EP3835480A1 - Fil combiné - Google Patents

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Publication number
EP3835480A1
EP3835480A1 EP20154782.5A EP20154782A EP3835480A1 EP 3835480 A1 EP3835480 A1 EP 3835480A1 EP 20154782 A EP20154782 A EP 20154782A EP 3835480 A1 EP3835480 A1 EP 3835480A1
Authority
EP
European Patent Office
Prior art keywords
single yarn
yarn
combination
additives
acid
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.)
Pending
Application number
EP20154782.5A
Other languages
German (de)
English (en)
Inventor
Melissa North
Wayne BEASON
Anthony CASCIO
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aladdin Manufacturing Corp
Original Assignee
Aladdin Manufacturing Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Aladdin Manufacturing Corp filed Critical Aladdin Manufacturing Corp
Priority to PCT/US2020/063929 priority Critical patent/WO2021119076A1/fr
Priority to EP20899270.1A priority patent/EP4073302A4/fr
Priority to AU2020399650A priority patent/AU2020399650A1/en
Priority to US17/780,692 priority patent/US20230020177A1/en
Publication of EP3835480A1 publication Critical patent/EP3835480A1/fr
Pending legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0065—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
    • 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
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/08—Properties of the materials having optical properties
    • D06N2209/0807—Coloured
    • 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]
    • 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
    • D10B2401/00—Physical properties
    • D10B2401/14—Dyeability
    • 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
    • D10B2503/00—Domestic or personal
    • D10B2503/04—Floor or wall coverings; Carpets

Definitions

  • This disclosure relates to combination yarns, and more particularly to polyester yarns and carpets using such yarns as pile yarn.
  • Carpets, rugs, and mats used in home or commercial applications are typically made from natural fibers (such as cotton or wool) or synthetic fibers (such as nylon, polyester, polyolefins, acrylics, rayon, and cellulose acetate). Synthetic fibers tend to be more favored in carpet manufacture as they are generally more commercially acceptable and can be used for a wider variety of applications.
  • Nylon is often used in carpet fiber since it is strong, easy to dye, and readily available. Nylon carpeting can be disadvantageous, however, as it generally requires various treatments in light of its susceptibility to developing static electric charges and its ease of staining. Carpets made from polyolefins, such as polypropylene, are very resistant to staining and are naturally antistatic; however, polypropylene is a more rigid and less resilient fiber and will not generally maintain its appearance or shape under prolonged or heavy use, or after repeated deformations.
  • Polyesters such a PET, PTT, and PBT are a favorable alternative to both nylon and polyolefins and are known to provide stain resistance and static resistance while also providing a "wool-like" feel with good physical performance.
  • the present disclosure provides combination yarns, in particular combination yarns formed from two or more polyester yarns having different polymeric compositions yet having substantially the same color strength when dyed under the same dyeing conditions, for example when both yarns are dyed together.
  • the present disclosure provides combinations yarns formed from two or more polyester yarns having different polymeric compositions that provide substantially different color strength between the two yarns when dyed under the same dyeing conditions, for example when both yarns are dyed together.
  • a combination yarn comprising a first single yarn and a second single yarn, wherein the first single yarn and the second single yarn are linked to each other, wherein the first single yarn comprises at least 60% polyethylene terephthalate (PET), wherein the second single yarn comprises at least 60% polytrimethylene terephthalate (PTT), and wherein at least one of the first single yarn and the second single yarn includes one or more additives that increase dye uptake such that the color strength of the at least one of the first single yarn and the second single yarn is increased when compared to the same first single yarn and/or the same second single yarn which does not include the one or more additives.
  • PET polyethylene terephthalate
  • PTT polytrimethylene terephthalate
  • the first single yarn includes the one or more additives. In some embodiments where the first single yarn includes the one or more additives, the second single yarn does not include the one or more additives. In some embodiments where the first single yarn includes the one or more additives, the color strength of the first single yarn is within 20% or within 10% of the color strength of the second single yarn when both yarns are subjected to the same dyeing conditions, for example when both yarns are dyed together.
  • the second single yarn includes the one or more additives. In some embodiments where the second single yarn includes the one or more additives, the first single yarn does not include the one or more additives. In other embodiments where the second single yarn includes the one or more additives, the first single yarn also includes the one or more additives. In some embodiments where both the first and the second single yarn include the one or more additives, the one or more additives included with the first single yarn are different from the one or more additives included with the second single yarn.
  • the color strength of the second single yarn is at least 10% or at least 20% greater than the color strength of the first single yarn when both yarns are subjected to the same dyeing conditions, for example when both yarns are dyed together.
  • a combination yarn comprising a first single yarn and a second single yarn, wherein the first single yarn and the second single yarn are linked to each other, wherein the first single yarn comprises polyethylene terephthalate (PET) and at least one or more additives which increase dye uptake, wherein the second single yarn comprises polytrimethylene terephthalate (PTT) and does not include one or more additives which increase dye uptake, and wherein the color strength of the first single yarn is within 20% or within 10% of the color strength of the second single yarn when both yarns are subjected to the same dyeing conditions, for example, when both yarns are dyed together.
  • the first single yarn comprises at least 75% PET.
  • the second single yarn comprises at least 75% PTT.
  • a combination yarn comprising a first single yarn and a second single yarn, wherein the first single yarn and the second single yarn are linked to each other, wherein the first single yarn comprises PET, wherein the second single yarn comprises PTT and one or more additives which increase dye uptake, and wherein the color strength of the second single yarn is at least 10% or at least 20% greater than the color strength of the first single yarn when both yarns are subjected to the same dyeing conditions, for example when both yarns are dyed together.
  • the first single yarn does not include one or more additives which increase dye uptake.
  • the first single yarn does include one or more additives which increase uptake, wherein the one or more additives for the first single yarn may be the same or different from the one or more additives for the second single yarn.
  • the one or more additives that increase dye uptake may include polybutylene terephthalate (PBT), at least one ester modifier, or combinations thereof.
  • the ester modifier includes a copolymer formed by polymerization of a mixture comprising terephthalic acid or esters thereof, at least one dicarboxylic acid monomer, and at least one diol monomer.
  • the ester modifier includes a copolymer formed by polymerization of a mixture comprising terephthalic acid or esters thereof, at least one diol monomer, and at least one polyalkylene glycol.
  • the ester modifier includes ortho-phthalic acid, isophthalic acid, esters thereof, or mixtures thereof.
  • first single yarn and/or the second single yarn are continuous filament yarns.
  • Each of the first single yarn and the second single yarn may comprise a given number of filaments per cross section, which number of filaments per cross section may be identical or different for the first single yarn and second single yarn.
  • all filaments of the first single yarn may have a substantially equal cross section. In some embodiments, all filaments of the second single yarn may have a substantially equal cross section. In some embodiments, the cross sections of the filaments of the first single yarn and the second single yarn may be substantially identical (having cross-sectional areas within 10% of each other).
  • the first single yarn or the second single yarn are bulked continuous filament (BCF) yarns. In other embodiments, the first single yarn or the second single yarn are spun yarns comprising staple fibers.
  • BCF bulked continuous filament
  • the combination yarn may be a plied or twisted yarn.
  • the combination yarn may be plied or twined in either the S- or Z-direction.
  • the first single yarn, second single yarn, or further single yarns may be untwisted, particularly when the single yarns are BCF yarns, or may be twisted as well.
  • the carpet is a tufted carpet.
  • a tufted carpet comprising a pile yarn providing the pile of the carpet, wherein the pile yarn is the combination yarn described herein.
  • compositions and methods of the appended claims are not limited in scope by the specific compositions and methods described herein, which are intended as illustrations of a few aspects of the claims and any compositions and methods that are functionally equivalent are intended to fall within the scope of the claims.
  • Various modifications of the compositions and methods in addition to those shown and described herein are intended to fall within the scope of the appended claims.
  • other combinations of the compositions and method steps also are intended to fall within the scope of the appended claims, even if not specifically recited.
  • a combination of steps, elements, components, or constituents may be explicitly mentioned herein; however, other combinations of steps, elements, components, and constituents are included, even though not explicitly stated.
  • a combination yarn comprising a first single yarn and a second single yarn, wherein the first single yarn and second single yarn are linked to each other, wherein the first single yarn comprises primarily polyethylene terephthalate (PET), and wherein the second single yarn comprises primarily polytrimethylene terephthalate (PTT).
  • PET polyethylene terephthalate
  • PTT polytrimethylene terephthalate
  • the color strength of the first single yarn is within 20%, within 15%, within 10%, or within 5% of the color strength of the second single yarn when both yarns are subjected to the same dyeing conditions.
  • the color strength of the second single yarn is at least 10%, at least 20%, at least 30%, or at least 20% greater than the color strength of the first single yarn when both yarns are subjected to the same dyeing conditions.
  • the first single yarn and second single yarn are subjected to dyeing together.
  • the first single yarn may comprise filaments or fibers, which filaments or fibers are made primarily from polyethylene terephthalate (PET) and hence comprise at least 60% PET, and may further include common additives like process enhancers, stabilizers, fillers, and the like.
  • PET polyethylene terephthalate
  • the PET as used in the first single yarn may originate from recycled PET products such as recycled PET bottles, also referred to as rPET.
  • the first single yarn includes at least 60%, at least 70%, at least 75%, at least 80%, at least 90%, at least 95%, or at least 99% PET.
  • the second single yarn may comprise filaments or fibers, which filaments or fibers are made primarily from polytrimethylene terephthalate (PTT) and hence comprise at least 60% PTT as the majority of the material, and may further include common additives like process enhancers, stabilizers, fillers and the like.
  • PTT polytrimethylene terephthalate
  • the PTT as used in the second single yarn may originate from recycled PTT products, also referred to as rPTT.
  • the second single yarn includes at least 60%, at least 70%, at least 75%, at least 80%, at least 90%, at least 95%, or at least 99% PTT.
  • the combination yarn may have a linear weight, expressed in denier, in the range of 1000 to 1600 denier, more preferably 1100 to 1500 denier.
  • a 'denier' equals one gram per 9000 meters of yarn.
  • Either the first single yarn or the second single yarn may have a linear weight, expressed in denier, in the range of 500 to 800 denier, more preferably 550 to 750 denier.
  • the first single yarn and the second single yarn, and if present also any further single yarn have substantially equal linear weights (within 10% of each other).
  • the first single yarn and/or the second single yarn are continuous filament yarns.
  • Each of the first single yarn and the second single yarn may comprise a given number of filaments per cross section, which number of filaments per cross section may be identical or different for the first single yarn and second single yarn.
  • the number of filaments may be between 120 and 160, preferably between 123 and 150.
  • Each filament has a thickness, in function as an element of the yarn, typically expressed as "denier per filament" or "dpf.”
  • the filaments of the first single and/or second single yarn may have a thickness in the range of 10 to 12 dpf, more preferably in the range of 10.4 to 11.2 dpf.
  • each filament of the first single yarn and the second single yarn may have a thickness in the range of 10 to 12 denier, more preferably in the range of 10.4 to 11.2 denier.
  • Each filament of the first and second single yarn has a cross section which may be circular, oval, triangular, trilobal, or square.
  • the filaments may be hollow, comprising one or a plurality of hollow channels. These one or more channels may be coaxial with the axis of the filament.
  • all filaments of the first single yarn may have a substantially equal cross section with a cross-sectional area within 10% of the mean cross-section.
  • all filaments of the second single yarn may have a substantially equal cross section with a cross-sectional area within 10% of the mean cross-section.
  • the mean cross-section of the filaments of the first single yarn and the mean cross-section of the filaments in the second single yarn are substantially identical, i.e., within 10% of each other.
  • the first single yarn or the second single yarn are bulked continuous filament (BCF) yarns. In other embodiments, the first single yarn or the second single yarn are spun yarns comprising staple fibers.
  • BCF bulked continuous filament
  • the first single yarn is a primarily PET single yarn as discussed herein including one or more additives that increase dye uptake.
  • the second single yarn is a primarily PTT single yarn as described herein including one or more additives that increase dye uptake.
  • both the first single yarn and the second single yarn as described herein include one or more additives that increase dye uptake.
  • an increase in dye uptake is defined by an increase in color strength for the first single yarn or the second single yarn, as measured by colorimetry, of 20% or more as compared to a control first single yarn or a control second single yarn respectively that does not contain the one or more additives that increase dye uptake when exposed to the same dyeing conditions.
  • the first single yarn or the second single yarn shows a greater than 20%, greater than 40%, greater than 60%, greater than 80%, greater than 100%, greater than 150%, greater than 200%, greater than 250%, greater than 300%, or greater than 400% increase in color strength, as compared to a control first single yarn or a control second single yarn that does not contain the one or more additives that increase dye uptake, when exposed to the same dyeing conditions.
  • Color Strength refers to the ability of a pigment or dye to change the color of an otherwise colorless material. Color strength may be measured, for example, by comparing the K/S value (where K represents the absorbance and S represents the scatter of the material) of a material, such as the first single yarn or the second single yarn described herein, to a known standard, for example a control first single yarn or a control second single yarn respectively that does not contain one or more additives that increase dye uptake, when exposed to the same dyeing conditions.
  • the first single yarn or the second single yarn as described herein shows an increase in its K/S value of 20% or more as compared to the K/S value of the control first single yarn or the control second single yarn, respectively.
  • the first single yarn or the second single yarn as described herein shows a 20% or greater, 40% or greater, 60% or greater, 80% or greater, 100% of greater, 150% or greater, 150% or greater, 200% or greater, 250% or greater, 300% or greater, or 400% or greater increase in its K/S value as compared to the K/S value of the control first single yarn or the control second single yarn, respectively.
  • K/S values may be measured using any number of commercially available spectrophotometers, for example, the Datacolor® 800 spectrophotometer.
  • first single yarn, the second single yarn, or both further include one or more additives that increase dye uptake depends on the desired color strength difference between the two single yarns for the particular desired application.
  • the color strength of the first single yarn is desired to be within 20% or within 10% of the color strength of the second single yarn when both are subjected to the same dyeing conditions.
  • the first single yarn may comprise primarily PET and one or more additives that increase dye uptake and the second single yarn may comprise primarily PTT and does not include any additives that increase dye uptake.
  • Such embodiments typically are directed to applications where uniformity of color is desired, such as unicolor carpets.
  • the color strength of the second single yarn is instead desired to be at least 10% or at least 20% greater than the color strength of the first single yarn when both yarns are subjected to the same dyeing conditions.
  • both the first single yarn and the second single yarn may further comprise one or more additives to increase dye uptake, or the second single yarn may further comprise one or more additives to increase dye uptake while the first single yarn does not include one or more of such additives.
  • the one or more additives that increase dye uptake may include polybutylene terephthalate (PBT), at least one ester modifier, or combinations thereof.
  • the one or more additives that increase dye uptake include polybutylene terephthalate (PBT).
  • the one or more additives that increase dye uptake include at least one ester modifier.
  • the one or more additives that increase dye uptake include both polybutylene terephthalate (PBT) and at least one ester modifier.
  • polybutylene terephthalate (PBT) can be present in an amount from 2.5 wt. % to 12 wt. %, from 3 wt. % to 12 wt.
  • PBT can be present at 2.5 wt. %, 3 wt. %, 4 wt. %, 5 wt. %, 6 wt. %, 7 wt. %, 8 wt. %, 9 wt. %, 10 wt. %, 11 wt. %, or 12 wt.
  • the ester modifier can be present in an amount ranging from 2.5 wt. % to 12 wt. %, from 3 wt. % to 10 wt. %, from 4 wt. % to 8 wt. %, from 5 wt. % to 7 wt. %, or from 5.5 wt. % to 6.5 wt. % based on the total polymer weight of the first or second single yarn. In some embodiments, the ester modifier can be present at 2.5 wt.
  • the ester modifier is present at 6 wt. % based on the total polymer weight of the first or second single yarn. In another embodiment, the ester modifier is present at 8 wt. % based on the total polymer weight of the first or second single yarn.
  • Ester modifiers may typically comprise compounds that chemically modify the polyester such that it has decreased crystallinity. This decrease in crystallinity provides more space for the dye to penetrate the polymer matrix formed from the polyester, resulting in an increase in dye uptake.
  • the ester modifier comprises a copolymer formed by polymerization of a mixture comprising terephthalic acid or esters thereof, at least one dicarboxylic acid monomer, and at least one diol monomer. In other embodiments, the ester modifier comprises a copolymer formed by polymerization of a mixture comprising terephthalic acid or esters thereof, at least one diol monomer, and at least one polyalkylene glycol. In one embodiment, the mixture comprises terephthalic acid or an ester thereof, a diol monomer, and a dicarboxylic acid monomer in a ratio of 1:2:1. In one embodiment, the mixture includes terephthalic acid. In one embodiment, the mixture includes dimethyl terephthalate.
  • the at least one dicarboxylic acid monomer can be selected from an aliphatic and/or aromatic acid. In some embodiments, the at least one dicarboxylic acid monomer can be selected from isophthalic acid, 2,6-naphthalene dicarboxylic acid, 3,4'-diphenyl ether dicarboxylic acid, hexahydrophthalic acid, 2,7-naphthalenedicarboxylic acid, phthalic acid, 4,4'-methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, undecanedioic acid, 1,12-dodecanedicarboxylic acid, hexadecan
  • the at least one diol monomer can be selected from an aliphatic diol, a cyclic diol, and/or an aromatic diol.
  • the at least one diol can be selected from monoethylene glycol, diethylene glycol, triethyleneglycol, poly(ethylene ether)glycols, 1,3-propanediol, 1,4-butanediol, poly(butylene ether)glycols, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, 1,14-tetradecanediol, 1,16-hexadecanediol, and cis- or trans-1,4-cyclohexanedimethanol.
  • the diol is selected from ethylene glycol, 1,3-propanediol, and 1,4-butanediol. In other embodiments, the diol ca be selected from 1,4-butanediol, 1,5-pentanediol, or 1,6-hexanediol. In one embodiment, the diol includes 1,4-butanediol.
  • the polyalkylene glycol can be selected from the group consisting of polyethylene glycol, polypropylene glycol, ethylene oxide-propylene oxide copolymers, or combinations thereof. In some embodiments, the polyalkylene glycol includes polyethylene glycol. In some embodiments, the polyethylene glycol has a molecular weight from 200 to 5000 g/mol.
  • the mixture further comprises sodium dimethyl-5-sulfoisophthalate (DMSIP), 5-sulfoisophthalic acid (SIPA), or combinations thereof.
  • the mixture includes dimethyl-5-sulfoisophthalate (DMSIP).
  • the mixture includes 5-sulfoisophthalic acid.
  • the ester modifier comprises polybutylene adipate terephthalate (PBAT).
  • PBAT polybutylene adipate terephthalate
  • the mixture further comprises a chain extender.
  • the chain extender can be selected from compounds comprising at least three groups capable of ester formation, for example but not limited to: tartaric acid, citric acid, malic acid, trimethylolpropane, trimethylolethane, pentaerythritol, polyether triols, glycerol, trimesic acid, trimellitic acid, trimellitic anhydride, pyromellitic acid, pyromellitic dianhydride and hydroxyisophthalic acid.
  • the chain extender is selected from compound comprising at least two isocyanate groups, for example but not limited to: aromatic isocyanates including tolylene 2,4-diisocyanate, tolylene 2,6-diisocyanate, 2,2'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 4,4'-diphenylmethane diisocyanate, naphthylene 1,5-diisocyanate, or xylylene diisocyanate; aliphatic diisocyanates such as 1,6-hexamethylene diisocyanate, isophorone diisocyanate, and methylenebis(4-isocyanatocyclohexane); trinuclear isocyanates such as tri(4-isocyanophenyl)methane; and isocyanurates derived from aliphatic isocyanates such as isophorone diisocyanate or methylenebis(
  • the ester modifier may be selected from a phthalate plasticizer.
  • phthalate plasticizers as can be used in the present invention include, but are not limited to, bis(2-ethylhexyl)phthalate (DEHP), bis(2-propylheptyl)phthalate (DPHP), diisononyl phthalate (DINP), di-n-butyl phthalate (DnBP), butyl benzyl phthalate (BBzP), diisodecyl phthalate (DIDP), dioctyl phthalate (DOP), diisooctyl phthalate (DIOP), diethyl phthalate (DEP), diisobutyl phthalate (DIBP), and di-n-hexyl phthalate.
  • the ester modifier may be selected from ortho-phthalic acid, isophthalic acid, or esters thereof.
  • the PET as used in the first single yarn described herein can further comprise one or more additional monomeric or polymeric units.
  • the one or more additional monomeric units comprises cyclohexane dimethanol (CHDM), wherein a PET polymer including a percentage of CHDM may also be known as PETG.
  • the one or more additional units can comprise one or more isophthalic acids, including sulfonated isophthalic acids.
  • the one or more additional units can be selected from diethylene glycol, polyethylene glycol, butylene glycol, polystyrene, vinyltoluene, halostyrene, dihalostyrene, styrene-butadiene copolymers, styrene-acrylonitrile copolymers, styrene-acrylonitrile-butadiene copolymers, styrene-butadiene-styrene terpolymers, styrene-isoprene copolymers, aromatic dicarboxylic acids such a 5-sodium sulfoisophthalic acid, aliphatic dicarboxylic acids such as adipic acid and itaconic acid, glutaric acid, azelaic acid, sebacic acid, and combinations thereof.
  • the one or more additional units can comprise branching agents such as trimesic acid, pyromellitic acid, tri
  • the PTT as used in the second single yarn described herein can further comprise one or more additional monomeric units.
  • additional monomeric units include 5-sodium sulfoisophthalic acid, 5-potassium sulfoisophthalic acid, 4-sodium sulfo-2,6-naphthalenedicarboxylate, tetramethylphosphonium-3,5-dicarboxybenzenesulfonate, tetrabutylphosphonium 3,5-dicarboxybenzenesulfonate, tributylmethylphosphonium 3,5-dicarboxybenzenesulfonate, tetrabutylphosphonium 2,6-dicarboxynaphthalene-4-sulfonate, tetramethylphosphonium 2,6-dicarboxynaphthalene-4-sulfonate, ammonium 3,5-dicarboxybenzenesulfonate, 1,2-butanediol, 1,3-but
  • the yarns as described herein may comprise one or more further additives, including but not limited to: flame retardant additives, for example decabromodiphenyl ether and triaryl phosphates such as triphenyl phosphate; reinforcing agents such as glass fibers; thermal stabilizers, for example thermal conductivity improves such as zinc oxide and titanium oxide; ultraviolet light stabilizers such as resorcinol monobenzoates, phenyl salicyclate and 2-hydroxybenzophenones; hindered amine stabilizers such as benzotriazole, benzophenone, oxalanilide, and cerium oxide; impact modifiers; flow enhancing additives; ionomers; liquid crystal polymers; fluoropolymers; olefins including cyclic olefins; polyamides; ethylene vinyl acetate copolymers; stabilizing agents such as ortho-phosphoric acid, trimethyl phosphate, triphenylphosphate, and triethylphos
  • a combination yarn comprising a first single yarn and a second single yarn, wherein the first single yarn and the second single yarn are linked to each other, wherein the first single yarn comprises at least 60% (for example, at least 75%) PET and an additive that includes at least one ester modifier, wherein the second single yarn comprises at least 60% (for example, at least 75%) PTT and does not include any additives that increase dye uptake, and wherein the color strength of the first single yarn is within 20% (for example, within 10%) of the color strength of the second single yarn when both yarns are subject to the same dyeing conditions, for example, when both yarns are dyed together.
  • a combination yarn comprising a first single yarn and a second single yarn, wherein the first single yarn and the second single yarn are linked to each other, wherein the first single yarn comprises at least 60% (for example, at least 75%) PET and does not include any additives that increase dye uptake, wherein the second single yarn comprises at least 60% (for example, at least 95%) PTT and an additive that includes PBT and at least one ester modifier, and wherein the color strength of the second single yarn is at least 10% (for example, at least 20%) greater than the color strength of the first single yarn when both yarns are subject to the same dyeing conditions, for example when both yarns are dyed together.
  • a disperse dye may be used to color the first single yarn and/or the second single yarn.
  • the same disperse dye may be used to color the first single yarn and the second single yarn.
  • the first single yarn and the second single yarn may be dyed together.
  • the first single yarn and the second single yarn may be dyed to the same or to a different dye tone using the same disperse dye.
  • a combination yarn comprising at least a first single yarn and a second single yarn, wherein the first single yarn is a polyethylene terephthalate (PET) single yarn, wherein the second single yarn is a polytrimethylene terephthalate (PTT) single yarn, and wherein the first single yarn and/or the second single yarn have been solution dyed.
  • PET polyethylene terephthalate
  • PTT polytrimethylene terephthalate
  • the first single yarn and/or the second single yarn have been solution dyed.
  • the first single yarn and the second single yarn may be dyed together.
  • the combination yarn as described herein may be dyed using a piece dyeing process.
  • the undyed combination yarn is first assembled as a component of the final object, for example as pile fibers in a carpet.
  • the assembled final object for example a carpet, is then immersed in a dye bath at an elevated temperature.
  • the final object such as a carpet may be unicolor or may be subject to a differential or tonal effect due to different dyeing levels for the first and second single yarns.
  • the piece dyeing process may be a continuous dyeing process, where the final objected is passed under dyeing equipment that flows dye solution through the object instead of requiring immersion within a dye bath.
  • the first single yarn and the second single yarn are dyed at the same temperature.
  • the first single yarn and the second single yarn can be dyed at a temperature less than 135 °C, for example at a temperature of from 100°C to 130°C.
  • the first single yarn and the second single yarn may be linked by being formed into a plied or twisted yarn.
  • the combination yarn may be plied or twined in either the S- or Z-direction.
  • the number of turns per inch may be in the range of 4.10 to 4.30 turns. In some embodiments, the number of turns per inch may be in the range of 4.20 to 4.25 turns.
  • the first single yarn, second single yarn, or further single yarns may be untwisted, particularly when the single yarns are BCF yarns, or may be twisted as well.
  • the twisted single yarn is twisted in a direction (S- or Z-direction) which is opposite to the twining or plying direction.
  • the twisted single yarn may be twisted in the range of 4.10 to 4.30 turns per inch. In some embodiments, the twisted single yarn may be twisted by 4.25 turns per inch.
  • the first single yarn and the second single yarn are linked to each other by air entanglement.
  • the combination yarn may comprise more than two single yarns, such as 3, 4, 5 or more single yarns all linked to each other as described herein.
  • the additional single yarns may be PET single yarns or PTT single yarns.
  • the weight ratio of PET to PTT in the combination yarn may vary.
  • the combination yarn may have a weight ratio of PET to PTT between 4:1 to 1:4.
  • the combination yarn may have a weight ratio of PET to PTT of 1:1.
  • the combination yarn is heat set.
  • the combined yarn is heat set through, e.g., a Suessen or Superba heat set tunnel, thereby imposing at least to some extent memory, strength and wearability to the yarn.
  • the combination yarns described herein have several advantages over prior PET-based yarns, particularly when used to provide the pile of a woven or tufted carpet.
  • the addition of PTT yarns to PET-based carpet brings durability, wear and stain resistance with only a portion of the PET yarns being replaced by PTT.
  • the carpet is a tufted carpet.
  • a tufted carpet comprising a pile yarn providing the pile of the carpet, wherein the pile yarn is the combination yarn described herein.
  • the tufted carpet may be provided from solely polyester material, i.e., all parts of the carpet, such as pile yarn, primary backing in which the pile is tufted, the adhesion layer to lock the pile in the primary backing, the secondary backing and the like are provided from a polyester material.
  • the polyester material is only PET or PTT.
  • the carpet is a unicolor carpet.
  • a unicolor carpet is defined by having all the yarns providing the pile of the carpet having a substantially uniform color over the surface of the carpet.
  • the carpets may instead have a tonal effect to differing coloration of the first single yarn and the second single yarn.
  • the carpet is initially assembled as a greige roll, i.e. a roll of the tufted undyed combination yarn without a secondary backing. This greige roll may then be subjected to a piece dyeing process as described herein by immersion into a dye bath or by a continuous dyeing process.
  • the carpet may be a loop pile carpet. In other embodiments, the carpet may be a cut pile carpet. In yet other embodiments, the carpet may comprise both cut piles and loop piles.
  • the surface weight of the carpet may vary between 25 and 60 ounces per square yard.
  • the height of the pile of the carpet may be between 6/32 inches and 2.5 inches, for example between 1/4 to 1/2 inches or between 1/2 to 3 ⁇ 4 inches.
  • the thickness of the carpet may be between 12/32 of an inch and 1 inch.
  • the number of tufts or pile units per surface unit may be between 250,000 and 25,000 per square meter.
  • the number of piles or tufts in the production direct per inch may be in the range of 6 to 13.
  • the distance between two adjacent tufts (or gauge) may range from 3/16 of an inch to 1/10 of an inch.
  • a first example of a combination yarn according to the present disclosure was provided by plying a first single yarn and a second single yarn, the first single yarn being a polyethylene terephthalate (PET) single yarn comprising 8% of BASF 3S ester modifier and the second single yarn being a polytrimethylene terephthalate (PTT) single yarn.
  • PET polyethylene terephthalate
  • PTT polytrimethylene terephthalate
  • the first single yarn was a bulk continuous filament yarn formed from 150 PET filaments. Each filament has a denier of 10.4 and has a trilobal cross section, providing a single yarn with 1560 denier.
  • the PET used includes 92 wt. % PET and 8% BASF 3S Modifier.
  • the second single yarn was a bulk continuous filament yarn formed from 123 PTT filaments. Each filament has a denier of 10.4 and a trilobal cross section, providing a single yarn with 1279 denier.
  • the two single yarns were plied with 4.25 turns per inch in the S-direction, providing a two-ply combination yarn.
  • the two-ply yarn was heat set using a Superba textured heat set tunnel.
  • a solid dyeable two-ply combination yarn was provided by the above process with little to no tonal aspect visible to the naked eye upon dyeing. This yarn was used to create a solid color fabric that shows better performance than 100% PET fabrics made of the same construction.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Artificial Filaments (AREA)
EP20154782.5A 2019-12-10 2020-01-31 Fil combiné Pending EP3835480A1 (fr)

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PCT/US2020/063929 WO2021119076A1 (fr) 2019-12-10 2020-12-09 Fil combiné
EP20899270.1A EP4073302A4 (fr) 2019-12-10 2020-12-09 Fil combiné
AU2020399650A AU2020399650A1 (en) 2019-12-10 2020-12-09 Combination yarn
US17/780,692 US20230020177A1 (en) 2019-12-10 2020-12-09 Combination yarn

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US20230020177A1 (en) 2023-01-19
AU2020399650A1 (en) 2022-06-09
EP4073302A1 (fr) 2022-10-19
WO2021119076A1 (fr) 2021-06-17

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