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
  • D02G3/26—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre with characteristics dependent on the amount or direction of twist
  • D02G3/28—Doubled, plied, or cabled threads
  • D02G3/285—Doubled, plied, or cabled threads one yarn running over the feeding spool of another yarn
• • 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
  • D02G3/36—Cored or coated yarns or threads
• • D—TEXTILES; PAPER
  • D03—WEAVING
  • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
  • D03D1/00—Woven fabrics designed to make specified articles
  • D03D1/0017—Woven household fabrics
• • D—TEXTILES; PAPER
  • D05—SEWING; EMBROIDERING; TUFTING
  • D05C—EMBROIDERING; TUFTING
  • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
  • D05C17/02—Tufted products
  • D05C17/023—Tufted products characterised by the base fabric
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
  • D06B3/00—Passing of textile materials through liquids, gases or vapours to effect treatment, e.g. washing, dyeing, bleaching, sizing, impregnating
  • D06B3/04—Passing of textile materials through liquids, gases or vapours to effect treatment, e.g. washing, dyeing, bleaching, sizing, impregnating of yarns, threads or filaments
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
  • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
  • D06P3/34—Material containing ester groups
  • D06P3/52—Polyesters
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/23907—Pile or nap type surface or component
  • Y10T428/23979—Particular backing structure or composition

Definitions

• 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.
• 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.
• 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.
• solution dye 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.
• Topical chemistries are used to treat carpets and other fabrics for improved stain resistance and/or soil resistance.
• stain blocker e.g. acid dye blocker
• anti-soil with fluorochemicals are traditionally used.
• 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.
• 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
• 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.
• 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.
• 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.
• low pH solutions, excess water, and energy are required for the SB and FC to penetrate the carpet and achieve uniform coverage.
• the typical prior art process is as follows: BCF yarn ⁇ Twist ⁇ heat set ⁇ tufting ⁇ carpet ⁇ dye ⁇ stain block / anti-soil.
• 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.
• 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.
• 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.
• 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.
• the disclosed process moves the back end, large scale and wasteful stain blocker application step up front during or after yarn twisting.
• the carpet manufacturing process now becomes: BCF yarn ⁇ twist ⁇ dye ⁇ optional SB/FC ⁇ heat set (optionally dry heat set) ⁇ tufting ⁇ carpet.
• the disclosed process is as effective, or even more effective, than processes of the prior art in terms of fabric soil resistance.
• 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.
• 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:
• a process for treating twisted BCF yarn with one or more dye compositions 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.
• a process for treating twisted BCF yarn with one or more dye compositions 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.
• a process for treating twisted BCF yarn with one or more dye compositions and performance enhancing compositions 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.
• a process for treating twisted BCF yarn with one or more dye compositions and performance enhancing compositions 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.
• an untufted, twisted BCF yarn comprising a dye component
• 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.
• an untufted, twisted BCF yarn comprising a dye component, an anti-soil component, and an optional anti-stain component
• 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.
• a process for manufacturing carpet 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.
• a system for applying a dye composition to twisted BCF fiber 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.
• a system for applying a dye composition and at least one performance enhancing composition to twisted BCF fiber 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.
• Figure 1 shows the current cable twisting process.
• Figure 2 shows one aspect of the disclosed process.
• Figure 3 shows another aspect of the disclosed process.
• Figure 4 shows the current heat setting process.
• Figure 5 shows a further aspect of the disclosed process.
• WPU Weight pick-up
• a process for treating twisted BCF yarn 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°C to about 200°C, including from about 60°C to about 195°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.
• 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.
• 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.
• 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.
• SACs sulfonated aromatic aldehyde condensation products
• 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.
• 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.), STAIN KLEER (from Dyetech, Inc., Dalton, Ga.), LANOSTAIN (from Lenmar Chemical Corporation, Dalton, Ga.), and SR-300, SR-400, and SR-500 (from E. I.
• 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.
• 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.
• 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 251 1 , and DuPont Capstone® 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. Patent No. 6,824,854, herein incorporated by reference).
• 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.
• a neutral pH e.g. 4 to 9, including 5.5 to 7.5
• the process foregoes the need for harsh low pH chemicals; deionized water is suitable for use in the disclosed process.
• 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.
• 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.
• 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.
• 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.
• Another option is to transport dye solution to the yarn using two rotating rolls covered with wicks.
• the yarn passes between the two rotating rolls.
• multiple rolls can be used in series.
• 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.
• 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.
• 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.
• 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.
• 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.
• the performance enhancing compositions can further comprise one or more components selected from the group consisting of: odor control agents, antimicrobial agents, anti-fungal agents, fragrance agents, bleach resist agents, softeners, and UV stabilizers.
• 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.
• 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.
• 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-
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• Figure 1 shows the current cable twisting process.
• 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.
• Figure 2 shows one aspect of the disclosed process.
• 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.
• Figure 3 shows another aspect of the disclosed process containing both a dye applicator and anti-stain / anti-soil applicator.
• 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.
• Figure 4 shows the current heat setting process.
• 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.
• Figure 5 shows another aspect of the disclosed process where cable twisted BCF yarn is dyed prior to heat setting.
• 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.
• 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 ® powder (Kraft/General Foods, White Plains, N.Y., a powdered drink mix containing, inter alia, FD&C Red No. 40).
• a carpet sample (4x6-inch) is placed on a flat non-absorbent surface.
• a hollow plastic 2-inch (5.1cm) diameter cup is placed tightly over the carpet sample.
• KOOL-AID® staining solution Twenty ml of the KOOL-AID® 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.
• the cable twisted yarn was heatset on Superba at 265° 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).
• 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°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.
• 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°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.
• 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 g/l, Blue 4R @ 5.90 g/l, 15 g/l wetting agent in deionized water) onto the cable twisted yarn at 350 ypm.
• 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°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).
• 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.
• 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°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 6 .5, a -8.9, b 2.7
• 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, 5 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.
• 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°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)
• 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.
• 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°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).
• 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 85° C at 375 ypm, -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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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Mechanical Engineering (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Carpets (AREA)
• Coloring (AREA)
• Chemical Or Physical Treatment Of Fibers (AREA)

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• 2012
  • 2012-09-24 WO PCT/US2012/056856 patent/WO2013048946A2/en active Application Filing
  • 2012-09-24 EP EP12836904.8A patent/EP2739776A4/de not_active Withdrawn
  • 2012-09-24 JP JP2014532065A patent/JP2014531524A/ja active Pending
  • 2012-09-24 US US14/346,486 patent/US20140255644A1/en not_active Abandoned
  • 2012-09-24 CN CN201280046844.9A patent/CN103814165A/zh active Pending
  • 2012-09-24 CA CA 2849458 patent/CA2849458A1/en not_active Abandoned
  • 2012-09-24 AU AU2012316378A patent/AU2012316378A1/en not_active Abandoned

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