U.S. patent application number 14/005142 was filed with the patent office on 2014-03-06 for processes to make water and oil repellent bcf yarn.
The applicant listed for this patent is Daniel Reynolds, Ronnie Rittenhouse, Wae-Hai Tung. Invention is credited to Daniel Reynolds, Ronnie Rittenhouse, Wae-Hai Tung.
Application Number | 20140065346 14/005142 |
Document ID | / |
Family ID | 46831338 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140065346 |
Kind Code |
A1 |
Tung; Wae-Hai ; et
al. |
March 6, 2014 |
PROCESSES TO MAKE WATER AND OIL REPELLENT BCF YARN
Abstract
Disclosed are processes for applying anti-soil compositions onto
BCF yarns during cable or air twisting processes prior to weaving,
knitting or tufting into finished carpet. The process foregoes the
need for downstream environmentally unfavorable dyeing and low pH
chemical treatment processes on the finished carpet. The anti-soil
composition can be comprised of a high specific surface energy
chemical or other material, for example a fluorochemical. Further,
the anti-soil composition can further comprise an anti-stain
component. Also disclosed are systems, BCF yarns, and carpets made
from the BCF yarn treated by the disclosed process.
Inventors: |
Tung; Wae-Hai; (Marietta,
GA) ; Rittenhouse; Ronnie; (Calhoun, GA) ;
Reynolds; Daniel; (Chattanooga, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tung; Wae-Hai
Rittenhouse; Ronnie
Reynolds; Daniel |
Marietta
Calhoun
Chattanooga |
GA
GA
TN |
US
US
US |
|
|
Family ID: |
46831338 |
Appl. No.: |
14/005142 |
Filed: |
March 15, 2012 |
PCT Filed: |
March 15, 2012 |
PCT NO: |
PCT/US2012/029151 |
371 Date: |
November 18, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61453326 |
Mar 16, 2011 |
|
|
|
Current U.S.
Class: |
428/92 ; 118/72;
28/159; 427/177; 428/371 |
Current CPC
Class: |
D02G 3/34 20130101; D06M
2200/10 20130101; D06M 2101/34 20130101; Y10T 428/23957 20150401;
A47G 27/02 20130101; Y10T 428/2925 20150115; D06M 15/256 20130101;
D06B 3/06 20130101; D06M 15/277 20130101; D06M 2200/01 20130101;
D06M 15/576 20130101 |
Class at
Publication: |
428/92 ; 427/177;
118/72; 428/371; 28/159 |
International
Class: |
A47G 27/02 20060101
A47G027/02; D06M 15/277 20060101 D06M015/277; D02G 3/34 20060101
D02G003/34 |
Claims
1. A process for treating twisted BCF yarn with an anti-soil
composition comprising an anti-soil component comprising: a.
providing twisted BCF yarn; b. winding said BCF yarn on a take-up
reel; and c. contacting said BCF yarn with said anti-soil
composition while said BCF yarn is in motion and prior to said BCF
yarn contacting and winding up on said take-up reel.
2. The process of claim 1, further comprising dry heat setting said
BCF yarn after contacting said BCF yarn with said anti-soil
composition.
3. The process of claim 1, wherein said anti-soil component
comprises a fluorochemical.
4. The process of claim 1, wherein the anti-soil composition has a
pH from about 3 to about 8.
5. The process of claim 3, wherein said fluorochemical is selected
from the group consisting of: fluorochemical allophanates,
fluorochemical polyacrylates, fluorochemical urethanes,
fluorochemical carbodiimides, fluorochemical quanidines, and
fluorochemicals incorporating C-2 to C-8 chemistries.
6. The process of claim 3, wherein said fluorochemical has less
than or equal to six fluorinated carbons.
7. The process of claim 3, wherein said fluorochemical is a
fluorochemical urethane.
8. The process of claim 1, wherein said anti-soil composition
further comprises a component selected from the group consisting
of: odor control agents, anti-microbial agents, anti-fungal agents,
fragrance agents, bleach resist agents, softeners, and UV
stabilizers.
9. The process of claim 1, wherein said anti-soil composition
further comprises an anti-stain component.
10. The process of claim 9, wherein said anti-stain component is
selected from the group consisting of: syntans, sulfonated
novolacs, sulfonated aromatic aldehyde condensation products (SACs)
and/or reaction products of formaldehyde, phenol, polymethacrylic
acid, maleic anyhydride, and sulfonic acid.
11. The process of claim 9, wherein said anti-stain component is
present at an on weight of fiber from about 500 ppm to about
4%.
12. The process of claim 9, wherein said anti-soil composition
further comprises a component selected from the group consisting
of: dye auxiliaries, sequestrants, pH control agents, and
surfactants.
13. The process of claim 2, wherein said heat setting is performed
at a temperature from about 125.degree. C. to about 200.degree.
C.
14. The process of claim 1, wherein said BCF yarn comprises
polyamide fiber.
15. The process of claim 14, wherein said polyamide fiber is
selected from the group consisting of: nylon 6,6, nylon 6, nylon
4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends
thereof.
16. The process of claim 1, wherein said BCF yarn comprises a
polymer component selected from the group consisting of polyester
and polyolefin.
17. The process of claim 1, wherein said anti-soil component is
present at an on weight of fiber from about 100 ppm to about 1000
ppm.
18. The process of claim 1, wherein said contacting is performed by
a device selected from the group consisting of: applicator pad,
ceramic tip, ceramic ring, wet-wick, dip-tank, sprayer, and
mister.
19. The process of claim 1, wherein said BCF yarn is dyed or
pigmented prior to contacting with said anti-soil composition.
20. The process of claim 18 wherein a plurality of devices are used
to perform said contacting.
21. The process of claim 20, wherein said plurality of devices are
different.
22. An untufted, twisted BCF yarn comprising an anti-soil component
present on a surface of said untufted, twisted BCF yarn.
23. The untufted, twisted BCF yarn of claim 22, wherein said
anti-soil component comprises a fluorochemical.
24. The untufted, twisted BCF yarn of claim 23, wherein said
fluorochemical is selected from the group consisting of:
fluorochemical allophanates, fluorochemical polyacrylates,
fluorochemical urethanes, fluorochemical carbodiimides,
fluorochemical quanidines, and fluorochemicals incorporating C-2 to
C-8 chemistries.
25. The untufted, twisted BCF yarn of claim 22, further comprising
an anti-stain component, wherein said anti-stain component is
present on said twisted BCF yarn prior to tufted said BCF yarn.
26. The untufted, twisted BCF yarn of claim 22, wherein said
anti-soil component is present at an on weight of fiber from about
100 ppm to about 1000 ppm.
27. The untufted, twisted BCF yarn of claim 22, wherein said BCF
yarn comprises polyamide fiber.
28. The untufted, twisted BCF yarn of claim 27, wherein said
polyamide fiber is selected from the group consisting of: nylon
6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its
copolymers, and blends thereof.
29. The untufted, twisted BCF yarn of claim 22, wherein said BCF
yarn comprises a polymer component selected from the group
consisting of polyester and polyolefin.
30. The untufted, twisted BCF yarn of claim 22, wherein said BCF
yarn is pigmented or dyed.
31. A carpet comprising twisted BCF yarn, wherein said twisted BCF
yarn comprises the twisted BCF yarn from claim 22 that has been
tufted.
32. The carpet of claim 31 having an oil repellency rating of at
least 5.
33. A process for manufacturing carpet comprising: a. providing an
untufted, twisted BCF yarn comprising an anti-soil component
present on a surface of said untufted, twisted BCF yarn; b. tufting
said BCF yarn; and c. weaving said tufted BCF yarn into said
carpet, wherein said process foregoes the need to further treat
said carpet with an anti-soil composition.
34. The process of claim 33, wherein said untufted, twisted BCF
yarn comprises polyamide fiber.
35. The process of claim 34, wherein said polyamide fiber is
selected from the group consisting of: nylon 6,6, nylon 6, nylon
4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends
thereof.
36. A system for applying an anti-soil composition to twisted BCF
fiber comprising: a. a first yarn take-up device that receives at
least two individual yarn members and transmits a single yarn
member; b. an anti-soil composition applicator disposed downstream
of said yarn take-up device that applies said anti-soil composition
to said single yarn member; and c. a second yarn take-up device
that receives said single yarn member.
37. The system of claim 36, wherein said applicator is selected
from the group consisting of: applicator pad, ceramic tip, ceramic
ring, wet-wick, dip-tank, sprayer, and mister.
38. The system of claim 36, wherein a plurality of applicators is
used to apply said anti-soil composition.
39. The system of claim 38, wherein said plurality of applicators
are different.
Description
FIELD OF THE INVENTION
[0001] The invention relates to anti-soil application processes for
bulk continuous filament (BCF) carpet and related textile fabrics,
and specifically, to processes for applying anti-soil compositions
on BCF yarns during cable or air twisting processes prior to
weaving, knitting or tufting. The process foregoes the need to
treat carpets and other textiles made from the BCF yarn, thus
eliminating costly and environmentally unfavorable dyeing and low
pH chemical treatment processes. Also disclosed herein are systems
used to apply the anti-soil formulations to the BCF yarn, and soil
repellant yarns, and carpets with improved anti-soil properties
made from the BCF yarn of the disclosed process.
BACKGROUND OF THE TECHNOLOGY
[0002] Carpets and other fabrics are currently treated with topical
chemistries for improved stain resistance and/or soil resistance.
For nylon carpets, both stain blocker (e.g. acid dye blocker) and
anti-soil with fluorochemicals are traditionally used. For
polyester carpets, such as 2GT and 3GT carpets, and polypropylene
carpets, anti-soil chemistry may be applied topically to the tufted
carpet as part of the carpet finishing process. Polyester and
polypropylene carpets typically do not require a stain blocker
treatment because of inherent stain resistance to acid dyes and
stains owing to their lack of amine end groups that function as
acid dye sites.
[0003] Topical application at the carpet mill can be in the form of
exhaust application and spray application. Exhaust application
(i.e. flex-nip process at high (300-400 wt. %) wet pick-up), is
known to provide an improvement in efficacy over spray-on
applications at 10-20 wt. % wet pick-up of anti-soil. Exhaust
applications typically use higher amounts of water and energy to
dry and cure the carpet than do spray applications. Spray-on
fluorochemical products are designed to use less water and energy
than exhaust applications, but they do not impart anti-soil
properties that are as good as those provided by the exhaust
applications owing to limited depth of penetration into the fabric,
especially deep pile fabrics and those incorporating the tightly
twisted yarns that are now becoming more popular.
[0004] While various processes are in use in the carpet industry
for the dyeing and finishing of carpets, some large scale and some
small, most of the carpet made today is dyed and finished on a
continuous dye range. This is done mainly in one of two ways: In
one case, a two stage process is employed, where the carpet is
steamed and dyed first, steamed, rinsed, and excess water
extracted; then stain blocker (SB) is applied, the carpet is again
steamed and washed, and then anti-soil fluorochemical (FC) is
applied in the form of a foam or liquid spray and the carpet is
finally dried. (See e.g. U.S. Pat. Nos. 5,853,814; 5,948,480 and
WO2000/000691). In the second, somewhat improved case, called the
co-application process, the carpet is also steamed and dyed first,
steamed again, rinsed and extracted; and then a blend of SB and FC
is applied together at high wet pick up, after which the carpet and
chemicals are exposed once again to steam to fix the treatment,
followed by drying. (See e.g. U.S. Pat. Nos. 6,197,378 and
5,520,962). In both cases, low pH solutions, excess water, and
energy are required for the SB and FC to penetrate the carpet and
achieve uniform coverage. In sum, the typical prior art process is
as follows: BCF yarn.fwdarw.Twist.fwdarw.heat
set.fwdarw.tufting.fwdarw.carpet.fwdarw.dye.fwdarw.stain
block/anti-soil.
SUMMARY OF THE INVENTION
[0005] There is a desire to reduce the overall usage of topical
anti-soil formulations, especially formulations that contain
fluorochemicals, for environmental and cost reasons. Further, there
is also a desire to reduce the amount of water and low pH chemicals
used to apply the anti-stain and anti-soil formulations. Thus,
processes for applying such beneficial compositions using less
water, nominal pH chemicals, and less energy are in demand.
[0006] While the development of a process that eliminates the
current carpet treatment systems for applying anti-stain and
anti-soil compositions is desirable; current processes do exist for
good reasons. First, because the appearance of carpet has
historically depended on the ability to dye wool or nylon or even
polyester tufted carpets to the desired shade, it would not be
permissible to treat the carpet with compositions such as
anti-stain or anti-soil chemistries beforehand that might interfere
with the process of uniform dyeing. Further, the dyeing process
would tend to remove the topical treatment chemistries, rendering
them ineffective.
[0007] Second, as mentioned above, treatment of yarn or fabric for
stain and soil resistance typically involves fixing with steam, and
low pH may also be required especially for acid dyed fabrics.
Therefore, it was deemed most practical to process carpets in the
order described above, where carpet is formed, then steamed and
dyed, steamed again, rinsed and extracted; and then SB and FC is
applied, again involving steaming and/or rinsing in the various
processes of the prior art.
[0008] Carpets have also long been constructed of dyed or pigmented
yarns, which constructions are treated in numerous possible ways,
including the options of further dyeing, and the application of
stain and/or soil resistant compositions with the concomitant use
of steam and rinse water, as in the processes described above.
[0009] The invention disclosed herein provides a process to make
textile fabrics, especially tufted articles, without the
requirement for subsequent stain and soil resistant chemistry
application, thus avoiding the cost and waste of steam fixing and
rinsing attendant with such large-scale fabric applications. As
disclosed herein, the process involves application of topical
chemistries to dyed or pigmented yarns immediately after twisting
or cabling one or more such yarns together. The chemistries are
then heat-set onto the twisted yarn under dry conditions, and the
twisted yarn subsequently weaved or tufted into a finished fabric
or carpet. Novel systems that enable the efficient application of
topical chemistries to yarn subsequent to twisting and prior to
winding and heat-setting are also disclosed.
[0010] Specifically, the disclosed process uses an atopical
chemistry composition applicator positioned within a mechanical
twisting process downstream of the twisted yarn take-up reel and
upstream of the yarn winder. In sum, the disclosed process moves
the backend, large scale and wasteful anti-soil application step,
and if necessary, stain block application step, up front during
yarn twisting. Thus, the carpet manufacturing process now becomes:
BCF yarn.fwdarw.twist.fwdarw.FC (and optional SB).fwdarw.heat set
(optionally dry heat set).fwdarw.tufting.fwdarw.carpet.
Surprisingly, the disclosed process is as effective, or even more
effective, than processes of the prior art in terms of fabric soil
resistance.
[0011] As describe above, the process of the disclosed invention is
counter intuitive since treating the carpet yarn prior to heat
setting and tufting is known to affect the quality of the finished
carpet, particularly during dyeing. Further, the inventive process
is also counter intuitive because soil resistant compositions tend
to be very difficult to apply uniformly to twisted yarn bundles at
the usual line speed without substantial waste. Moreover, the
disclosed process is counter intuitive because the prior art yarn
twisting apparatuses have not previously accepted topical chemistry
applications to twisted yarn prior to winding. However, as shown
below, Nylon carpets manufactured with the treated BCF yarn show
superior anti-soil properties over the same carpets without such
treatment.
[0012] In one aspect, a process for treating twisted BCF yarn with
an anti-soil composition comprising an anti-soil component is
disclosed. The process comprises: (a) providing twisted BCF yarn;
(b) winding said BCF yarn on a take-up reel; and (c) contacting
said BCF yarn with said anti-soil composition while said BCF yarn
is in motion and prior to said BCF yarn contacting and winding up
on said take-up reel. The anti-soil composition can be comprised of
a high specific surface energy chemical or other material, for
example a fluorochemical that imparts high specific surface energy
properties such as high contact angles for water and oil, or even a
non-fluorochemical particulate material having similar properties.
The anti-soil composition can further comprise an anti-stain
component.
[0013] In another aspect, an untufted, twisted BCF yarn comprising
an anti-soil component is disclosed, wherein said anti-soil
component is present on said twisted BCF yarn prior to tufting the
BCF yarn. The anti-soil component is present at an on weight of
fiber from about 100 ppm to about 1000 ppm. The yarn can comprise
polyamide fiber and/or have polymer components selected from
polyester and polypropylene. The yarn can be tufted and
manufactured into carpet or fabrics.
[0014] In a further aspect, a process for manufacturing carpet is
disclosed comprising providing an untufted, twisted BCF yarn
comprising an anti-soil component, tufting said BCF yarn, and
weaving into said carpet. Because of the anti-soil component
present on the BCF yarn prior to tufting and weaving, there is no
need to treat the finished carpet with an anti-soil
composition.
[0015] In yet another aspect, a system for applying an anti-soil
composition to twisted BCF fiber is disclosed. The system
comprises: (a) a first yarn take-up device that receives at least
two individual yarn members and transmits a single yarn member; (b)
an anti-soil composition applicator disposed downstream of said
yarn take-up device that applies said anti-soil composition to said
single yarn member; and (c) a second yarn take-up device that
receives said single yarn member. The anti-soil composition can be
comprised of a high specific surface energy chemical or other
material, for example a fluorochemical that imparts high specific
surface energy properties such as high contact angles for water and
oil, or even a non-fluorochemical particulate material having
similar properties. The anti-soil composition can further comprise
an anti-stain component.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIG. 1 shows the current cable twisting process.
[0017] FIG. 2 shows one aspect of the disclosed process.
DEFINITIONS
[0018] While mostly familiar to those versed in the art, the
following definitions are provided in the interest of clarity.
[0019] OWF (On weight of fiber): The amount of chemistry that was
applied as a % of weight of fiber.
[0020] WPU (Wet pick-up): The amount of water and solvent that was
applied on carpet before drying off the carpet, expressed as a % of
weight of fiber.
DETAILED DESCRIPTION OF THE INVENTION
[0021] A process for treating twisted BCF yarn is disclosed
comprising contacting the BCF yarn with an anti-soil composition
while said yarn is in motion and prior to contacting and winding
the yarn onto a take-up reel or winder to create a yarn package or
cake. The anti-soil composition comprises an anti-soil component
and is adapted to be applied onto twisted BCF yarn at a wet pick-up
of between about 5 wt. % and about 50 wt. %., including between
about 10 wt. % and about 30 wt %, about 20 wt. % to about 30 wt. %,
and about 10 wt. % to about 20 wt. %. The twisted BCF yarn can be
optionally heat set after contacting the yarn with the anti-soil
composition. Heat setting temperatures can range from about
125.degree. C. to about 200.degree. C., including from about
160.degree. C. to about 195.degree. C. Heat setting dwell times can
range from about 0.5 to about 4 minutes, including from about 0.5
to about 3 minute and from about 0.5 to about 1 minute.
[0022] Anti-soil components for use in the disclosed anti-soil
compositions impart high specific surface energy properties such as
high contact angles for water and oil (e.g. water and oil "beads
up" on surfaces treated by it). The anti-soil component can
comprise a fluorochemical dispersion, which dispersion may be
predominantly either cationic or anionic, including those selected
from the group consisting of fluorochemical allophanates,
fluorochemical polyacrylates, fluorochemical urethanes,
fluorochemical carbodiimides, fluorochemical quanidines, and
fluorochemicals incorporating C-2 to C-8 chemistries.
Alternatively, the fluorochemical can have less than or equal to
eight fluorinated carbons, including less than or equal to six
fluorinated carbons. Example fluorochemical anti-soil components
include: DuPont TLF 10816 and 10894; Daikin TG 2511, and DuPont
Capstone RCP. Non-fluorinated anti-soil components can include:
silicones, silsesquioxanes and fluorosilanated and fluoroalkylated
particulates, anionic non-fluorinated surfactants and anionic
hydrotrope non-fluorinated surfactants, including sulfonates,
sulfates, phosphates and carboxylates. (See U.S. Pat. No.
6,824,854, herein incorporated by reference).
[0023] The anti-soil compositions can also have an optional stain
blocker component comprising an acidic moiety which associates with
polymer amine end groups and protects them from staining by acidic
dye stains. The general category of chemicals suitable to the
process of the instant invention can comprise any chemical that
blocks positively charged dye sites. Stain blockers are available
in various forms such as syntans, sulfonated novolacs, or
sulfonated aromatic aldehyde condensation products (SACs), and/or
reaction products of formaldehyde, phenol, polymethacrylic acid,
maleic anyhydride, and sulfonic acid. They are usually made by
reacting formaldehyde, phenol, polymethacrylic acid, maleic
anyhydride, and sulfonic acid depending on specific chemistry.
Further, the stain blocker is typically water soluble and generally
penetrates the fiber while the anti-soil, usually a fluorochemical,
is a non-water soluble dispersion that coats the surface of
fiber.
[0024] Examples of stain blockers include, but are not limited to:
phenol formaldehyde polymers or copolymers such as CEASESTAIN and
STAINAWAY (from American Emulsions Company, Inc., Dalton, Ga.),
MESITOL (from Bayer Corporation, Rock Hill, N.C.), ERIONAL (from
Ciba Corporation, Greensboro, N.C.), INTRATEX (from Crompton &
Knowles Colors, Inc., Charlotte, N.C.), STAINKLEER (from Dyetech,
Inc., Dalton, Ga.), LANOSTAIN (from Lenmar Chemical Corporation,
Dalton, Ga.), and SR-300, SR-400, and SR-500 (from E. I. du Pont de
Nemours and Company, Wilmington, Del.); polymers of methacrylic
acid such as the SCOTCHGARD FX series carpet protectors (from 3M
Company, St. Paul Minn.); sulfonated fatty acids from Rockland
React-Rite, Inc., Rockmart, Ga.); and stain resist chemistries from
ArrowStar LLC, Dalton and Tri-Tex, Canada.
[0025] The anti-soil composition is adapted to contact the twisted
BCF yarn while it is in motion and prior to contacting the take-up
reel or winder. Further, the anti-soil composition can be at a
neutral pH (e.g. 6 to 8) because the yarn can be optionally heat
set after application of the composition. The process foregoes the
need for harsh low pH chemicals.
[0026] Any suitable device that applies wet ingredients to a dry
substrate can perform the contacting. Such devices include, but are
not limited to: applicator pad, ceramic tip, ceramic ring, nip
rollers, wet-wick, dip-tank, sprayer, and mister. Further, the
contacting can be done by one or more devices, where each device
can be the same or different. For example, two, three, or more
application devices can be used to apply the anti-soil composition
at different points in the process. Further, one or more
application devices can apply an anti-soil component and one or
more separate devices an anti-stain component. Multiple application
devices and locations can provide better application uniformity
when using certain BCF yarns.
[0027] The wet pick-up of anti-soil composition is between about 5
wt. % and about 50 wt. %., including between about 10 wt. % and
about 30 wt %, about 20 wt. % to about 30 wt. %, and about 10 wt. %
to about 20 wt. %. The resulting twisted BCF yarn, if a fluorine
based anti-soil component is used, can have an on weight of fiber
from about 100 ppm to about 1000 ppm fluorine, including from about
100 to about 500 ppm fluorine, from about 200 to about 400 ppm, and
from about 100 ppm to about 300 ppm fluorine. If the anti-soil
composition further comprises a stain blocker, it is present on
weight of fiber from about 500 ppm to about 4%, including from
about 1000 ppm to about 3%, from about 0.5% to about 2%, and from
about 0.5% to about 1%.
[0028] Common stain blockers use sulfonated moieties as part of the
chemistry, which results in the presence of sulfur on the treated
fiber. The sulfur content can range from about 50 ppm with 5% stain
blocker to about 1 ppm with 0.1% stain blocker on weight of fiber.
Thus, based on the above stain blocker concentrations, the sulfur
content on weight of fiber will range from about 0.5 ppm to about
40 ppm, including from about 1 ppm to about 30 ppm, from about 5
ppm to about 20 ppm, and from about 5 ppm to about 10 ppm. Sulfur
content can be determined by x-ray diffraction or other
methods.
[0029] The anti-soil composition can further comprise a component
selected from the group consisting of: odor control agents,
anti-microbial agents, anti-fungal agents, fragrance agents, bleach
resist agents, softeners, and UV stabilizers.
[0030] The twisted BCF yarn can be made from polyamide fibers, such
as those made from nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon
10,10, nylon 12, its copolymers, and blends thereof. Further, the
twisted BCF yarn can also have additional polymer components, such
as polyester and/or polyolefin components. The polyolefin component
can be polypropylene. The additional polymer components can be
incorporated with the polyamide (by melt-blend or
co-polymerization) prior to making a polyamide fiber (e.g. a
polyamide/polyester fiber), or can be stand-alone fibers that are
twisted with the polyamide fibers to make the twisted BCF yarn.
[0031] As stated above, the BCF yarn can be manufactured with
olefin, polyamide, and/or polyester polymer components. An
unexpected benefit of the disclosed process has been discovered in
that, whereas a small amount of anti-soil composition is applied
compared to known exhaust processes, a high anti-soil component
content, such as fluorine, is achieved on the surface of the yarn.
Further, the anti-soil composition applied in the process of the
disclosed invention can be either fluorochemical or
non-fluorochemical based, or a mixture of fluorochemical or
fluoropolymer material with non-fluorinated soil resistant
materials.
[0032] The disclosed process may be applied to yarns that do not
require subsequent dyeing, having either a pigment or pigment
included in their composition prior to twisting. The pigmented
yarns can be made by solution dyed as well as cationic and anionic
dyed fibers. Yarns suitable for use in the process may further
comprise inherent stain resistance, whether by base composition as
in the case of polypropylene or polyester, or by the inclusion of
strong acid functionality in the polymer composition of the yarn,
as in the case of nylon. Use of dyed or pigmented yarns (i.e.
colored yarns) with the disclosed process eliminates the need for
subsequent dyeing and enables the creation of colored carpets that
are soil resistant, without the need for subsequent dyeing and soil
resistant chemical application.
[0033] Where both inherently stain resistant and colored yarns are
employed in the disclosed process, then all of the cost of dyeing,
and of SB/FC application to the tufted carpet are eliminated. As
observed above, this not only reduces the cost of making carpets
having superior performance attributes, but also minimizes the
environmental impact of carpet manufacture by reducing water, steam
and energy consumption.
[0034] The twisted BCF yarn made with the various aspects of the
disclosed process, by itself or blended with non-treated fibers and
yarns, can be tufted and manufactured into carpets or fabrics.
Carpets made with the twisted BCF yarn exhibit an oil repellency
rating of 5 or higher and a water repellency rating of 5 or
higher.
[0035] Alternatively, the disclosed process can also be
advantageously applied in certain processes where a styling
advantage might be derived from differential dyeing and finishing
after carpet formation. For example, a soil resistant or stain
resistant twisted yarn of the disclosed invention could optionally
be tufted into a carpet among untreated yarns prior to dyeing, thus
creating an aesthetic alternative.
[0036] Further disclosed is a system for applying the anti-soil
composition to the twisted BCF yarn. The system includes: (a) a
first yarn take-up device that receives at least two individual
yarn members and transmits a single yarn member; (b) an anti-soil
composition applicator disposed downstream of the first yarn
take-up device that applies the anti-soil composition to the single
yarn member; and (c) a second yarn take-up device that receives the
single yarn member. The first yarn take-up device can be a take-up
roll or reel that can twist the at least two individual yarn
members into a single yarn member. The individual yarn members can
be single filaments or fibers, or yarns made from a plurality of
filaments or fibers. The applicator can be any suitable device that
applies wet ingredients to a dry substrate, including, but not
limited to: applicator pad, nip rollers, wet-wick, dip-tank,
sprayer, and mister. The wet pick-up of composition is between
about 5 wt. % and about 50 wt. %., including between about 10 wt. %
and about 30 wt %, about 20 wt. % to about 30 wt. %, and about 10
wt. % to about 20 wt. %. The resulting twisted BCF yarn, if a
fluorine based anti-soil component is used, can have an on weight
of fiber from about 100 ppm to about 1000 ppm fluorine, including
from about 100 to about 500 ppm fluorine, from about 200 to about
400 ppm, and from about 100 ppm to about 300 ppm fluorine. If the
anti-soil composition further comprises a stain blocker, it is
present on weight of fiber from about 500 ppm to about 4%,
including from about 1000 ppm to about 3%, from about 0.5% to about
2%, and from about 0.5% to about 1%. The second yarn take-up device
can be a winder.
[0037] FIG. 1 shows the current cable twisting process. Here, creel
yarn 10 and bucket yarn 15, which is fed at a spindle speed of 7000
rpm, pass through an anti-balloon device 20 and onto a take-up roll
25. From here, the twisted yarn 30 is wound up on a winder 35. FIG.
2 shows one aspect of the disclosed process. Here, creel yarn 110
and bucket yarn 115, which is fed at a spindle speed of 7000 rpm,
pass through anti-balloon device 120 and onto a take-up roll 125.
An anti-soil composition applicator 140 is disposed downstream of
take-up roll 125, which applies an anti-soil component to the
twisted yarn 130. From here, the twisted and treated yarn is wound
up on a winder 135.
[0038] The disclosed process is counterintuitive and surprisingly
results in yarn that contains acceptable anti-soil properties when
manufactured into a carpet or fabric. One would expect that
rearranging the process as described above would fowl up
down-stream carpet manufacturing processes and lead to poor quality
carpet. Thus, the results reported below are surprising and
unexpected.
EXAMPLES
[0039] The following are examples of nylon 6,6 carpets made from
two 922 denier beige color solution dyed BCF fibers that have been
treated various aspects of the process disclosed above and similar
fibers with no treatment. Selection of alternative anti-soil
components and stain blocker components, fibers and textiles having
different surface chemistries will necessitate minor adjustments to
the variables herein described.
[0040] Test Methods
Acid Dye Stain Test.
[0041] Acid dye stain resistance is evaluated using a procedure
modified from the American Association of Textile Chemists and
Colorists (AATCC) Method 175-2003, "Stain Resistance: Pile Floor
Coverings." 9 wt % of aqueous staining solution is prepared,
according to the manufacturer's directions, by mixing
cherry-flavored KOOL-AID.RTM. powder (Kraft/General Foods, White
Plains, N.Y., a powdered drink mix containing, inter alia, FD&C
Red No. 40). A carpet sample (4.times.6-inch) is placed on a flat
non-absorbent surface. A hollow plastic 2-inch (5.1 cm) diameter
cup is placed tightly over the carpet sample. Twenty ml of the
KOOL-AID.RTM. staining solution is poured into the cup and the
solution is allowed to absorb completely into the carpet sample.
The cup is removed and the stained carpet sample is allowed to sit
undisturbed for 24 hours. Following incubation, the stained sample
is rinsed thoroughly under cold tap water, excess water is removed
by centrifugation, and the sample is dried in air. The carpet
sample was visually inspected and rated for staining according to
the FD&C Red No. 40 Stain Scale described in AATCC Method
175-2003. Stain resistance is measured using a 1-10 scale. An
undetectable test staining is accorded a value of 10.
Oil and Water Repellency Tests
[0042] The following liquids were used for oil repellency
tests.
TABLE-US-00001 Rating Number Liquid Composition 1 Kaydol (Mineral
Oil) 2 65%/35% Kaydol/n-Hexadecane 3 n-Hexadecane 4 n-Tetradecane 5
n-Dodecane 6 n-Decane
[0043] The following liquids were used for water repellency
tests
TABLE-US-00002 Liquid Composition Rating Number % Isopropanol %
Water 1 2 98 2 5 95 3 10 90 4 20 80 5 30 70 6 40 60
[0044] Repellency Test Procedure
[0045] Five drops of rating number 1 liquid are placed from a
height of 3 mm onto the carpet surface. If after 10 seconds, four
out of the five drops were still visible as spherical to
hemispherical, the carpet is given a passing rating. Repeat the
test with a higher rating number liquid. The repellency rating of
the sample is the highest rating number liquid used to pass the
repellency test. Carpets with a rating of 4 or higher have good
anti-soiling properties. Without anti-soil treatment, most nylon
carpets have a rating of 1 for both oil and water repellency.
Example 1
Comparative
[0046] Two 922 denier beige color solution dyed Nylon 66 BCF made
from cationic dyeable polymer were cable twisted on a Volkman at
7000 rpm to form a 6.0 tpi two ply yarn using the process described
in FIG. 1. The winding speed was about 50 ypm. The cable twisted
yarn was subsequently heat-set on a Suessen with 200.degree. C. dry
air. The holdup time in the channel was about 60 seconds. The heat
treated yarn was converted into a 35 oz per square yard, 1/12
gauge, 3/8'' pile height cut pile carpet.
Example 2
Inventive
[0047] Two 922 denier beige color solution dyed Nylon 66 BCF made
from cationic dyeable polymer were cable twisted on a Volkman at
7000 rpm to form a 6.0 tpi two ply yarn using the process described
in FIG. 2. The winding speed was about 50 ypm. A chemical
applicator was inserted between the take up roll and winder as
described in FIG. 3 option A. A 1/2 inch wide cotton wick (Wet Wick
by Perperell MA) was used to apply 50% A-201 anti-soil chemical
onto the cable twisted yarn at a wet-pickup of about 20 wt %. The
cable twisted yarn went through the wet wick at about 50 ypm. The
cable twisted yarn was subsequently heat-set on a Suessen with
200.degree. C. dry air. The holdup time in the channel was about 60
seconds. The heatset yarn was analyzed to have 925 ppm Fluorine.
The heat treated yarn was converted into a 35 oz per square yard,
1/12 gauge, 3/8'' pile height cut pile carpet.
Example 3
Inventive
[0048] Two 922 denier beige color solution dyed Nylon 66 BCF made
from cationic dyeable polymer were cable twisted on a Volkman at
7000 rpm to form a 6.0 tpi two ply yarn using the process described
in FIG. 2. The winding speed was about 50 ypm. A chemical
applicator was inserted between the take up roll and winder as
described in FIG. 2. A 1/2 inch wide cotton wick (Wet Wick by
Perperell MA) was used to apply 25% A-201 anti-soil chemical onto
the cable twisted yarn. The cable twisted yarn went through the wet
wick at about 50 ypm. The cable twisted yarn was subsequently
heat-set on a Suessen with 200.degree. C. dry air. The holdup time
in the channel was about 60 seconds. The heatset yarn was analyzed
to have 445 ppm Fluorine. The heat treated yarn was converted into
a 35 oz per square yard, 1/12 gauge, 3/8'' pile height cut pile
carpet.
Example 4
Inventive
[0049] Two 922 denier beige color solution dyed Nylon 66 BCF made
from cationic dyeable polymer were cable twisted on a Volkman at
7000 rpm to form a 6.0 tpi two ply yarn using the process described
in FIG. 2. The winding speed was about 50 ypm. A chemical
applicator was inserted between the take up roll and winder as
described in FIG. 2. A 1/2 inch wide cotton wick (Wet Wick by
Perperell MA) was used to apply 12.5% A-201 anti-soil chemical onto
the cable twisted yarn. The cable twisted yarn went through the wet
wick at about 50 ypm. The cable twisted yarn was subsequently
heat-set on a Suessen with 200.degree. C. dry air. The holdup time
in the channel was about 60 seconds. The heatset yarn was analyzed
to have 270 ppm Fluorine. The heat treated yarn was converted into
a 35 oz per square yard, 1/12 gauge, 3/8'' pile height cut pile
carpet.
[0050] Table 1 below reports the repellency and stain tests of the
four examples. Here, carpets made from the treated BCF yarn show
excellent and good oil and water repellency ratings. This indicates
that the disclosed inventive process is an acceptable replacement
to existing exhaust type applications for applying anti-soil
compositions to carpets and fabrics.
TABLE-US-00003 TABLE 1 Example Oil Rating Water Rating Stain Rating
Remarks 1 1 1 10 no repellency 2 6 6 10 excellent repellency 3 6 6
10 excellent repellency 4 5 5 10 good repellency
[0051] The invention has been described above with reference to the
various aspects of the disclosed treatment process, treated fibers,
carpets, fabrics, and systems used to apply anti-soil compositions
to BCF yarn. Obvious modifications and alterations will occur to
others upon reading and understanding the proceeding detailed
description. It is intended that the invention be construed as
including all such modifications and alterations insofar as they
come within the scope of the claims.
* * * * *