U.S. patent application number 14/346486 was filed with the patent office on 2014-09-11 for processes to dye and treat bcf yarn.
This patent application is currently assigned to INVISTA North America S.a r.l.. The applicant listed for this patent is INVISTA North America S.a r.l.. Invention is credited to Daniel R. Reynolds, Ronnie Rittenhouse, Wae-Hai Tung.
Application Number | 20140255644 14/346486 |
Document ID | / |
Family ID | 47996701 |
Filed Date | 2014-09-11 |
United States Patent
Application |
20140255644 |
Kind Code |
A1 |
Tung; Wae-Hai ; et
al. |
September 11, 2014 |
PROCESSES TO DYE AND TREAT BCF YARN
Abstract
Disclosed are processes for applying dyes, stain blocker and
anti-soil compositions on BCF yarns during cable or air twisting
processes, or heat setting processes, prior to weaving, knitting or
tufting. Further discloses are process for applying dyes, stain
blocker and anti-soil compositions on BCF yarns prior to heat
setting. The processes forego the need to dye and otherwise treat
carpets and other textiles made from the BCF yarn using current
methods. 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 R.; (Chattanooga, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
INVISTA North America S.a r.l. |
Wilmington |
DE |
US |
|
|
Assignee: |
INVISTA North America S.a
r.l.
Wilmington
DE
|
Family ID: |
47996701 |
Appl. No.: |
14/346486 |
Filed: |
September 24, 2012 |
PCT Filed: |
September 24, 2012 |
PCT NO: |
PCT/US12/56856 |
371 Date: |
March 21, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61539284 |
Sep 26, 2011 |
|
|
|
Current U.S.
Class: |
428/95 ; 28/166;
57/258; 68/158; 8/490; 8/539 |
Current CPC
Class: |
D05C 17/023 20130101;
D02G 3/445 20130101; D03D 1/0017 20130101; D02G 3/285 20130101;
D10B 2331/02 20130101; Y10T 428/23979 20150401; D02G 3/36 20130101;
D06P 3/52 20130101; D10B 2331/04 20130101; D06B 3/04 20130101 |
Class at
Publication: |
428/95 ; 57/258;
28/166; 68/158; 8/539; 8/490 |
International
Class: |
D02G 3/44 20060101
D02G003/44; D06P 3/52 20060101 D06P003/52; D03D 1/00 20060101
D03D001/00; D05C 17/02 20060101 D05C017/02; D02G 3/36 20060101
D02G003/36; D06B 3/04 20060101 D06B003/04 |
Claims
1. A process for treating twisted BCF yarn with a dye composition
comprising: a. providing twisted BCF yarn; b. winding said BCF yarn
on a take-up reel; and c. contacting said BCF yarn with said dye
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 heat setting said BCF
yarn after contacting said BCF yarn with said dye composition.
3. The process of claim 1, wherein said dye composition comprises
one or more acid dye components.
4. The process of claim 1, wherein said dye composition comprises
one or more disperse dye components.
5. The process of claim 1, wherein said dye composition comprises
at least one performance enhancing composition.
6. A process for treating twisted BCF yarn with a dye composition
and at least one performance enhancing composition comprising: a.
providing twisted BCF yarn; b. winding said BCF yarn on a take-up
reel; c. contacting said BCF yarn with said dye composition; and d.
contacting said BCF yarn with a first performance enhancing
composition prior to said BCF yarn contacting and winding up on
said take-up reel, wherein said BCF yarn is in motion while
contacted with said dye composition and said first performance
enhancing composition.
7. The process of claim 6, wherein said first performance enhancing
composition comprises an anti-soil component.
8. The process of claim 6, wherein said first performance enhancing
composition comprises an anti-stain component.
9. The process of claim 6, wherein said first performance enhancing
composition comprises both an anti-stain component and an anti-soil
component.
10. The process of claim 6 further comprising contacting said BCF
yarn with a second performance enhancing composition after
contacting with said first performance enhancing composition and
prior to said BCF yarn contacting and winding up on said take-up
reel.
11. The process of claim 10, wherein said first performance
enhancing composition comprises an anti-stain component and said
second performance enhancing composition comprises an anti-soil
component.
12. The process of claim 6 further comprising heat setting said BCF
yarn after contacting said BCF yarn with said first performance
enhancing composition.
13. The process of claim 10 further comprising heat setting said
BCF yarn after contacting said BCF yarn with said second
performance enhancing composition.
14. The process of claim 8, wherein said anti-stain component is
one or more selected from the group consisting of: syntans,
sulfonated novolacs, sulfonated aromatic aldehyde condensation
products (SACs) and/or reaction products of formaldehyde,
phenolics, substituted phenolics, thiophenolics, sulfones,
substituted sulfones, polymers or copolymers of olefins, branched
olefins, cyclic olefins, sulfonated olefins, acrylates,
methacrylates, maleic anyhydride, and organosulfonic acids.
15. The process of claim 7, wherein said anti-soil component is
selected from the group consisting of fluorochemicals, silicones,
silsesquioxanes, silane-modified particulates,
organosilane-modified particulates, alkylated particulates, anionic
non-fluorinated surfactants, and anionic hydrotrope non-fluorinated
surfactants.
16. The process of claim 15, wherein said fluorochemical is
selected from the group consisting of: fluorochemical allophanates,
fluorochemical polyacrylates, fluorochemical urethanes,
fluorochemical carbodiimides, fluorochemical guanidines, and
fluorochemicals incorporating C2 to C8 chemistries.
17. The process of claim 15, wherein said fluorochemical has one or
more monomeric repeat units bearing less than or equal to six
perfluorinated carbons.
18. The process of claim 15, wherein said fluorochemical is a
fluorochemical urethane.
19. The process of claim 8, wherein said anti-stain component is
present at an on weight of fiber from about 500 ppm to about
4%.
20. The process of claim 1, wherein said dye composition has a pH
from about 4 to about 9.0.
21. The process of claim 6, wherein said first performance
enhancing composition 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.
22. The process of claim 6, wherein said first performance
enhancing composition comprises a component selected from the group
consisting of: dye auxiliaries, sequestrants, pH control agents,
and surfactants.
23. The process of claim 7, wherein said anti-soil component is
present at an on weight of fiber from about 100 ppm elemental
fluorine to about 1000 ppm elemental fluorine.
24. The process of claim 2, wherein said heat setting is performed
at a temperature from about 125.degree. C. to about 200.degree.
C.
25. The process of claim 1, wherein said BCF yarn comprises
polyamide fiber.
26. The process of claim 25, 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.
27. The process of claim 1, wherein said BCF yarn comprises
polyester fiber.
28. The process of claim 27, wherein said polyester fiber is
selected from the group consisting of poly(ethylene terephthalate),
polypropylene terephthalate), poly(butylene terephthalate),
copolymers, and blends thereof.
29. The process of claim 1, wherein said BCF yarn comprises a
polyamide component and a polyester component.
30. The process of claim 1, wherein said contacting is performed by
a device selected from the group consisting of: applicator pad,
wet-wick, dip-tank, sprayer, and mister.
31. An untufted, twisted BCF yarn comprising a dye component,
wherein said dye component is present on said untufted, twisted BCF
yarn.
32. The untufted, twisted BCF yarn of claim 31 further comprising
an anti-soil component, wherein said anti-soil component is present
on said untufted, twisted BCF yarn.
33. The untufted, twisted BCF yarn of claim 31 further comprising
an anti-stain component, wherein said anti-stain component is
present on said untufted, twisted BCF yarn.
34. The untufted, twisted BCF yarn of claim 33, 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.
35. The untufted, twisted BCF yarn of claim 32, wherein said
anti-soil component selected from the group consisting of
fluorochemicals, silicones, silsesquioxanes, silanted particulates,
alkylated particulates, anionic non-fluoronated surfactants, and
anionic hydrotrope non-fluoronated surfactants.
36. The untufted, twisted BCF yarn of claim 35, wherein said
fluorochemical is selected from the group consisting of:
fluorochemical allophanates, fluorochemical polyacrylates,
fluorochemical urethanes, fluorochemical carbodiimides,
fluorochemical guanidines, and fluorochemicals incorporating C2 to
C8 chemistries.
37. The untufted, twisted BCF yarn of claim 35, wherein said
anti-soil component is present at an on weight of fiber from about
100 ppm elemental fluorine to about 1000 ppm elemental
fluorine.
38. The untufted, twisted BCF yarn of claim 31, wherein said BCF
yarn comprises polyamide fiber.
39. The untufted, twisted BCF yarn of claim 38, 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.
40. The untufted, twisted BCF yarn of claim 31, wherein said BCF
yarn comprises a polyamide component and a polyester component.
41. The untufted, twisted BCF yarn of claim 31, wherein said BCF
yarn comprises polyester fiber.
42. The untufted, twisted BCF yarn of claim 41, wherein said
polyester fiber is selected from the group consisting of:
polyethylene terephthalate), poly(propylene terephthalate),
polybutylene terephthalate), copolymers, and blends thereof.
43. A carpet comprising twisted BCF yarn, wherein said twisted BCF
yarn comprises the twisted BCF yarn from claim 31 that has been
tufted.
44. The carpet of claim 43 having an AATCC 175-2003 Test rating of
at least 7.
45. A process for manufacturing carpet comprising: a. providing an
untufted, twisted BCF yarn comprising a dye component and at least
one optional performance enhancing composition 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 dye or treat said carpet with
dyes and performance enhancing compositions.
46. The process of claim 45, wherein said untufted, twisted BCF
yarn comprises polyamide fiber.
47. The process of claim 46, 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.
48. The process of claim 45, wherein said untufted, twisted BCF
yarn comprises polyester fiber.
49. The process of claim 48, wherein said polyester fiber is
selected from the group consisting of: polyethylene terephthalate),
poly(propylene terephthalate), polybutylene terephthalate),
copolymers, and blends thereof.
50. A system for applying a dye composition to twisted BCF fiber
comprising: a. a first yarn take-up device that transmits a single
yarn member made from at least two individual yarn members; b. a
dye composition applicator disposed downstream of said yarn take-up
device that applies said dye composition to said single yarn
member; and c. a second yarn take-up device that receives a dyed
single yarn member.
51. A system for applying a dye composition and at least one
performance enhancing composition to twisted BCF fiber comprising:
a. a first yarn take-up device that transmits a single yarn member
made from at least two individual yarn members; b. a dye
composition applicator disposed downstream of said yarn take-up
device that applies said dye composition to said single yarn
member; c. a performance enhancing composition applicator disposed
downstream of said dye composition applicator, and d. a second yarn
take-up device disposed downstream of said performance enhancing
composition applicator that receives a dyed single yarn member.
52. The process of claim 6, wherein said dye composition has a pH
from about 4 to about 9.
53. The process of claim 6, wherein said BCF yarn comprises
polyester fiber.
54. The process of claim 6, wherein said BCF yarn comprises a
polyamide component and a polyester component.
55. The untufted, twisted BCF yarn of claim 31 further comprising
an anti-soil component and an anti-stain component, wherein said
anti-soil component and said anti-stain component are present on
said untufted, twisted BCF yarn.
Description
FIELD OF THE INVENTION
[0001] The invention relates to treatment processes for bulk
continuous filament (BCF) carpet and related textile fabrics, and
specifically, to processes for applying dyes and topical treatment
compositions on BCF yarns during twisting processes (cable or air)
or heatseting process prior to weaving, knitting or tufting. The
process foregoes the need to dye and otherwise treat carpets and
other textiles made from the BCF yarn using current methods. Thus,
low inventory overhead is achieved and costly and environmentally
unfavorable dyeing and low pH chemical treatment processes are
eliminated. Also disclosed herein are systems used to apply the dye
and performance enhancement formulations to the BCF yarn, and
stain/soil repellent yarns, and carpets with improved anti-stain
and anti-soil properties made from the BCF yarn of the disclosed
process.
BACKGROUND OF THE TECHNOLOGY
[0002] Carpets and other fabrics made from synthetic yarns are
currently colored using two well-established processes. The first
process involves converting colorless white yarns into carpet, and
dyeing the carpet in a dye bath. This process is referred to as the
"acid dye process." The acid dye process can be either a batch or a
continuous dyeing operation. Each dyeing operation requires a large
volume of water, steam to set the dyes, and heat to dry the carpet.
In addition, collection and disposal of excess dye and acidified
performance enhancing solutions add manufacturing cost and place
additional burden on waste management and water treatment
facilities. The second process adds color pigments into the polymer
during the melt spinning process. This process is referred to as
the "solution dye process." The solution dye process is a low cost
operation, but in comparison to the acid dye process it imposes
undesirable inventory allocation measures on the fiber producer and
the carpet mill. In order to meet consumer demand, then, the fiber
producer and carpet mill may need to keep a costly inventory of
colored yarns produced by the solution dye process. Variable
production demands and large inventory costs can affect inventory
flexibility with the result being the color availability of
solution dyed carpets is undesirably limited.
[0003] Topical chemistries are used to treat carpets and other
fabrics 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.
[0004] 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 greater 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 do not impart satisfactory anti-soil
properties.
[0005] 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
[0006] There is a desire to reduce the overall usage of dyeing
solutions and stain blocker formulations 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 dyeing and anti-stain
formulations. Thus, processes which provide for low inventory needs
while applying such beneficial compositions using less water,
nominal pH chemicals, and less energy are in demand.
[0007] 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.
[0008] Second, as mentioned above, treatment of yarn or fabric with
performance enhancement formulations 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.
[0009] 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.
[0010] The invention disclosed herein provides a process to make
textile fabrics, especially tufted articles, without the
requirements for dyeing and subsequent stain and soil resistant
chemistry application, thus avoiding the costs associated with
maintaining large inventories as well as waste generated by steam
fixation and rinsing attendant with such large-scale fabric
applications. As disclosed herein, the process involves application
of dyes and topical chemistries to undyed 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 dye solutions and topical chemistries to
yarn subsequent to twisting and prior to winding and heat-setting
are also disclosed.
[0011] Specifically, the disclosed process uses a dye solution or
topical 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 back end, large scale and wasteful stain blocker
application step up front during or after yarn twisting. Thus, the
carpet manufacturing process now becomes: BCF
yarn.fwdarw.twist.fwdarw.dye.fwdarw.optional SB/FC.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. Additionally, neutral pH dye solutions (4-7.5 pH) can
be used instead of the prior art low pH dye solutions (1-3 pH).
This reduces the environmental impact of prior art processes.
[0012] As described above, the process of the disclosed invention
is counterintuitive 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 [30 to 80
yards-per-minute (ypm)]. 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 and polyester
carpets manufactured with the treated BCF yarn show one or more of
the following desirable characteristics: [0013] At least equivalent
dyeing characteristics vs. the current state of the art processes.
[0014] At least equivalent stain and soil repellant performance vs.
the current state of the art processes. [0015] Desirable aesthetic
attributes otherwise not generated by the current state of the art
processes.
[0016] In one aspect, a process for treating twisted BCF yarn with
one or more dye compositions 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 dye
composition while said BCF yarn is in motion and prior to said BCF
yarn contacting and winding up on said take-up reel. The dye
composition can be comprised of an acid dye composition or a
disperse dye composition.
[0017] In another aspect, a process for treating twisted BCF yarn
with one or more dye compositions is disclosed. The process
comprises: (a) providing twisted BCF yarn; (b) contacting said BCF
yarn with said dye composition while said BCF yarn is in motion;
and (c) heat setting said BCF yarn after contacting said BCF yarn
with said dye composition. The dye composition can be comprised of
an acid dye composition or a disperse dye composition.
[0018] In a further aspect, a process for treating twisted BCF yarn
with one or more dye compositions and performance enhancing
compositions is disclosed. The process comprises: (a) providing
twisted BCF yarn; (b) winding said BCF yarn on a take-up reel; (c)
contacting said BCF yarn with said dye composition; (d) optionally
contacting said BCF yarn with a first performance enhancing
composition comprising a stain blocking composition; and (e)
contacting said BCF yarn with a second performance enhancing
composition comprising an anti-soil composition and prior to said
BCF yarn contacting and winding up on said take-up reel, wherein
said BCF yarn is in motion while contacted with said dye, said
optional first performance enhancing composition, and said second
performance enhancing composition. The dye composition can be
comprised of an acid dye composition or a disperse dye composition.
The stain blocking composition can be comprised of species having
acidic moieties that associate with polymer amine end groups and
protect 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. 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.
[0019] In even another aspect, a process for treating twisted BCF
yarn with one or more dye compositions and performance enhancing
compositions is disclosed. The process comprises: (a) providing
twisted BCF yarn; (b) contacting said BCF yarn with said dye
composition; (c) optionally contacting said BCF yarn with a first
performance enhancing composition comprising a stain blocking
composition; (d) contacting said BCF yarn with a second performance
enhancing composition comprising an anti-soil composition, wherein
said BCF yarn is in motion while contacted with said dye, said
optional first performance enhancing composition, and said second
performance enhancing composition and; (e) heat setting said BCF
yarn after contacting said BCF yarn with said dye composition, said
optional first performance enhancing composition, and said second
performance enhancing composition. The dye compositions and
performance enhancing compositions are disclosed above.
[0020] In a further aspect, an untufted, twisted BCF yarn
comprising a dye component is disclosed, wherein said dye component
is present on said twisted BCF yarn prior to tufting the BCF yarn.
The dye component is selected from acid and disperse dye
ingredients. The yarn can comprise polyamide fiber and/or have
polymer components selected from polyester. The yarn can be tufted
and manufactured into carpet or fabrics.
[0021] In yet another aspect, an untufted, twisted BCF yarn
comprising a dye component, an anti-soil component, and an optional
anti-stain component is disclosed, wherein said dyeing component,
anti-soil component and optional anti-stain component are present
on said twisted BCF yarn prior to tufting the BCF yarn. The dye
component is selected from acid and disperse dye ingredients. The
anti-soil component and optional anti-stain component can be
selected from the compositions disclosed above. The stain blocking
component is optionally present at an amount on weight of fiber of
about 0.5 to about 40 ppm elemental sulfur content. The anti-soil
component is present at an amount on weight of fiber from about 100
ppm to about 1000 ppm elemental fluorine content. The yarn can
comprise polyamide fiber and/or have polymer components selected
from polyester. The yarn can be tufted and manufactured into carpet
or fabrics.
[0022] In yet a further aspect, a process for manufacturing carpet
is disclosed comprising providing an untufted, twisted BCF yarn
comprising a dye component, an optional stain blocker component,
and an anti-soil component, tufting said BCF yarn, and weaving into
said carpet. Because of the dye and performance enhancing
components present on the BCF yarn prior to tufting and weaving,
there is no need to process the finished carpet by dyeing or
treating with an acidified stain blocker composition and an
anti-soil composition under the current state of the art
processes.
[0023] In yet even another aspect, a system for applying a dye
composition to twisted BCF fiber is disclosed. The system
comprises: (a) a first yarn take-up device that transmits a single
yarn member made from at least two individual yarn members; (b) a
dye composition applicator disposed downstream of said yarn take-up
device that applies said dye composition to said single yarn
member; and (c) a second yarn take-up device that receives a dyed
single yarn member. The dyeing composition can be comprised of acid
dye or disperse dye ingredients.
[0024] In yet even a further aspect, a system for applying a dye
composition and at least one performance enhancing composition to
twisted BCF fiber is disclosed. The system comprises: (a) a first
yarn take-up device that transmits a single yarn member made from
at least two individual yarn members; (b) a dye composition
applicator disposed downstream of said yarn take-up device that
applies said dye composition to said single yarn member; (c) an
optional anti-stain component applicator disposed downstream of
said dye composition applicator that applies anti-stain composition
to said single yarn member; (d) an anti-soil applicator disposed
downstream of said dye composition applicator that applies
anti-soil composition to said single yarn member; and (d) a second
yarn take-up device that receives a dyed single yarn member. The
dyeing composition can be comprised of acid dye or disperse dye
ingredients. The anti-stain composition can be comprised of species
having acidic moieties which associate with polymer amine end
groups and protect them from staining by acidic dye stains. 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
[0025] FIG. 1 shows the current cable twisting process.
[0026] FIG. 2 shows one aspect of the disclosed process.
[0027] FIG. 3 shows another aspect of the disclosed process.
[0028] FIG. 4 shows the current heat setting process.
[0029] FIG. 5 shows a further aspect of the disclosed process.
DEFINITIONS
[0030] While mostly familiar to those versed in the art, the
following definitions are provided in the interest of clarity.
[0031] OWF (On weight of fiber): The amount of chemistry that was
applied as a % of weight of fiber.
[0032] 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
[0033] A process for treating twisted BCF yarn is disclosed
comprising contacting the BCF yarn with a dye 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
process can also include contacting the BCF yarn with one or more
performance enhancing compositions comprising stain blockers and
anti-soil compositions. The dye composition comprises a dye
component and is adapted to be continuously applied onto twisted
BCF yarn at 10 to 100 ypm, preferably, 30 to 80 ypm. The stain
blocker composition comprises an anti-stain component and is
adapted to be continuously applied onto twisted BCF yarn at a wet
pick-up of 10 to 50%, preferably 15 to 30%. The anti-soil
composition comprises an anti-soil component and is adapted to be
continuously 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 dye
composition and the one or more performance enhancing compositions.
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.
[0034] Dye components for use in the disclosed dye compositions are
acid dyes or disperse dyes. Acid dye components are well known to
those skilled in the art and are water-soluble ionic species
containing one or more organic chromophore moieties. Acid dyes are
typically provided in powder form and different acid dyes can be
used in combinations to arrive at a precisely defined color choice
depending on process conditions such as the use rate of each
selected dye component, the use rate of the one or more acid
auxiliaries employed, and the residence time of the substrate in
the dyeing zone. Examples of suitable acid dye compositions are
Orange 3G, Red 2B and Blue 4R. Disperse dye components are likewise
well known to those skilled in the art and are water-insoluble
nonionic species containing one or more organic chromophore
moieties. Disperse dyes are either provided in paste form in
combination with a dispersing agent or in powder form. Different
disperse dyes can be used in combinations to arrive at a precisely
defined color choice depending on process conditions such as the
use rate of each selected disperse dye component, the specific
dispersing agent or agents employed, and the residence time of the
substrate in the dyeing zone. Examples of suitable disperse dye
compositions are Disperse Red 60, Disperse Yellow 86 and Disperse
Violet 33.
[0035] Anti-stain components for use in the disclosed stain blocker
compositions have a component bearing 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, sulfonated aromatic aldehyde condensation products (SACs)
and/or reaction products of formaldehyde, phenolics, substituted
phenolics, thiophenolics, sulfones, substituted sulfones, polymers
or copolymers of olefins, branched olefins, cyclic olefins,
sulfonated olefins, acrylates, methacrylates, maleic anyhydride,
and organosulfonic acids. 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.
[0036] 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.
[0037] 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 guanidines,
non-telomeric fluorochemicals, and fluorochemicals incorporating C2
to C8 chemistries. Alternatively, the fluorochemical can have one
or more monomeric repeat units hearing 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.RTM. RCP. Non-fluorinated anti-soil components can
include: silicones, silsesquioxanes and silane-modified
particulates, organosilane-modified particulates and alkylated
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).
[0038] The dye 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 dye composition can be at a neutral pH
(e.g. 4 to 9, including 5.5 to 7.5) because the yarn can be
optionally heat set after application of the composition. The
process foregoes the need for harsh low pH chemicals; deionized
water is suitable for use in the disclosed process.
[0039] The stain blocker 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 stain blocker 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.
[0040] 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.
[0041] The contacting can be performed by 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.
[0042] For example, cotton wicks can be stacked together to form
the desired thickness (e.g. 1/2''-3'') and submersed in the dye
bath for transporting dye solution to the moving yarn at a constant
flow-rate. The wick thickness selection was based on the optimum
wick and yarn contacting time needed to achieve the desired color
depth and color consistency. A further option is to use multiple
sets of wicking applicator stations. The first wicking applicator
station applies the primary color onto the yarn and the second
wicking applicator station applies a second color or performance
enhancing chemical onto the yarn. Each wicking applicator station
can be made up of one or more wicks.
[0043] Another option is to transport dye solution to the yarn
using two rotating rolls covered with wicks. Here, the yarn passes
between the two rotating rolls. Further, multiple rolls can be used
in series. For example, one roll can apply a first color onto one
side of the moving yarn and another roll to apply a second color
onto the other side of the yarn to create a unique two color yarn.
Further, two sets of nip rolls can be used. The first set can apply
the primary color and the second set can apply a second color or
performance enhancing chemical onto the yarn. Any combination of
the above options can be used to make yarn with multiple colors,
color depth and with various performance chemicals.
[0044] The wet pick-up of the 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 elemental fluorine,
including from about 100 to about 500 ppm elemental fluorine, from
about 200 to about 400 ppm, and from about 100 ppm to about 300 ppm
elemental fluorine.
[0045] The wet pick-up of the stain blocker composition 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%. 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.
[0046] The performance enhancing compositions can further comprise
one or more components selected from the group consisting of: odor
control agents, anti-microbial agents, anti-fungal agents,
fragrance agents, bleach resist agents, softeners, and UV
stabilizers.
[0047] 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. 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.
[0048] As stated above, the BCF yarn can be manufactured with
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.
[0049] The disclosed process may be used with yarns that do not
require subsequent dyeing or performance enhancing chemical
treatments, having been dyed and optionally treated with one or
more performance enhancing compositions prior to twisting. The
yarns can be made by acid dyed as well as disperse dyed fibers.
Yarns suitable for use in the process may further comprise inherent
stain resistance, whether by base composition as in the case of
polyester, or by the inclusion of strong acid functionality in the
polymer composition of the yarn, as in the case of nylon. Use of a
dye applicator with the disclosed process eliminates the need for
subsequent dyeing and enables the creation of colored carpets that
improve inventory flexibility, improve color options, are stain
resistant, and are soil resistant without the need for dyeing and
performance enhancing chemical applications as practiced under the
current state of the art.
[0050] 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.
[0051] 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.
[0052] Alternatively, the disclosed process can be modified to
include dye application, optional anti-stain application and/or
anti-soil application after the twisted BCF yarn is wound and prior
to heat setting. For example, the twisted BCF yarn is unwound from
a core or package, contacts the dye applicator, contacts the
optional anti-stain applicator, and contacts the anti-soil
applicator, then goes through a heat setting process to lock in the
yarn twist, dye, anti-soil, and optional anti-stain.
[0053] Further disclosed is a system for applying a dye composition
and one or more performance enhancing compositions to the twisted
BCF yarn. The system includes: (a) a first yarn take-up device that
transmits a single yarn member made from at least two individual
yarn members; (b) a dye composition applicator disposed downstream
of said yarn take-up device that applies said dye composition to
said single yarn member; (c) an optional anti-stain blocker
applicator disposed downstream of said dye composition applicator
that applies anti-stain composition to said single yarn member; (d)
an anti-soil applicator disposed downstream of said dye composition
applicator that applies anti-soil composition to said single yarn
member; and (e) a second yarn take-up device that receives a dyed
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. Alternatively, the first yarn
take-up device can receive BCF yarn that has been air twisted. The
individual yarn members can be single filaments or fibers, or yarns
made from a plurality of filaments or fibers. Each 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 stain blocker is used, 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 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 elemental fluorine,
including from about 100 to about 500 ppm elemental fluorine, from
about 200 to about 400 ppm, and from about 100 ppm to about 300 ppm
elemental fluorine. The second yarn take-up device can be a
winder.
[0054] 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 is wound up on a winder 30. 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. A dye
applicator 140 is disposed downstream of take-up roll 125, which
applies a dye component to the twisted yarn. From here, the twisted
and dyed yarn is wound up on a winder 130. FIG. 3 shows another
aspect of the disclosed process containing both a dye applicator
and anti-stain/anti-soil applicator. Here, creel yarn 310 and
bucket yarn 315, which is fed at a spindle speed of 7000 rpm, pass
through anti-balloon device 320 and onto a take-up roll 325. A dye
applicator 340 is disposed downstream of take-up roll 325, which
applies a dye component to the twisted yarn. An
anti-soil/anti-stain applicator 350 is disposed downstream of the
dye applicator 340, which applies an anti-soil/anti-stain component
to the dyed, twisted yarn. From here, the twisted and treated yarn
is wound up on a winder 330.
[0055] FIG. 4 shows the current heat setting process. Here, cable
twisted BCF yarn 410 enters a false twisting unit 420, followed by
a coiler or stuffer box 430, prebulker 440, and finally a heatset
chamber 450 to produce a heatset yarn 455. FIG. 5 shows another
aspect of the disclosed process where cable twisted BCF yarn is
dyed prior to heat setting. Here, cable twisted BCF yarn 510 enters
the dye applicator 515, followed by a false twisting unit 520, a
colier or stuffer box 530, prebulker 540, and finally a heatset
chamber 550 to produce a dyed, heatset yarn 555.
[0056] The disclosed process is counterintuitive and surprisingly
results in yarn that contains acceptable dyed and performance
enhancement 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
[0057] The following are examples of carpets made from BCF fibers
that have been treated according to various aspects of the process
disclosed above, and similar fibers with no treatment. Selection of
alternative dyeing and performance enhancing components, fibers and
textiles having different surface chemistries will necessitate
minor adjustments to the variables herein described.
Test Methods
Acid Dye Stain Test.
[0058] 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.
Example 1
Comparative
[0059] Two 920 denier, 8 dpf, colorless nylon 6,6 BCF yarns were
processed on a Volkman twisting machine as described in FIG. 1 to
form a 5.75 tpi (twist per inch) 2-ply cable twisted yarn. The
twisting speed was about 7000 rpm (turns per minute) and winding
speed was about 50 meter per minute. The cable twisted yarn had no
color. The cable twisted yarn was heatset on Superba, and converted
into cut pile carpet on a 1/8 ga tufting machine to 22/32 inch pile
height, 35 oz/sq yard carpet and dyed on a continuous dye line to
get medium pie crust color. This example was made using the state
of art carpet making process with continuous dyer to add color to
carpet.
Example 2
Inventive
[0060] Two 920 denier, 8 dpf, colorless nylon 6,6 BCF yarns were
processed on a Volkman twisting machine as described in FIG. 2 to
form a 5.75 tpi (twist per inch) 2-ply cable twisted yarn. A
wicking dye applicator was inserted between take up roll and
winder. A % inch wide, 1 inch thick cotton wick (Wet Wick by
Perperell MA) was used to apply a mixture of acid dyes (Blue 4R @
5.0 g/l & Orange 3G @ 2.0 g/l in deionized water, pH 9.47) onto
the cable twisted yarn. The twisting speed was about 7000 rpm
(turns per minute) and winding speed was about 50 meter per minute.
The cable twisted yarn was heatset on Superba at 265.degree. F.,
and tufted into cut pile carpet on a 1/8 ga tufting machine to
22/32 inch pile height, 35 oz/sq yard carpet. The tufted carpet had
medium shade green color (L 51.26, a -9.71, b+1.45 by Minolta).
Example 3
Inventive
[0061] Two 920 denier, 8 dpf, colorless nylon 6,6 BCF yarns were
processed on a Volkman twisting machine as described in FIG. 2 to
form a 5.75 tpi (twist per inch) 2-ply cable twisted yarn. A
wicking dye applicator was inserted between take up roll and
winder. A 1/2 inch wide, 1 inch thick cotton wick (Wet Wick by
Perperell MA) was used to apply a mixture of acid dyes (Orange 3G @
5.712 g/l, Red 2B @ 2.52 g/l, Blue 4R @ 2.268 g/l in deionized
water, pH 6) onto the cable twisted yarn. The twisting speed was
about 7000 rpm (turns per minute) and winding speed was about 50
meter per minute. The cable twisted yarn was heatset on Superba at
265.degree. F., and tufted into cut pile carpet on a 1/8 ga tufting
machine to 22/32 inch pile height, 35 oz/sq yard carpet. The tufted
carpet had light shade brown color (L 39.17, a 10.48, b 18.14 by
Minolta). There were numerous dark, medium and light spots randomly
distributed over the carpet that created an interesting salt and
pepper toner mixture effect.
Example 4
Inventive
[0062] Two 920 denier, 8 dpf, colorless nylon 6,6 BCF yarns were
processed on a Volkman twisting machine as described in FIG. 2 to
form a 5.75 tpi (twist per inch) 2-ply cable twisted yarn. A
wicking dye applicator was inserted between take up roll and
winder. A 1/2 inch wide, 1 inch thick cotton wick (Wet Wick by
Perperell MA) was used to apply a mixture of acid dyes (Orange 3G @
11.424 g/l, Red 2B @ 5.040 g/l, Blue 4R @ 4.536 g/l in deionized
water, pH 6.0) onto the cable twisted yarn. The twisting speed was
about 7000 rpm (turns per minute) and winding speed was about 50
meter per minute. The cable twisted yarn was heatset on Superba at
265.degree. F., and tufted into cut pile carpet on a 1/8 ga tufting
machine to 22/32 inch pile height, 35 oz/sq yard carpet. The tufted
carpet had dark brown color (L 23.63, a 12.61, b 15.15). This
carpet also had dark and light spots similar to example 3 except
the contrast was very subtle, almost invisible.
Example 5
Inventive
[0063] Two 901 denier, 3 dpf, colorless nylon 6,6 BCF yarns were
processed on Volkman twisting machine as described in FIG. 1 to
form a 4.5 tpi (twist per inch) 2-ply cable twisted yarn. The
twisting speed was about 7000 rpm (turns per minute) and winding
speed was about 60 meter per minute. The cable twisted yarn had no
color.
[0064] The cable twisted yarn was heatset on Superba equipped with
two wicking dye applicators inserted in tandem between the creel
and the false twisting unit. Each dye applicator had one inch wide,
4 inch thick cotton wick (Wet Wick by Perperell MA) that wicked a
mixture of acid dyes (Orange 3G @ 14.85 g/l, Red 2B @ 6.55 WI, Blue
4R @ 5.90 g/l, 15 g/l wetting agent in deionized water) onto the
cable twisted yarn at 350 ypm. After color application, the cable
twisted yarn was processed through a coiler, a prebulker with steam
and heatset in a pressurized chamber with saturated steam at
129.4.degree. C. The dwell time in the pressurized chamber was
about 36 seconds. The yarn was cooled with air and wound on tube.
The colored yarn was subsequently converted into 5/8 inch pile
height, 12 stitches per inch cut pile carpet on a 1/10 gauge
tufting machine. The finished carpet had a medium brown color (L
37.9, a 10.7, b 16.9).
Example 6
Inventive
[0065] Two 901 denier, 3 dpf, colorless nylon 6,6 BCF yarns were
processed on Volkman twisting machine as described in FIG. 1 to
form a 4.5 tpi (twist per inch) 2-ply cable twisted yarn. The
twisting speed was about 7000 rpm (turns per minute) and winding
speed was about 60 meter per minute. The cable twisted yarn had no
color.
[0066] The cable twisted yarn was heatset on Superba equipped with
two wicking dye applicators inserted in tandem between the creel
and the false twisting unit. Each dye applicator had one inch wide,
4 inch thick cotton wick (Wet Wick by Perperell MA) that wicked a
mixture of green acid dyes (orange 3 G 4 g/l, Blue 4 R 10 g/l, 15
g/l wetting agent in deionized water) onto the cable twisted yarn
at 350 ypm. After color application, the cable twisted yarn was
processed through a coiler, a prebulker with steam and heatset in a
pressurized chamber with saturated steam at 129.4.degree. C. The
dwell time in the pressurized chamber was about 36 seconds. The
yarn was cooled with air and wound on tube. The colored yarn was
subsequently converted into 5/8 inch pile height, 12 stitches per
inch cut pile carpet on a 1/10 gauge tufting machine. The finished
carpet had a light green color (L 61.5, a -8.9, b 2.7)
Example 7
Inventive
[0067] Two 901 denier, 3 dpf, colorless nylon 6,6 BCF yarns were
processed on Volkman twisting machine as described in FIG. 1 to
form a 4.5 tpi (twist per inch) 2-ply cable twisted yarn. The
twisting speed was about 7000 rpm (turns per minute) and winding
speed was about 60 meter per minute. The cable twisted yarn had no
color.
[0068] The cable twisted yarn was heatset on Superba equipped with
two wicking applicators inserted in tandem between the creel and
the false twisting unit. The first wicking applicator was use to
apply brown color dyes (Orange 3G @ 14.85 g/l, Red 2B @ 6.55 g/l,
Blue 4R @ 5.90 g/l, 15 g/l wetting agent in deionized water, pH 6)
and the second applicator was used to apply stain block chemistry
(SR-500, 250 g/l, pH 6) onto the cable twisted yarn. The processing
speed was about 350 ypm. After color and stain chemical
application, the cable twisted yarn was processed through a coiler,
a prebulker with steam and heatset in a pressurized chamber with
saturated steam at 129.4.degree. C. The dwell time in the
pressurized chamber was about 36 seconds. The yarn was cooled with
air and wound on tube. The colored yarn was subsequently converted
into 5/8 inch pile height, 12 stitches per inch cut pile carpet on
a 1/10 gauge tufting machine. The finished carpet had a medium
brown color and excellent stain resistance (rating 10 on 24 hour
Kool-aid test).
Example 8
Inventive
[0069] Two 901 denier, 3 dpf, colorless nylon 6,6 BCF yarns were
processed on a Volkman twisting machine as described in FIG. 1 to
form a 4.5 tpi (twist per inch) 2-ply cable twisted yarn. The
twisting speed was about 7000 rpm (turns per minute) and winding
speed was about 60 meter per minute. The cable twisted yarn had no
color.
[0070] The cable twisted yarn was heatset on Superba equipped with
two wicking applicators inserted in tandem between the creel and
the false twisting unit. The first wicking applicator was used to
apply green color acid dyes (orange 3 G 4 g/l, Blue 4 R 10 g/l, 15
g/l wetting agent in deionized water) and the second applicator was
used to apply brown color acid dyes (Orange 3G @ 14.85 g/l, Red 2B
@ 6.55 g/l, Blue 4R @ 5.90 g/l, 15 g/l wetting agent in deionized
water, pH 6) onto the cable twisted yarn. The processing speed was
about 350 ypm. After color and stain/soil chemical application, the
cable twisted yarn was processed through a coiler, a prebulker with
steam and heatset in a pressurized chamber with saturated steam at
129.4.degree. C. The dwell time in the pressurized chamber was
about 36 seconds. The yarn was cooled with air and wound on tube.
The colored yarn was subsequently converted into 5/8 inch pile
height, 12 stitches per inch cut pile carpet on a 1/10 gauge
tufting machine. The finished carpet had an interesting salt and
pepper brown and green color (L 47.5, a -3.5, b 9.4).
Example 9
Inventive
[0071] Two 1400 denier, 10 dpf, colorless polyester BCF yarns were
processed on a Volkman twisting machine as described in FIG. 2 to
form a 5.25 tpi (twist per inch) 2-ply cable twisted yarn. A
wicking dye applicator was inserted between take up roll and
winder. A 1/2 inch wide, 1.25 inch thick cotton wick (Wet Wick by
Perperell MA) was used to apply a mixture of disperse dyes (Dianix
yellow E-3GE 21.5 g/l, Red E-FB 15.3 g/l, blue ER-AM 5.6 g/l all by
Dystar in deionized water, pH 5.0) onto the cable twisted yarn. The
twisting speed was about 7000 rpm (turns per minute) and winding
speed was about 60 meter per minute. The cable twisted yarn was
heatset on Suessen at 185.degree. C. at 375 ypm, .about.60 second
dwell time, and tufted into cut pile carpet on a 5/32 ga tufting
machine to 22/32 inch pile height, 45 oz/sq yard carpet. The tufted
carpet had medium brown color (L 47.43, a 15.58, b 15.98).
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