EP0324773B1 - Fil synthetique avec fibre de liaison thermoactivee - Google Patents
Fil synthetique avec fibre de liaison thermoactivee Download PDFInfo
- Publication number
- EP0324773B1 EP0324773B1 EP87906522A EP87906522A EP0324773B1 EP 0324773 B1 EP0324773 B1 EP 0324773B1 EP 87906522 A EP87906522 A EP 87906522A EP 87906522 A EP87906522 A EP 87906522A EP 0324773 B1 EP0324773 B1 EP 0324773B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fiber
- yarn
- binder fiber
- carpet
- nylon
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/44—Yarns or threads characterised by the purpose for which they are designed
- D02G3/445—Yarns or threads for use in floor fabrics
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/40—Yarns in which fibres are united by adhesives; Impregnated yarns or threads
- D02G3/402—Yarns in which fibres are united by adhesives; Impregnated yarns or threads the adhesive being one component of the yarn, i.e. thermoplastic yarn
Definitions
- the invention relates to synthetic yarn for carpet face fiber and other applications, the yarn comprising a blend of fibers including a first synthetic base fiber and a second heat-activated adhesive fiber with a melting point substantially below that of the first synthetic base fiber.
- a process for production of carpet exposure of the yarn to usual process conditions for twist setting the yarn causes the heat-activated adhesive fiber to melt substantially completely, losing its identity as a fiber, and to flow to points of intersecting base fibers to create a bond upon subsequent cooling, thus altering properties and performance of the resulting product.
- Patent 3,494,819 to McAlister discloses a blend of fusible and non-fusible polyethylene terephthalate fibers incorporated into fabric, wherein the finished fabric is heated to fusion temperatures to provide improved pill resistance.
- U.S. Patent 3,978,267 to Selwood, issued August 31, 1976 discloses a substantially twistless compact yarn comprising a proportion of potentially adhesive fiber which have been activated to bond to contacting fibers.
- thermoplastic binder fibers in combination with structural fibers to form self-bonding nonwoven fabrics.
- U.S. Patent 2,880,112 to Drelich, issued March 31, 1959 discloses the use of nylon-6 to bond viscose rayon and other cellulosic materials to form washable nonwoven fabrics.
- Cut-pile carpet is customarily produced from staple yarns or bulked continuous filament yarn.
- staple fiber is conventionally carded, pinned, and spun or wrap spun into a singles yarn, which typically is twisted and plyed with similar yarn to form a 2-ply or 3-ply yarn construction.
- This yarn is twist set by utilizing one of several commercially available twist setting processes. In a typical process the yarn is passed through a heated chamber, while in a relaxed condition. The temperature of this process step is crucial to the proper twist setting of the base fiber, to obtain desired properties of the final carpet product.
- the conditions for this step are typically 195-200°C with a residence time of about 60 seconds for the Suessen process and about 135-140°C with a residence time of about 60 seconds for the Superba process.
- bulked continuous filament nylon yarn is produced according to various conventional methods. Twisting, entangling, or direct cabling may be utilized in various processes. For example, a 2-ply twisted yarn combining 2 ends of 1185 denier 70 filament yarn is prepared and subjected to conventional twist setting conditions, such as that for the staple yarn above or in an autoclave at 132°C in saturated steam, with a residence time of about 60 seconds.
- twist set yarns Multiple ends of the twist set yarns are tufted into cut pile carpet and conventionally finished to obtain the desired carpet product.
- Synthetic yarn comprises a blend of base fiber selected from the group consisting of polyester, nylon-6 and nylon 6,6 and 1-12 weight percent, preferably 1-8 weight percent, of a heat activated binder fiber with a melting point within the range of 110-170°C, preferably 130-160°C.
- a preferred binder fiber is a copolyamide fiber within the specified melting point range. Ternary copolyamides of the 6/66/12 type are examples of preferred binder fibers.
- the base fiber is selected from known synthetic fiber suitable for carpet use.
- Preferred base fiber includes polyamide, particularly nylon-6 and nylon-6,6, and polyester, particularly polyethylene terephthalate.
- the binder fiber is selected to provide good adhesion to the base fiber. It is important that the melting point of the binder fiber be in the range of 110-170°C, preferably 130-160°C, under ambient humidity conditions. This range ensures that the binder fiber will melt during the conventional twist setting process yet will provide adequate adhesive properties during any subsequent dyeing steps and final use. A saturated steam environment, such as in an autoclave, reduces the fiber melting point dramatically.
- a preferred class of binder fiber for use with polyamide base fibers are copolyamides within the specified melting point ranges. Suitable copolyamides of the 6/66/12 type and a process for their production are disclosed in U.K. Patent 1,168,404, issued October 22, 1969 to Inventa A. G., incorporated herein by reference.
- a melt bonding copolyamide adhesive fiber is commercially available from EMS as GRILON O type K 140 (melting range 130-140°C) and type K 115 (melting range 110-117°C).
- the binder fiber can be blended with base staple fiber, and the resulting staple fiber blend can then be processed in known ways. It is important to insure a thorough blending to avoid potential clumps in the finished carpet.
- the staple fiber blend should contain 1-12 weight percent binder fiber, preferably 1-8 weight percent. Higher amounts cause undesirable harshness of hand due to the conditions of the twist setting process causing the binder fiber to melt substantially completely.
- Spun yarns prepared from such a staple fiber blend and subjected to thermal activation can provide strength properties approaching that of bulked continuous filament (BCF) yarns. Properties of BCF yarns can also be enhanced.
- thermally activated binder fiber within the weight ranges and melting point ranges specified it is possible to modify end-use properties of the finished carpet to improve wear resistance, resilience, reduced change of appearance over time and with use, and increased hand, lustre and apparent value.
- Denier per filamant, cut length, fiber cross-section, crimp type and frequency, surface finish, melt viscosity, softening point, melting point, dye affinity, and other properties are crucial to achieving ideal properties in the final product.
- a proper selection of the binder fiber must be made to obtain the desired, or optimum results from the finished carpet product. This will depend on numerous factors including the denier, length, crimp, finish, and other properties of the base fiber product.
- twist setting conditions normally used are sufficient to activate the binder fiber, to create bind points which strengthen the final product, thereby imparting other characteristics which are desirable.
- the twisted yarn is subjected to a temperature of 190-205°C for a residence time of 50-60 seconds.
- motion of the fiber while in the relaxed state caused by vibration or air currents, sufficiently motivates the molten binder fiber to flow to the intersecting "touch points" of the base fiber, as a function of the melt flow properties of the binder fiber and surface characteristics.
- the binder solidifies and encapsulates or bonds two or more base fibers together at intersecting points in a durable bond.
- the resultant carpet can be of many forms, but a typical style would be cut-pile carpet with about 40 ounces per square yard (1.4 kg/m 2 ) of face yarn including the binder, with an attached backing. Carpet construction would be typically 5/32" (4 mm) gauge, 3/4" (20 mm) pile height, and the carpet would be dyed, dried, backcoated, and sheared using normal processing techniques.
- the yarn of the invention would also provide important property improvements in the production of loop-pile carpet.
- a blend of staple fiber was produced with 3 weight percent GRILONO Type K 140 copolyamide fiber having a melt point range of 130-140°C and 97 weight percent base staple fiber (Allied Type 521 nylon-6 fiber having a melt point range of 215-225°C).
- the blended fiber was carded, pinned and spun into a singles yarn by conventional processing methods.
- the yarn a 3's cotton count yarn containing 4.7 "Z" twists per inch (185 tpm), was plyed with a similar yarn to produce a 2-ply 3's/2 cotton count 4.7Z x 4.0S yarn (185Z x 160S).
- the 2-ply yarn was twist set by a conventional Sussen twist setting process.
- the yarn was passed through a heated chamber at about 195°C while in a relaxed condition, with a residence time of about 60 seconds.
- the resulting carpet was compared to a control carpet prepared in the same manner from 100 percent base staple fiber.
- the carpet containing the binder staple fiber blend displayed enhanced carpet tuft appearance, more resilience, and better wear resistance.
- Carpets also may be produced from bulked continious filament (BCF) yarns, and carpets thus made can, be improved in surface, aesthetics, hand, or in durability and wear by using this invention.
- BCF bulked continious filament
- Filament nylon yarn is produced according to various conventional fiber producer manufacturing methods. These methods are not particularly related to the invention, except that another, smaller, filament yarn will accompany a base yarn throughout subsequent process steps. Often the combination will result in a 2-ply, 3-ply, or other form needed for the carpet style.
- twisting, entangling, or direct cabling may be utilized.
- Direct cabling is often used, as in this example, where a 70 denier (78 dtex) 14 filament yarn is combined with a 1185 denier (2000) dtex) 70 filament in the creel of the direct cabler to produce a yarn with 3.5 "S" twist per inch (140 tpm) in each of the singles and 3.5 "Z" twist (140 tpm) in the resultant 2-ply twisted yarn (1185 x 2 ply).
- the final yarn contains a third component, a binder yarn, which has a lower melting point and which will lose much of its identity in subsequent process steps, as it is melted and flows to bind fibers and yarn together, thereby retaining the twist in cut pile carpet.
- a copolyamide 70 denier (78 dtex) nylon yarn having a melt point range of 130-140°C results in the binder fiber for the combination, combined with 2 ends of 1185 denier (2000 dtex), results in a blend of about 2.8 percent binder.
- This ratio can be doubled by using two ends, or varied by providing other denier products to the system.
- the binder When the product is subjected to conventional twist setting, the binder is activated producing a final product with the desirable characteristics of enhanced carpet tuft appearance, more resilience, and better wear resistance than similar carpets not containing the binder.
- the twist setting conditions for this are typically 270°F (130°C), in saturated steam, with a residence time of about 60 seconds.
- the binder solidifies and encapsulates or bonds two or more base yarns together in a permanent or durable bond.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Carpets (AREA)
- Artificial Filaments (AREA)
Abstract
Claims (9)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US93438986A | 1986-11-24 | 1986-11-24 | |
US934389 | 1986-11-24 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0324773A1 EP0324773A1 (fr) | 1989-07-26 |
EP0324773B1 true EP0324773B1 (fr) | 1990-11-22 |
Family
ID=25465490
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP87906522A Expired - Lifetime EP0324773B1 (fr) | 1986-11-24 | 1987-09-15 | Fil synthetique avec fibre de liaison thermoactivee |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0324773B1 (fr) |
JP (1) | JP2719338B2 (fr) |
AU (1) | AU606085B2 (fr) |
CA (1) | CA1314771C (fr) |
WO (1) | WO1988003969A1 (fr) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE4240335A1 (de) * | 1992-12-01 | 1994-06-09 | Spindor N V | Bondiertes Fasermischgarn sowie daraus herstellbare gewebte oder gewirkte textile Flächengebilde |
Families Citing this family (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6682618B1 (en) * | 1986-11-24 | 2004-01-27 | Alliedsignal Inc. | Yarn with heat-activated binder material and process of making |
US6969437B1 (en) | 1997-01-30 | 2005-11-29 | Alliedsignal Inc. | Yarn with heat-activated binder material and process of making |
NZ220444A (en) * | 1987-05-26 | 1991-06-25 | Wool Res Organisation | Yarn pile fabrics with fusible fibre bonding agent |
DE3717921A1 (de) * | 1987-05-27 | 1988-12-15 | Ackermann Goeggingen Ag | Garn, insbesondere naehgarn, sowie verfahren und vorrichtung zu dessen herstellung |
US5032333A (en) * | 1990-02-27 | 1991-07-16 | E. I. Du Pont De Nemours And Company | One-line interlacing of bulked continuous filament yarns and low-melting binder fibers |
US5175038A (en) * | 1990-09-07 | 1992-12-29 | E. I. Du Pont De Nemours And Company | Carpet yarns and carpets with improved balance of newness retention and bulk |
US5079810A (en) * | 1990-12-28 | 1992-01-14 | E. I. Du Pont De Nemours And Company | Ultrasonic cutting of fabric tufts to provide improved retention of tuft indentity during use |
WO1994009196A1 (fr) * | 1992-10-14 | 1994-04-28 | Allied-Signal Inc. | Fil synthetique a fibre thermoactivee de liaison |
US5284009A (en) * | 1993-03-09 | 1994-02-08 | E. I. Du Pont De Nemours And Company | Fiber blends for improved carpet texture retention |
US5698480A (en) * | 1994-08-09 | 1997-12-16 | Hercules Incorporated | Textile structures containing linear low density polyethylene binder fibers |
BR9609396A (pt) * | 1995-06-07 | 1999-06-15 | Allied Signal Inc | Produtos de tapetes de fibras sintéticas e fios combinados para os mesmos |
US6117546A (en) * | 1996-03-03 | 2000-09-12 | Hercules Incorporated | Yarns containing linear low density polyethylene fibers |
EP1038059B2 (fr) * | 1997-09-19 | 2008-01-02 | AlliedSignal Inc. | Fil comprenant un materiau de liaison active par la chaleur et procede de production de ce fil |
AU5701599A (en) * | 1998-08-31 | 2000-03-21 | Allied-Signal Inc. | Yarn with heat-activated binder material and process of making |
US6658835B1 (en) | 2000-11-28 | 2003-12-09 | Honeywell International Inc. | Untwisted wrapped singles yarns and carpets manufactured therefrom |
US7261849B2 (en) * | 2002-04-30 | 2007-08-28 | Solutia, Inc. | Tacky polymer melt spinning process |
US20040175534A1 (en) * | 2002-12-23 | 2004-09-09 | Bridges James C. | Enhanced surface coverings, yarns and methods |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1085567A (en) | 1965-06-28 | 1967-10-04 | Ici Ltd | Improvements in or relating to compact filament bundles and their production |
CH491150A (de) | 1967-03-13 | 1970-05-31 | Inventa Ag | Verfahren zur Herstellung von ternären Mischpolyamiden |
ZA72545B (en) * | 1971-01-29 | 1972-10-25 | Coats Ltd J & P | Process for production of filamentary structures |
JPS6133382Y2 (fr) * | 1980-06-23 | 1986-09-30 |
-
1987
- 1987-09-15 AU AU80254/87A patent/AU606085B2/en not_active Expired
- 1987-09-15 EP EP87906522A patent/EP0324773B1/fr not_active Expired - Lifetime
- 1987-09-15 JP JP62505896A patent/JP2719338B2/ja not_active Expired - Fee Related
- 1987-09-15 WO PCT/US1987/002339 patent/WO1988003969A1/fr active IP Right Grant
- 1987-09-22 CA CA000547494A patent/CA1314771C/fr not_active Expired - Lifetime
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE4240335A1 (de) * | 1992-12-01 | 1994-06-09 | Spindor N V | Bondiertes Fasermischgarn sowie daraus herstellbare gewebte oder gewirkte textile Flächengebilde |
Also Published As
Publication number | Publication date |
---|---|
AU8025487A (en) | 1988-06-16 |
EP0324773A1 (fr) | 1989-07-26 |
CA1314771C (fr) | 1993-03-23 |
AU606085B2 (en) | 1991-01-31 |
JPH02501835A (ja) | 1990-06-21 |
JP2719338B2 (ja) | 1998-02-25 |
WO1988003969A1 (fr) | 1988-06-02 |
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