those of ordinary skill in the art and in possession of this disclosure and its teachings, the upper portions 130, 230, 340 of the carpets 100, 200, 300 will then be contacted by the hydrophobic composition.

For example, if the pile is measured from the top of the backing 110, 210, 310 to level top of the tufts 120, 220, 320, then it may be preferable to have at least a majority of the hydrophobic coating within an upper portion of each tuft 120, 220, 320. For example, within the upper half of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%. As another example, within the upper 40% of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%. As another example, within the upper 30% of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%. As another example, within the upper 20% of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%. As another example, within the upper 10% of the pile depth, it may be preferable to have the hydrophobic coating in an amount of at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or 100%.

This may also be expressed as a percentage of the hydrophobic coating applied to pile overall as expressed by viewing the height of the tufts in the pile. In some embodiments, >60%, >70%, >80%, >85%, >90%, >91%, >92%, >93%, >94%, >95%, >96%, >97%, >98%, >99%, >99.5%, >99.9%, or 100% of the hydrophobic coating is within the top half of the tufts in the pile. In some embodiments, >50%, >60%, >70%, >80%, >85%, >90%, >91%, >92%, >93%, >94%, >95%, >96%, >97%, >98%, >99%, >99.5%, >99.9%, or 100% of the hydrophobic coating is within the top quarter of the tufts in the pile. In some embodiments, >50%, >60%, >70%, >80%, >85%, >90%, >91%, >92%, >93%, >94%, >95%, >96%, >97%, >98%, >99%, >99.5%, >99.9%, or 100% of the hydrophobic coating is within the top quartile of the tufts in the pile. In some embodiments, >50%, >60%, >70%, >80%, >85%, >90%, >91%, >92%, >93%, >94%, >95%, >96%, >97%, >98%, >99%, >99.5%, >99.9%, or 100% of the hydrophobic coating is within the top quintile of the tufts in the pile. In some embodiments, >50%, >60%, >70%, >80%, >85%, >90%, >91%, >92%, >93%, >94%, >95%, >96%, >97%, >98%, >99%, >99.5%, >99.9%, or 100% of the hydrophobic coating is within the top decile of the tufts in the pile.

On either of the methods of applying the hydrophobic coating, or any other method that may be envisioned to accomplish this, some additives may be useful in the hydrophobic coating solution. For example, a surfactant or other dispersing agent may be useful in dispersing the solution to a desired depth. This may be needed for dense piles where the composition may not otherwise penetrate to a desired level of the wear surface. Another example may be that of gelling agents so that once the hydrophobic coating composition has been applied, it will not spread far and will not drip away from the wear surface while the carrier is being removed.

Then, after the hydrophobic coating has been applied such that it will be retained only in the upper portions of the wear surface, the product may be advanced through an oven to drive off any carrier, which in some embodiments may be water.

Applicant has found that carpets with different types of pile may require different amounts of hydrophobic coatings to effectively reduce soiling and the adherence of soilants. For example, a densely tufted level loop pile treated with a hydrophobic coating may bead water with a contact angle greater than 90° as is usually descriptive of a hydrophobic material, or greater than 150° for a superhydrophobic material as may be described using Young’s equation of superhydrophobicity. Saxony and velour carpet piles may be similar. However, a treated shag or a multilevel loop pile may be hydrophobic but not exhibit those contact angles when a drop of water is placed upon its surface. In some embodiments, a wear surface of a carpet may exhibit a surface more alike to a Wenzel state or a Cassie-Baxter state, or even a hybrid between those states.

Ideally, the contact between a soilant within an aqueous carrier and a carpet wear surface should be non-wetting. Applying sufficient hydrophobic coating to obtain a non-wettable carpet pile surface has been difficult to determine before now. Applicant has devised a method to determine if sufficient hydrophobic coating has been applied without relying upon a contact angle.

A test section of a griege product may be created. For a tufted product a lightweight primary backing may be used, while a woven product may be formed without any backing or coatings. For the most accurate results, the test section should be prepared similarly to the desired product. That is to say that for a carpet with a desired pile, the fibers should be formed that way on the test section. As a nonlimiting example, if the carpet being developed is a shag carpet, then the test section should be tufted with yam, and the yarn cut in such a way that would be done with the desired shag carpet.

The hydrophobic coating is then applied in any way that may be envisioned by those skilled in the art. The application of the hydrophobic coating includes setting, curing, or otherwise finalizing, such that any carrier used to apply the hydrophobic coating has been removed, and the hydrophobic coating adheres to the fibers of the griege product.

The test section may then be cut into squares or rectangles. The exact dimensions are not critical; Applicant has found that pieces cut into 1-inch by 1-inch (2.54cm by 2.54cm) squares and 2-inch by 2-inch (5.08cm by 5.08cm) squares perform as expected for this test.

The treated pieces are then gently lowered to lay atop a surface of water and observed after a period of fifteen minutes. In this, the pieces are laid pile downwards on the water such that the treated portion of the pile is in contact with the water.

If a statistically significant number of the test pieces remain floating after the fifteen- minute period, then the application of a hydrophobic coating for that type of pile may be deemed to be sufficient. If a statistically significant number of the test pieces have sunk at the end of the fifteen-minute period, then the application of a hydrophobic coating for that type of pile may be deemed to be insufficient.

Without wishing to be bound to any theory, this test may be viewed as similar to evaluating if the treated carpet may overcome a surface tension of the water since the weight of the test piece in conjunction with the area of the test piece may be seen as similar to a pressure upon the surface of the water. However, the hydrophobic coating applied may trap air within the tight bundles 122 and possibly around the loose filaments 124 as illustrated in Figure 1 A. As may be envisioned by those of skill in the art, the entrapment of air bubbles within the tight bundles and/or around loose filaments will add to the buoyancy of the test pieces. An application of a hydrophobic coating where a test piece passes this test may be seen as an indication that the produced carpet with the same application will produce a carpet that has superior soilant resistance characteristics.

Applicant tested griege products that had passed and failed the float test for soilant adherence and release. In this, sections of 6-inch by 8-inch (16.24cm by 20.32cm) or 8-inch by 12-inch (20.32cm by 32.48cm) test strips and were tumbled with residential soilant beads for 900 rotations. The residential soilant beads are nylon beads that have a coating of simulated soil, such as is made by 3M. In these tests, around 260 grams of loaded soilant beads are added to the tumbler along with six test strips.

A panel of people then observed each test strip and assigned it a value of between 1 and 5, where: 1 = severe change; 2 = considerable change; 3 = moderate change; 4 = slight change; and 5 = no change or negligible change. After this rating, the samples were vacuumed and again rated. After that rating, the samples were rinsed with water, vacuumed, allowed to dry and again rated.

In each of these tests, the samples that had passed the float test, and were considered to be effectively coated with a hydrophobic coating, displayed superior anti-soiling properties and superior soilant release properties. Conversely, those that failed the float test displayed poor anti-soiling properties and poor soilant release properties and were thus deemed to be not effectively coated with a hydrophobic coating. As may be envisioned by those of ordinary skill in the art and in possession of this disclosure and its teachings, a series of tests may be efficiently and effectively run to determine an amount of a hydrophobic coating that should be applied to a carpet. This amount is usually described in terms of ounces (or grams) of a treatment chemical, which in this case would be the hydrophobic coating, applied per square yard (or square meter) of the carpet.

When a preferred amount of hydrophobic coating (such as in ounces per square yard or grams per square meter) is determined, it will need to be placed within a carrier so that it may be applied. Those of ordinary skill in the art will know how to determine an amount of hydrophobic material to be put in a hydrophobic composition such that the hydrophobic composition may be applied to a carpet as it is progressing through the manufacturing process so that a desired amount of the hydrophobic coating remains on the finished carpet.

Applicant has found that this methodology may be consistently applied to a plethora of diverse carpet types with consistent results. As nonlimiting examples, griege products with low pile weights, such as those that have a relatively distant stitch rate (a product having a relatively low face weight) will require relatively more hydrophobic coating to reach desirable anti-soilant and soil release characteristics. On the other hand, griege products that have relatively high pile weights, such as those that have a relatively close stitch rate (products having a relatively higher face weight) will require less hydrophobic coating to reach the same characteristics. In this, products with a higher pile density (tufts per square yard or square meter, or weave pattern) will present a face to the surface of the water in the float test that will not allow water to reach any untreated portions of yam in the pile nor the backing. However, less dense piles, where the tufts are spaced further apart, may let the water seep in between tufts so that they fail the float test. For the latter additional hydrophobic coating may be required for the product to pass the float test.

All this is to say that this test methodology may be applied to very different types of carpets, carpet tiles, mgs, mats, and other soft surface articles with repeatable results. For example, this test methodology may be used to determine an amount of hydrophobic coating that will be effective in preventing soiling and in aiding soilant release in a carpet that has a polyamide yam tufted in a tight level loop pattern. The results from this test may be different from a carpet having the same tuft pattern but using a polyolefin yam. In a similar way, an effective amount of hydrophobic coating that will need to be applied to a carpet made with a woven polyolefin pile may be determined.

Performing these tests and obtaining results will allow anyone skilled in the art and in possession of the inventions disclosed and taught herein to determine an amount of hydrophobic coating that will need to be applied to a soft surface article, and then make that soft surface article so that it will exhibit superior anti-soiling properties and superior soil release properties. One way of doing so may be to compare two sets of test samples where each has a different amount (applied as a rate such as a weight per area of the griege good) on their piles. Using the results of the two tests where each has a statistically significant number of test pieces that float or sink, an extrapolation or an interpolation may be made that will indicate if more or less hydrophobic coating should be applied and by how much. For example, if the first set of test samples were applied with a first amount of hydrophobic coating such that all floated, and a second set were applied with a second and lower amount such that most sank, then an interpolation would indicate that an amount to be applied to provide optimal anti-soiling and soil release characteristics is between the first amount and the second amount.

Once the soft surface article has been prepared, it may be installed in any way known to those of skill in the art. If it is a broadloom and carpet edges need to be joined, they may be joined through any method known by those ordinarily skilled in the art. That is to say that broadloom edges may be bound together through the use of sewing, serging, seam tape sealing, or any other method used to join carpet segments. If it is a carpet tile, the edges may be abutted as long as the tiles do not slide apart. Alternatively, tiles may be secured through any other method used to secure tiles to subflooring and/or to each other.

If the carpet pieces or carpet tiles are properly adjoined, then the adjoining wear surfaces will present a continuous wear surface and will not permit soilant within aqueous carriers to penetrate between the seams. The present invention is in no way limited to the herein above-described embodiments. On the contrary, many such soft surface articles may be devised from applying a hydrophobic composition to adhere a hydrophobic coating to tufts in a soft surface articles according to various variations of the inventions disclosed and taught herein, without leaving the scope of the present invention.

Claims

Claims

1. A soft surface article comprising: a wear surface secured to a backing, wherein the wear surface comprises a visible surface and a hydrophobic coating.

2. The soft surface article of claim 1, wherein the wear surface is tufted or woven.

3. The soft surface article of claim 1, wherein the wear surface is tufted and is either a loop pile or a cut pile.

4. The soft surface article of any preceding claim 1-3, wherein the wear surface comprises a pile depth comprising the distance from the visible surface to the backing.

5. The soft surface article of claim 4, wherein the hydrophobic coating is within the pile depth.

6. The soft surface article of claim 5, wherein at least 60% of the hydrophobic coating is within the half of the pile depth closest to the visible surface.

7. The soft surface article of any preceding claim 5-6, wherein at least 70% of the hydrophobic coating is within the half of the pile depth closest to the visible surface.

8. The soft surface article of any preceding claim 5-7, wherein at least 80% of the hydrophobic coating is within the half of the pile depth closest to the visible surface.

9. The soft surface article of claim 5, wherein at least 60% of the hydrophobic coating is within the 40% of the pile depth closest to the visible surface.

10. The soft surface article of claim 9, wherein at least 60% of the hydrophobic coating is within the 30% of the pile depth closest to the visible surface.

11. The soft surface article of any preceding claim 9-10, wherein at least 60% of the hydrophobic coating is within the 25% of the pile depth closest to the visible surface.

12. The soft surface article of any preceding claim 1-11, wherein the wear surface comprises a yarn.

13. The soft surface article of any preceding claim 1-11, wherein the wear surface comprises a polymeric fiber or a natural fiber.

14. The soft surface article of any preceding claim 12-13, wherein the yarn comprises a polymeric fiber wherein the polymeric fiber is selected from the group consisting of a polyamide, a polyester, a polyolefin, or combinations thereof.

15. The soft surface article of any preceding claim 1-14, wherein the hydrophobic coating provides superior anti-soiling properties and superior soil release properties.

16. The soft surface article of any preceding claim 1-15, wherein water placed upon the soft surface article will not seep below the visible surface.

17. The soft surface article of any preceding claim 1-16, wherein the hydrophobic coating comprises an adhering agent.

18. The soft surface article of claim 17, wherein the adhering agent comprises polymeric particles.

19. The soft surface article of claim 18, wherein the polymeric particles are selected from a group consisting of a polyester, a polyolefin, a polyamide, and combinations thereof.

20. The soft surface article of claim 17, wherein the adhering agent comprises a resin.

21. The soft surface article of claim 20, wherein the resin is selected from a group consisting of an alkyd resin, a polyester resin, an MDI resin, a polyurethane resin, an acrylic resin, a polyurethane modified polyester resin, silanes, siloxanes, and mixtures thereof.

22. The soft surface article of any preceding claim 20-21, wherein the resin is heat settable or settable by drying or radiation curable.

23. The soft surface article of any preceding claim 1-22, wherein the hydrophobic coating is fluorine free.

24. The soft surface article of any preceding claim 1-23, wherein the hydrophobic coating comprises a hydrophobic polymer.

25. The soft surface article of claim 24, wherein the hydrophobic polymer is selected from the group consisting of a hydrophobic polycarbodiimide; a hydrophobic polyurethane; or a hydrophobic acrylate polymer, wherein the hydrophobic polymer comprises an aliphatic hydrocarbon group preferably with 6 to 34 carbon atoms; or combinations thereof.

26. The soft surface article of any preceding claim 1-25, wherein the hydrophobic coating comprises a wax.

27. The soft surface article of claim 26, wherein the wax is selected from a group consisting of a paraffin wax; a polyethylene wax; or a polypropylene wax; or combinations thereof.

28. The soft surface article of any preceding claim 1-27, wherein the hydrophobic coating comprises an additive.

29. A soft surface article comprising: a backing and a pile, wherein the soft surface article comprises a hydrophobic coating.

30. The soft surface article of claim 29, wherein the pile is selected from a group consisting of a loop pile, a cut pile, a shag pile, a Saxony pile, a Berber pile, a Frieze pile, a twist pile, a tip sheared pile, a velvet or plush pile, or a woven pile.

31. The soft surface article of any preceding claim 29-30, wherein the pile is comprised of yam made from a natural or polymeric fiber.

32. The soft surface article of any preceding claim 29-31, wherein the pile is comprised of staple fibers or bulked continuous filaments.

33. The soft surface article of any preceding claim 29-32, wherein the pile comprises a pile depth comprising the distance from a top of the pile to the backing.

34. The soft surface article of claim 33, wherein the hydrophobic coating is within the pile depth.

35. The soft surface article of claim 34, wherein at least 60% of the hydrophobic coating is within the half of the pile depth closest to the visible surface.

36. The soft surface article of any preceding claim 34-35, wherein at least 70% of the hydrophobic coating is within the half of the pile depth closest to the visible surface.

37. The soft surface article of any preceding claim 34-36, wherein at least 80% of the hydrophobic coating is within the half of the pile depth closest to the visible surface.

38. The soft surface article of claim 34, wherein at least 60% of the hydrophobic coating is within the 40% of the pile depth closest to the visible surface.

39. The soft surface article of claim 38, wherein at least 60% of the hydrophobic coating is within the 30% of the pile depth closest to the visible surface.

40. The soft surface article of any preceding claim 38-39, wherein at least 60% of the hydrophobic coating is within the 25% of the pile depth closest to the visible surface.

41. The soft surface article of any preceding claim 31-40, wherein the yarn comprises a polymeric fiber wherein the polymeric fiber is selected from the group consisting of a polyamide, a polyester, a polyolefin, or combinations thereof.

42. The soft surface article of any preceding claim 29-41, wherein the hydrophobic coating provides superior anti-soiling properties and superior soil release properties.

43. The soft surface article of any preceding claim 29-42, wherein water placed upon the soft surface article will not seep below the visible surface.

44. The soft surface articles of any preceding claim 29-43, wherein the pile is comprised of filaments and the hydrophobic coating is disposed on the surface of the filaments.

45. The soft surface article of any preceding claim 29-44, wherein the hydrophobic coating comprises an adhering agent.

46. The soft surface article of claim 45, wherein the adhering agent comprises polymeric particles.

47. The soft surface article of claim 46, wherein the polymeric particles are selected from a group consisting of a polyester, a polyolefin, a polyamide, and combinations thereof.

48. The soft surface article of claim 45, wherein the adhering agent comprises a resin.

49. The soft surface article of claim 48, wherein the resin is selected from a group consisting of an alkyd resin, a polyester resin, an MDI resin, a polyurethane resin, an acrylic resin, a polyurethane modified polyester resin, silanes, siloxanes, and mixtures thereof.

50. The soft surface article of any preceding claim 48-49, wherein the resin is heat settable or settable by drying or radiation curable.

51. The soft surface article of any preceding claim 29-50, wherein the hydrophobic coating is fluorine free.

52. The soft surface article of any preceding claim 29-51, wherein the hydrophobic coating comprises a hydrophobic polymer.

53. The soft surface article of claim 50, wherein the hydrophobic polymer is selected from the group consisting of a hydrophobic polycarbodiimide; a hydrophobic polyurethane; or a hydrophobic acrylate polymer, wherein the hydrophobic polymer comprises an aliphatic hydrocarbon group preferably with 6 to 34 carbon atoms; or combinations thereof.

54. The soft surface article of any preceding claim 29-53, wherein the hydrophobic coating comprises a wax.

55. The soft surface article of claim 54, wherein the wax is selected from a group consisting of a paraffin wax; a polyethylene wax; or a polypropylene wax; or combinations thereof.

56. The soft surface article of any preceding claim 29-55, wherein the hydrophobic coating comprises an additive.

57. The soft surface article of claim 56, wherein the additive is selected from the group consisting of surface-active agents, coalescing agents, frost resisting agents, emulsifying agents, surfactants, stabilizing agents, and combinations thereof.

58. A method of making the soft surface article of any prior claim 1-57 comprising: providing an unfinished product comprising woven fibers or tufts of fibers, wherein the woven fibers or tufts of fibers present an upper wear surface; applying a hydrophobic composition to at least the upper wear surface.

59. The method of claim 58, wherein the hydrophobic composition comprises a hydrophobic compound in a solution.

60. The method of claim 59, wherein the solution is an aqueous solution.

61. The method of claim 59, wherein the solution is a non-aqueous solution.

62. The method of claim 61, wherein the non-aqueous solution is selected from a group consisting of butylacetate, propyl acetate, a dibasic ester, a glycol di ether; a benzoate ester; a diphenylmethane or diphenylethane, acetone, a tetramathoxy ether, and combinations thereof.

63. The method of claim 61, wherein the non-aqueous solution is selected from the group consisting of an alkane, an alcohol with 1 to 6 carbon atoms, an ester from an alcohol with 1 to 10 carbon atoms, or combinations thereof.

64. The method of claim 61, wherein the non-aqueous solution is an oil-based solvent.

65. The method of claim 64, wherein the oil-based solvent is selected from the group consisting of: turpentine; linseed oil; castor oil; soy oil; a protein-based liquid; and combinations thereof.

66. The method of any preceding claim 58-65, wherein the step of applying a hydrophobic composition comprises spraying the hydrophobic composition onto the upper wear surface.

67. The method of any preceding claim 58-65, wherein the step of applying a hydrophobic composition comprises dredging the unfinished product through a bath of the hydrophobic composition such that the upper wear surface contacts the hydrophobic composition.

68. The method of any preceding claim 58-65, wherein the step of applying a hydrophobic composition comprises flooding the hydrophobic composition onto the upper wear surface.

69. The method of any preceding claim 58-65, wherein the step of applying a hydrophobic composition comprises foaming the hydrophobic composition onto the upper wear surface.

70. The method of any preceding claim 58-69, wherein the method includes a step of applying other treatment chemicals to at least the upper wear surface.

71. The method of any preceding claim 59-70, wherein the method includes a step of removing a solvent of the solution, which occurs after the step of applying the hydrophobic composition.

72. The method of claim 71, wherein the step of removing the solvent comprises heating the unfinished product.

73. The method of any preceding claim 58-72, wherein the method includes a step of determining an amount of hydrophobic composition to apply to the unfinished product.

74. The method of any preceding claim 58-73, wherein the hydrophobic composition comprises an adhering agent.

75. The method of claim 74, wherein the adhering agent comprises polymeric particles.

76. The method of claim 75, wherein the polymeric particles are selected from a group consisting of a polyester, a polyolefin, a polyamide, and combinations thereof.

77. The method of claim 74, wherein the adhering agent comprises a resin.

78. The method of claim 77, wherein the resin is selected from a group consisting of an alkyd resin, a polyester resin, an MDI resin, a polyurethane resin, an acrylic resin, a polyurethane modified polyester resin, silanes, siloxanes, and mixtures thereof.

79. The method of any preceding claim 77-78, wherein the resin is heat settable or settable by drying or radiation curable.

80. The method of any preceding claim 58-79, wherein the hydrophobic composition is fluorine free.

81. The method of any preceding claim 58-80, wherein the hydrophobic composition comprises a hydrophobic polymer.

82. The method of claim 81, wherein the hydrophobic polymer is selected from the group consisting of a hydrophobic polycarbodiimide; a hydrophobic polyurethane; or a hydrophobic acrylate polymer, wherein the hydrophobic polymer comprises an aliphatic hydrocarbon group preferably with 6 to 34 carbon atoms; or combinations thereof.

83. The method of any preceding claim 58-82, wherein the hydrophobic composition comprises a wax.

84. The method of claim 83, wherein the wax is selected from a group consisting of a paraffin wax; a polyethylene wax; or a polypropylene wax; or combinations thereof.

85. The method of any preceding claim 58-84, wherein the hydrophobic composition comprises an additive.

86. The method of claim 85, wherein the additive is selected from the group consisting of surface-active agents, coalescing agents, frost resisting agents, emulsifying agents, surfactants, stabilizing agents, and combinations thereof.

87. A method for determining an amount of hydrophobic composition to be applied to a soft surface article, comprising: defining a pile configuration for the soft surface article; creating a first and a second griege product comprising a pile defined from the pile configuration; applying a hydrophobic composition to the pile of the first griege product at a first rate, and applying the hydrophobic composition to the pile of the second griege product at a second rate; cutting the first and second griege product into a plurality of test samples; placing at least a portion of the test samples from the first and second griege products in a water bath with the pile of all test samples facing a surface of the water bath for a time period; performing a statistical analysis on a number of test samples that float at the end of the time period; using a result of the statistical analysis to determine the amount of hydrophobic substance to be applied to the soft surface article.

88. The method of claim 87, wherein the step of defining a pile configuration comprises configuring a pile height, a stitch rate, a stitch pattern, a pile weight.

89. The method of claim 88, wherein the step of defining a pile configuration comprises configuring a loop cut.

90. The method of claim 89, wherein the step of defining a pile configuration comprises configuring a yarn to be used to form a pile.

91. The method of claim 90, wherein configuring a yarn comprises selecting a yarn from a group consisting of a bulked continuous filament, a staple fiber, a polymeric fiber, a natural fiber, a polyamide fiber, a polyester fiber, a polyolefin fiber, and combinations thereof.