AU2017217405A1 - Process for heat setting twisted, bulked continuous filament yarn - Google Patents

Abstract

A multi-step process is disclosed for heat setting twisted, bulk continuous filament (BCF) yarn comprising the steps of developing crimp in the yarn under hot atmospheric air and heat setting the yarn by saturated steam treatment.

Description

PROCESS FOR HEAT SETTING TWISTED, BULKED CONTINUOUS FILAMENT YARN

Field of Invention [0001] The present invention relates to an apparatus and method for heat-setting yarn, More partícularly, the present invention relates to an apparatus and method for heat-setting cable twisted bulk continuous fílament (BCF) yarn.

Background [0002] Background art methods for making BCF yarns for carpets typically inelude the steps of twisting, heat-setting, tuíting, dyeing and finishíng, In particular, heat-setting of twisted yarn is an important step in converting BCF yams to carpets. Heat-setting develops crimp and locks the twist memory in the BCF yarns. The development of crimp and twist memory have a significant impact on yartt bulk. and newness retention of finished carpets.

[0003] Two types of heating-setting methods are used in continuous heat-setting machines of the background art. The first type uses pressurized steam, which can be saturated or near saturated steam. The most common pressurized steam heat-setting machine in the background art is referred to as a Superba RTM machine such as that produced by American Superba, Inc.

[0004] The second type of heat-setting method uses hot atmospheric air. The most common hot atmospheric air heat-setting machine in the background art is referred to as a "Suessen" machine, or “Power-Heat-Set” machine such as those produced by Power-FIeat-Set of America.

[0005] The erystalline slrueture of heat-set yarns and the end use performance of the finished carpets produced from heat-set varas primarily depend on the heat-setting method used in producing the yarn. It is well understood by those skilled in the industry, carpet yarns produced by hot atmospheric air heat-setting machines (e.g., Seussen) have higher bulk and better stain resistance than carpet yams produced by pressurized steam heat-setting machines (e.g·, Superba RTM.).

[0008] ft is well understood that the heatsetting method used has a great impact on nylon carpet stain performances. Solution dyed nylon (SDN) carpets made from cationic dyeable polymer and heatset using hot atmospheric air have longer-lived, built-in stain resistance. However, SDN nylon carpets made from cationic dyeable polymer, and heatset with saturated steam, are found to have uttacceptable stain resistances.

[0007] Curreníly, the majority of heatsetting machines used are pressurized steam heat-setting machines, such as Superba RTM machines. It is this commercial environment which plays a parí. in limiting the use of SON nylon carpet fíber to only those yarn tufling and processing facilities that wíll heatsetusing Suessen, or Power Heat-Set processes..

[0008] Hiere have been improved heatsetting processes disclosed ín the background art. For example, US Patent No. 7,073,318 discloses an apparatus and method for texture heat-setting bulk continuous filament (BCF) yams in hot air heat-setting machines that ineludes a preheatíng device/step using a mixture of steam and atmospheric air to preheat a twisted BCF yarn bundle to develop crimp memory and provide cohesión to the twisted BCF yarn bundle, [0009] US Patent pubÜeation 2007 0137166 is directed to flow management improvement to the known yam texturing process, and is directed to devices and methods to accumulate one or more yarns between texturing device(s) and eoiling deviee(s) prior to treatnient in a heat-setting chamber.

[00101 US Patent No. 7,543,463 relates to a machine and process for heat settíng yam, prineipally, but not exclusively, carpet yam. The machine conditions twisted yams with saturated steam to increase the crystallínity of the yam and lock the twist or the crimp into the yam. The machine is a continuous process machine with yarn entering one end of the machine, movíng downstream through the machine and exitíng the downstream end properly treated and ready for the next produetíon step.

[0011] Therefore, a strong need remaíns for a heatsetting process and apparatus to treat texturized BCF yam using pressurízed steam that resulte in the required crimp retention, yarn tip definition and stain resistan! properties,

Bríef Description of the Drawings [0012] FIG. 1 depiets 24 hr. stain test resulte for carpet samples made from embodiments of the current invention and comparative examples.

[0013] FIG. 2 depiets WAQE stain test resulte for carpet samples made from embodiments of the current invention and comparative examples.

Summaiy of the Invention [0014] The present disclosure relates to processes and apparatuses for heat settíng twisted. bulk continuous filamení (BCF) yarn. Also disclosed are árdeles, inciuding cárpete, formed from. using these processes or apparatuses.

[0015] In one nonlimiting aspect of the current invention, a multí-step process is disclosed for heat setting twisted, bulk continuous filament (BCF) yarn comprísing the steps of (a) developing crimp in the yarn under hot atmospheric air and (b) heat setting the yarn by s'aturated steam treaíment.

[0016] In one nonlimiting embodiment, step (a) is performed under hot air ai a.temperatura in the range from about 140°C to about 210°C. In one nonlimiting embodiment, the yarn is treated in step (a) for a period of about 3 seconds or greater. In another nonlimiting embodiment, the yarn is treated in step (a) for a period of about 3 to about 7 seconds.

[0017] In one nonlimiting embodiment, step (b) is achíeved with saturated steam at a temperature ín the range írorn about 11()°C to about 13()°C. In one nonlimiting embodiment, the yarn is heat set in step (b) for a period of about 25 to about 60 seconds.

[0018] In another nonlimiting embodiment, the yarn is formed from a synthetic polyrner seleeted from the group consisting of nylon, polvester, polyolefin and copolymers and blends thereof. In another nonlimiting embodiment, the yam is formed from nylon 6,6 or nylon 6 polyrner.

[0019] In another nonlimiting embodiment, the yarn is made from cationic dyeable nylon polyrner, In another nonlimiting embodiment, the cationic dyeable nylon polyrner comprises a stain blocking additive capadle of disabling acid dye sites in the polyrner. In another nonlimiting embodiment, the stain blocking additive is present in a range from about 1 to 10 percent by weight. In another nonlimiting embodiment, the stain blocking additive is anaromatíc sulfonate or an alkali metal salí thereof. In another nonlimiting embodiment, the yarn is solution dye nylon yarn.

[0020] ín another aspee! of the current invention, anieles are disclosed that are formed from the yarn treated by any of the processes descríbed above. In another aspect of the current invention cárpete are disclosed that are formed .from the yarn treated by any of the processes descríbed above. In one nonlimiting embodiment, the carpe! has a stain ratíng of 8 or hígher according. to the 24 hour stain test. In another nonlimiting embodiment, the earpet has a stain ratíng of 7 or higher according to the WAQE stain test.

[0021] In another aspect of the current invention, an apparatus is disclosed for heat setting twisted, bulk continuous filament (BCF) yarn comprísing a bulking apparatus configurad to bulk the yarn with hot atmospheric air to develop crimp and a heat setting tunnel configurad to heat set the yarn by steam injection.

Detailed Descriptíon of tira Invention [0022] The present disclosure· relates to processes and apparatuses for heat settíng twisted, bulked continuous fílament (BCF) yarn. Also dísclosed are articles, .incíuding carpets, formed from usjng these proeesses or apparatuses.

[0023] I n one nonlimiting embodiment, a multi-step process for heat settíng twisted, bulked continuous fílament (BCF) yarn is dísclosed comprísing the steps of (a) developing crírnp in íhe yarn under hot atmospberic air and heat settíng the yarn from step (b) by saturated steam. ifeatment [0024] In one embodiment, the twisted, bulked continuous fílament (BCF) yarn ís íexturized prior to step (a). Hot air treatment is an effective process for developing crírnp in yam. In one nonlimiting embodímení, step (a) is perforrned under hot air at a temperatura in the range from about 140°C to about 210°C. It is understood the hot air treatment may be applied ín any method known to those skílled in the art to develop yarn crírnp in the BCF yarn. The hot air treatment may be applied for a duration necessary to achieve the desíred crimp development ín the yarn. In one nonlimiting embodímení, the yam is treated in step (a) for aperíod of about 3 seconds or greater. In another nonlimiting embodiment, the yarn is treated in step (a) for a period of about 3 to about. 7 seconds.

[0025] In order for yam used in carpets ío have the necessary aesthetics and floor performance for residential applícátions it is necessary ío develop tip defínition in the tam. In one nonlimiting embodiment of the current inventi on, tip defínition is achieved by treating the BCF yarn from step (a.) with saturated steam, In another embodiment step (b) may be perfonned with pressurized steam at near saturation leve!. ín another nonlimiting embodiment, step (b) is achieved with saturated steam at a temperatura in the range from about 110°C to about 130°C. the steam treatment in step (b) may be for any duration necessary to achieve the desired tip defínition. In one nonlimiting embodiment, the yarn is heat set in step (b) for a period of about 25 to about 60 seconds.

[0026] Embodiments of the current invention may be perforrned with yarns formed from a synthetic polymer selected. from the group consisting of polyamide, polyester, polyolefín and copolymers and bíends thereof.

[0027] Nonlimiting examples of polyamide fibers inelude fibers comprísing nylon 5,6; nylon 6/6; nylon 6; nylon 7; nylon 1 ]; nylon 12; nylon 6/10;, nylon 6/12; nylon DT; nylon 6T; nylon 61; and blenda or copolymers thereof Nonlímiting examples of polyolefin fibers inelude fíbers eomprising polypropylene. Nonlímiting examples of polyester fibers include fibers eomprising polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polylactic aeid (PLA) and blends or copolymers thereof.

[0028] In one nonlímiting embodiment, the yam is formed from nylon 6,6 or nylon 6 polymer. [0029] Without being bouud any particular theory, it is bebe ved that using pressurized steam treatment to develop yarn crimp prevenís the polymer erystal structure in yams made fiom polyamides from opening and beeoming more susceptible to aeid stains. It. is well known in that art that this phenomenon prevent the use of most polyamíde yarns with built in stain resistance from being used with. heat settíng proc-esses. Through undue experimentaíion, the inventors have discovered that using a multi-step process, twisted BCF yarn conld be heat set to achieve crimp development, tip definition without opening the polymer structure to the point that the yam hecomes more susceptible to acid stains. Tire embodiments of the current invention thus aliow polyamide yams with built in stain resistance to be used wíth heat settíng machines that use pressurized stearn or saturated steam to create tip definition.

[0030] In one nonlímiting embodiment, the yam used is made from cationic dyeable nylon polymer. As used herein, cationic dyeable nylon polymer are nylon polymers modifíed to make them receptivo to cationic dyes. In one nonlímiting embodiment, the cationic dyeable nylon polymer comprises a stain blocking additive capáble of disabling aeid dye sites.

[0031] Suitable built-in stain blocking addítives include Ihose that are known to disable acid dye sites. For examples, in polyamides, such as nylon 6,6 or nylon 6, acid dyes sites refer to amine end groups or amide linkages that react or associate with aeid dyes, which results in staining. Stain blocking addítives react or associate wíth these acid dye sites to prevent the aeid dye sites from reactíng or associating with aeid dyes. Suitable stain blocking addítives for use in polyamides are discussed in US Pat. No. 5,155,178, herein incorporated by reference. Suitable stain blocking addítives include, but are not límited to aromatic sulfonat.es and alkali metal salís thereof, such as 5-sulfoisophthalic acid, sodium salí and dñnethyl-5-sulfoisophíhalate, sodium salí. In one nonlímiting, embodiment, the stain blocking additive is 5-sulíbisophthalic acid, sodium salí (SSIPA). In one nonlímiting embodiment, the stain blocking additive is present in a range from about 1 to 10 percent by weight. In anothef nonlímiting embodiment, the stain blocking additive is present in a range from about 1 to 5 percent by weight [0032] In another nonlimitng embodiment, the yam is solution dye nylon (SDN) yam.

[0033] In another aspect of the current invention, artieles are disclosed that are formed from íhe yam treated by any of the processes disclosed herein. In another aspect of the current ínvention, carpeta are disclosed that are formed frota the yam treated by any of the processes disclosed herein. As shown in examples 2 and 3, in nonlimiting embodiments, catpets are disclosed that have a stain rating of 8 or liigher according to the 24 hour stain test. As shown in examples 2 and 3. in nonlimiting embodiments, earpets are disclosed that have a stain rating of 7 or higher according to the WAQE stain test.

[0034] In another aspect of the current invention an apparatus is disclosed for heat setting twisted, buík continuous filament (BCF) yarn comprising a bulking apparatus configurad to bulk the yarn with hot atmospheric air to develop crimp and a heat setting tunnel confignred to heat set the yarn by steam injectíon.

[0035] Suitable bulking apparatus may be any apparatus known to those skilled in the art that can develop crimp in twisted BCF yarn. In one nonlimiting embodiment, suitable bulking apparatuses inelude tiróse that utilize circulating hot air to develop yam crimp. In one nonlimiting embodiment, the bulking apparatus is capable of developing crimp under hot air at a temperatura in the range from about 140°C: to about 210°C. It is understood the hot air treatment may be applíed ín any method known ío those skilled in the art to develop yarn crimp in the BCF yarn. The hot aír treatment may be applíed for a duration necessary to achíeve the desired crimp development in the yam. In one nonlimiting embodiment, the bulking apparatus is capable of developing crimp for a period of about 3 to about 7 seconds.

[0036] Suitable heat setting tunnels may be known to those skilled ín the art that can develop tip definition in. twisted BCF yam. As used herein, tip defínition is defíned the leve! of dístínction between the típs of tufts ín carpe! yam. Tip definition is considerad to be excellent if there is deán tip separation between the tufts. In one nonlimiting embodiment of the current invention, the heat setting tunnel is configurad to treat the BCF yarn from the bulking apparatus vía pressurized steam injectíon with saturated steam. In another nonlimiting embodiment, íhe heat setting tunnel is confignred to treat íhe BCF yarn with pressurized steam at near saturation level. In another nonlimiting embodiment, the heat setting tunnel is conñgured to treat vía pressurized steam injectíon with saturated steam at a temperatura in the range from about 110°C to about 130°C. The heat setting tunnel may be configurad to inject pressurized steam for any duratíon neeessary to achieve the desired tip definition. In one nonlimiting embodiment, the yarn is heat set in heat setting tunnel for a period of about 25 to about 60 seconds.

[0037] Embodiments of the eurrent ínvention may be performed with varos formed from a synthetic polymer seleeied from the group consísting of polyamide, polyester, polyolefin and copolyraers and blends thereof, [0038] Nonlimiting examples of polyamide fibers inelude fibers comprising nylon 5,6; nylon 6/6; nylon 6; nylon 7; nylon 11; nylon 12; nylon 6/10;, nylon 6/12; nylon DT; nylon 6T; nylon 61; and blends or copolymers thereof. Nonlimiting examples of polyolefin fibers ínclude fibers comprising polypropylene. Nonlimiting examples of polyester fibers inelude fibers comprising polyethylene terephthalate, polytrímethylene terephthalate, polybutylene terephthalate, poiyethylene napnthalate, polyíactic acid (P.LA) and blends or copolymers thereof [0039] In one nonlimiting embodiment, the yarn is fonned fiom nylon 6,6 or nylon 6 polymer. [0040] In one nonlimiting embodiment, the yarn used is made from cationic dyeable nylon polymer. As used herein, catíonic dyeable nylon polymer are nylon polymers modified to malee them receptíve to catíonic dyes. In one nonlimiting embodiment, the cationic dyeable nylon polymer complises a stain blocking additive capable of disabling acid dye sites.

[0041] Suitable built-ϊη stain blocking additives ínclude those that are known to disable acid dye sites. For examples, in polyamides, such as Nylon 6,6 or Nylon 6, acid dyes sites refer to amine end groups or amide linkages which react or associate with acid dyes which resalí in staining. Stain blocking additives react or associate with these acid dye sites to preven! the acid dye sites from reacting or assocíatíng with acid dyes. Suitable stain blocking additives for use in polyamides are diseussed in US Pat. No. 5,155,178, herein ineorporated by reference. Suitable stain blocking additives inelude, but are not limited to aromatic sulfonates and alkali metal salís thereof, such as 5-sulfoisophthalic acid, sodium salí and dÍmethyl-5-sulfoisophthalate, sodium salí, In one nonlimiting, embodiment, the stain blocking additive ís 5-sulfoisophthalic acid, sodium salí (SSIPA). In one nonlimiting embodiment, the stain blocking additive is present in a range from about 1 to 10 percent by weight, In another nonlimiting embodiment, the stain blocking additive is present in a range from about i to 5 percent by weight.

[0042] In another nonlimitng embodiment, the varo is solution dye nylon (SDN) yarn.

[0043] In another aspect of the current invention, artícles are disclosed that are formed from the yarn. treated by any of the apparatuses disclosed herein. In another aspect of the current invention, carpets are disclosed that are formed from the yarn treated by any of the apparatuses disclosed herein. As shown in examples 2 and 3, in noníimiting ewbodiments, carpets are disclosed that have a stain rating of 8 or higher according to tíre 24 hour stain test. As shown in examples 2 and 3, in noníimiting embodiments, carpets are disclosed that have a stain rating of 7 or higher according to the WAQE stain test.

[0044] The following section provides further illustration of the processes and apparatuses of this invention. These working examples are illustrative only and are not intended to limit the scope of the invention in any way.

EXAMPLES

Test Methods [0045] ACID DYE STAIN TEST: Acid dye stain resistance is evaluated using a procedure adapted from the American Association of Textiie Chemists and Coiorists { AATCC) Method 175-2003, "Stain Resistance: Pile Floor Coveríngs." 9 wt % of aqueous staining soíution is prepared, according to the manufacturéis directions, by mixing cherry-flavored KOOL-AID® powder (Kraft/General Foods, Northfield, IL Wlrite Plañís, N.Y., a powdered drink mix containíng, ínter alia, FD&C Red No. 40). A knitted soek (4x6-inch) is placed on a fíat nonabsorbent surface. A hollow plástic 2-inch (5.1 cm) diameter cup is placed tightly over the test sample, which can be a knitted sock, or a tañed caipet, for example. Twenty mi. of the KOOL-AID® staining soíution is poured hito the cup and the soíution is allowed to absorb completely into the test sample. The cup is removed and the stained sample is allowed to sit nndisturbed for 24 hours. .Following incubation, the stained sample is rinsed thoroughly under coid tap water, excess water ís removed by eentrifugation, and the sample is dried in aír. The sample was vísually inspected and rated for staining according to the .FD&C Red No. 40 Stain Scale descrihed in AATCC Method 175-2003. Stain resistance ís nreasured using a 1-10 scale, An undetectable test staining ís accorded a valué of 10.

[0046] WAQE SHAMPOO TEST: Carpeting wash durability was tested by the Shampoo-Wash Durability Test, using Duponol WAQE as detergen!, as referenced and described in U.S. Pat, Nos, 5,853,814 and 5,948,480. Each sample tested according to this method was vísually ínspecíed and rated for staining according to the FD&C Red No. 40 Stain Scale described in AATCC Method 175-2003.

[0047] CARPE!' DURABILITY TEST; Carpet durability was evaluated based on procedures described in the Vettennan Drum Texture Retention Test (ASTM D5417).

Example 1 (comparative) £0048] A 997 denier Antique White color solution dyed BCF (997-H 2779 by Invista) made from cationic dyeable nylon 66 polymer was first converted into 6,0 twist per ineh. cable twisted yarns, and subsequentlv heatset on Superba using different process settings. The cable twisted and heatset yarns were converted into 45 oz carpets for stain and floor performance tests [0049] This ítem was heatset on Superba using the State of art process. Twelve ends of cable twisted yarns were fírst processed tluOugh the texturing unit, heated with 99° C atmospheric saturated steam for about 5 seeonds in the pre-bulker and set in tunnel with 130° C pressurized saturated steam for about 60 seeonds. The processed yarn was converted into a 45 oz/yd., 19/32 inch pile height cut pile carpet on a. 1/10 ga. machine. The tufted carpet was coated with látex to secute tufts using the State of art latexing process. The finished carpet had excelíent típ definition.

[0050] This Item was test for stain and texture retention. It scored a 6 (1 to 10 rating, 10 has no stain) for 24 hour stain resistance, and a 5 for WAQE Shampoo stain resistance. It failed the stain performance requirement for premíum carpets, Tire texture retention was excelíent This ítem was rated 3.8 (1 to 5 scale) for carpet durability after five thousand cycles in a Vettennan drum.

Example 2 (current invenüon) [0051] Twelve ends of cable twisted yarns were fírst processed through the texturing unit, heated with 200° C dry air for about 5 seeonds in the pre-bulker and set in tunnel with 115° C pressurized saturated steam for about 60 seeonds. The processed yarn was converted into a 45 oz/yd. 19/32 ineh pile height cut pile carpet on a 1/10 ga. machine. The íufted carpet was coated with látex to secure tufts using the State of art latexing process, The finished carpet had excelíent tip definition.

[0052] This itera was test for stain and texture retention. It scored an 8 (1 to 10 rating, 10 has no stain) for 24 hours stain resistance and an 8 for WAQE Shampoo stain resistance. It performed signifícantly better than the carpet described ín Example 1. The texture retention was excelíent.

It also scored 3.8 (1 to 5 scale) for carpet durability after 5 thousand cycle test in a Vettennan drum.

Example 3 (curren! invention) [0053] Twelve ends o f cable twisted yarns were first processed through. the texturing unít, heated wiíh 190" C dry air for about 5 seconds in the pre-bulker and set in tunnel with 115° C pressurlzed saturated stearn for about 60 seconds. The processed yarn was converted ínfo a 45 oz/yd. 19/32 ínch pile heíghí cut pile carpet on a 1/10 ga. machine. The tufted carpet was coated wiíh látex to secure íufts using the State of art latexing process. The ñnished carpet also had excellent tip definitíon.

[0054] This ítem was test for stain and texture reteníion. Jt scored an 8 (1 to 10 rating, 10 has no stain) for 24 hours stain resistance and a 7 for WAQE Shampoo stain resistance. It performed significantíy better thanthe carpet described in Example 1. The texture reteníion was excellent, It also scored 3.8 (1 to 5 scale) for carpet durability after 5 thousand cycle test in a Vetterman drum.

Example 4 (comparative) [0055] Twelve ends of cable twisted yarns were first processed through the texturing unit, heated wiíh 200° C dry air for approximately 5 seconds in the pre-bulker, and passed through the tunnel in the absence of supplied steam, or hot air. This ítem was used to pin poínt the impact of steam. in the tunnel on stain and texture reteníion. The processed yarn was converíed into a 45 oz/yd. 19/32 inch pile heíghí cut pile carpet on a 1/10 ga. machine. The tufted carpet was coated with látex to secure íufts using the state of art latexing proeess, The fínished carpet had poor tip definitíon, It was not an attractive carpet, [0058] This ítem was iested for stain and texture reteníion. it scored an 8 (1 to 10 rating, 10 has no stain) for 24 hours stain resistance and a 9 for WAQE Shampoo stain resistance, It performed significantíy better than Example 1. The texture reteníion was acceptable, but not good as previous examples. It scored 3.2 (1 to 5 scale) for carpet durability after 5 thousand cycle test in a Vetterman drum, Although it passed the end use tests, it cannot be sold as a premium commerciai product due to poor tip definitíon.

Claims (30)

1. A multi-step proeess for heat setting twisted, bulk continuous fílament (BCF) yam comprísing the steps of: a) deveíoping crimp in the yarn under hot atmospheric air; and b) heat setting the yam ftom step (a) by pressurized steam treaíment.

2. The proeess of claim 1 wherein step (a) is performed under hot air at a temperature in the range ífom about 140°C to about 210°C.

3. The proeess of claim 1 wherein step (b) is achieved wiíh saturated steam at a temperature in the range from about 110°C to about 130°C,

4. The proeess of claim 1 the yam is treated in step (a) for a period of about 3 to about 7 seeonds.

5. The proeess of claim 1 wherein the yarn is heat set in step (b) for a period of about 25 to about 60 seeonds,

6. The proeess of claim 1 wherein the yarn is formed from a synthetie polymer selected from the group consisting of nylon, polyester, polyolefín and copolymers and blends thereof,

7. The proeess of claim 1 wherein the yarn is formed from nylon 6,6 or nylon 6 polymer.

8. The process of elaím 1 wherein the yam i a made from catíonic dyeable nylon polymer.

9. The process of elaím 8 wherein the catíonic dyeable nylon polymer comprises a stain blocking additíve capable of disabling acid dve sites in the polymer.

10. The process of claim 9 wherein the stain blocking additíve is presení in a tange from about 1 to 10 percent by weight.

11. The process of claim 9 wherein the stain blocking additíve is an aromatíe sulfonate or an alkali metal salí thereof.

12. The process of claim 9 wherein the yam is solution dye nylon yam.

13. .An article formed from the yarntreated by process of any of elaims 1 to 12,

14. A carpet formed from the yam treated by process of any of elaims 1 to 12.

15. The carpet of claim 14 wherein the carpet has a stain raíing of 8 or higher according to the 24 hour stain test.

16. The carpet of claim 14 wherein the carpet has a stain raíing of 7 or higher according to the WAQE stain test.

17. An apparatus for heat settmg twisted, bulk contmuous fílament (BCF) yam comprising: a) a bulking apparatus configured to bulk the yam with hoí aímospheric air to develop crimp; and b) a heat setting tunnel configured to heat set the yarn by pressurized steam injection.

18. The apparatus ofclaim 17 whereinthe bulking apparatus is capable oí developing crimp in the yam at a temperatura in the range from about 140°C to about 210°C.

19. The apparatus of claim 17 whereín the heat. set tunnel is capable of heat setting the yam by pressurized stearn injection of saturated steam at a temperatura in the range from about 110°Cto about 130°C.

20. The apparatus of claim 17 whereinthe yarn is formed from a syníhetic polymer selected from the group consisíing of nylon, polyester, polvolefin and copoiymers and blends thereof.

21. The apparatus of claim 17 wherein the yam is formed from nvlon 6,6 or nylon 6 polymer.

22. The apparatus of claim 17 wherein the yam is rnade from catiomc dyeable nylon polymer.

23. The apparatus of claim 22 -wherein the cationic dyeable nylon polymer compríses a stain blocking additíve eapable of disabling acid dye sites ir. the polymer.

24. The apparatus of claim 23 wherein the stain blocking additíve ís present in a range from about 1 to 10 percent by weight. .

25. The apparatus of claim 23 wherein the stain blocking additíve ís an aromatic sulfonate or an alkali metal salt thereof.

26. The apparatus of claim 23 wherein the yarn is solution dye nylon yarn.

27. An árdele from the yam treated by apparatus of any of claims 17 to 26.

28. A caípet from the yarn treated by apparatus of any of claims 17 to 26'.

29. The carpet of claim 28 wherein the carpet has a stain rating of 8 or higher aeeording to the 24 hour staín test.

30. The carpet of claim 28 wherein the carpet has a staín rating of 7 or higher aeeording to the WAQE stain test.