EP3957782A1 - Bauschgarn mit kontinuierlichem nebeneinanderliegendem zweikomponentenfilament, verfahren zur herstellung und daraus hergestelltes bodenbelagsmaterial - Google Patents

Bauschgarn mit kontinuierlichem nebeneinanderliegendem zweikomponentenfilament, verfahren zur herstellung und daraus hergestelltes bodenbelagsmaterial Download PDF

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Publication number
EP3957782A1
EP3957782A1 EP20202322.2A EP20202322A EP3957782A1 EP 3957782 A1 EP3957782 A1 EP 3957782A1 EP 20202322 A EP20202322 A EP 20202322A EP 3957782 A1 EP3957782 A1 EP 3957782A1
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EP
European Patent Office
Prior art keywords
yarn
component
range
bcf
continuous
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.)
Withdrawn
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EP20202322.2A
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English (en)
French (fr)
Inventor
Khushboo Abhishek Mandawewala
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Individual
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Individual
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Publication date
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Publication of EP3957782A1 publication Critical patent/EP3957782A1/de
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Classifications

    • 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
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/32—Side-by-side structure; Spinnerette packs therefor
    • 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
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • D02G3/045—Blended or other yarns or threads containing components made from different materials all components being made from artificial or synthetic material
    • 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
    • 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
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/10—Conjugate fibres, e.g. core-sheath, side-by-side
    • 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
    • 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]
    • D10B2331/041—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] derived from hydroxy-carboxylic acids, e.g. lactones
    • 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
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/063—Load-responsive characteristics high strength
    • 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

  • the present disclosure relates to a textile industry, and, more particularly, to a bulked continuous side-by-side bi-component filament (BCF) yarn, a method for making such BCF yarn, and a floor covering material made from such BCF yarn.
  • BCF bi-component filament
  • Continuous filament yarn comprises a group of filaments, wherein each such filaments are made of a polymer material that is extruded as a long fiber.
  • Continuous filament yarn may be a continuous mono-component filament yarn or a continuous bi-component filament yarn. Depending upon the requirements and usages, the continuous mono-component filament yarn or the continuous bi-component filament yarn are chosen for respective purposes.
  • the continuous bi-component filament yarn may be available is various arrangements, such as a sheath-core arrangement and a side-by-side arrangement. In the sheath-core arrangement, each filament of the continuous bi-component filament yarn includes one of the two polymers forming a core while the other forming a sheath.
  • each filament of the continuous bi-component filament yarn includes the two polymers arranged side-by-side to each other. While both types of continuous bi-component filament yarns are widely used and have specific requirements in a textile industry, the present disclosure discuss about the continuous side-by-side bi-component filament yarn and articles made therefrom.
  • the continuous side-by-side bi-component filament yarns are used for making various kinds of articles, including, but not limited to, carpets, as an alternative to carpets made using spun yarn comprised of staple fibers.
  • such continuous side-by-side bi-component filament yarns are texturized for increasing bulkiness and for better wear resistance, prior to making the carpet therefrom.
  • the articles, such as, the carpets, made from such continuous side-by-side bi-component filament yarns may undergo delamination over time, a degradation process wherein the bi-component polymers begin to separate from one another, particularly, when such carpets are subject to high level of wear and tear, affecting integrity and long-term durability of such articles.
  • the general purpose of the present disclosure is to provide a bulked continuous side-by-side bi-component filament (BCF) yarn, a method for making such BCF yarn, and a floor covering material made from such BCF yarn, to include all advantages of the prior art, and to overcome the drawbacks inherent in the prior art.
  • BCF bi-component filament
  • an object of the present disclosure is to provide such bulk continuous side-by-side bi-component filament yarns that may be able to withstand high level of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.
  • Another object of the present disclosure is to provide a method for making such bulk continuous side-by-side bi-component filament yarns that may be able to withstand high level of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.
  • Yet another object of the present disclosure is to provide a floor covering material, such as, carpets that may be able to withstand high level of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.
  • a Bulked Continuous side-by-side bi-component Filament (BCF) yarn is provided.
  • the BCF yarn may include a plurality of side-by-side bi-component filaments.
  • Each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments may include a first polymer component and a second polymer component.
  • the first polymer component may form a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn.
  • PBT polybutylene terephthalate
  • the second polymer component may form a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn.
  • PET polyethylene terephthalate
  • PLA polylactic acid
  • the BCF yarn may be obtained by a single-step continuous process, and subsequently, after the single-step continuous process, is followed by steps of cabling and heat-setting at predetermined parameters.
  • the BCF yarn as obtained may include an elongation in a range of 40% to 65%, and a Hexapod rating after 12000 cycles is of more than 2.
  • a method for forming a Bulked Continuous side-by-side bi-component Filament (BCF) yarn may include: extruding the first polymer component and the second polymer component at a gradual temperature having a range of 240°C to 300°C through a plurality of temperature zones, and at a pressure range of 60 bars to 130 bars to obtain a plurality of side-by-side bi-component filaments grouped together to obtain a continuous side-by-side bi-component filament yarn.
  • Each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments may include a first polymer component and a second polymer component.
  • the first polymer component may form a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn.
  • the second polymer component may form a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn.
  • PET polyethylene terephthalate
  • PLA polylactic acid
  • the method may further include: cabling the continuous side-by-side bi-component filament yarn in a range of 40 TPM (Twist Per meter) to 350 TPM, with at least one ply to obtain the continuous side-by-side bi-component filament yarn having twists; and heat setting the continuous side-by-side bi-component filament yarn with the twists in a range of 100°C to 200°C to obtain a twisted heat set BCF yarn having: an elongation in a range of 40% to 65%, and a Hexapod rating after 12000 cycles is more than 2.
  • TPM Torist Per meter
  • a floor covering material may include a base backing, and a plurality of Bulked Continuous side-by-side bi-component Filament (BCF) yarn configured on the base backing.
  • the BCF yarn may include a plurality of side-by-side bi-component filaments.
  • Each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments may include a first polymer component and a second polymer component.
  • the first polymer component may form a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn.
  • PBT polybutylene terephthalate
  • the second polymer component may form a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn.
  • PET polyethylene terephthalate
  • PLA polylactic acid
  • the BCF yarn may be obtained by a single-step continuous process, and subsequently, after the single-step continuous process, is followed by steps of cabling and heat-setting at predetermined parameters.
  • the BCF yarn as obtained may include an elongation in a range of 40% to 65%, and a Hexapod rating after 12000 cycles is of more than 2.
  • the exemplary embodiments described herein detail for illustrative purposes are subject to many variations in implementation.
  • the present disclosure provides a bulked continuous side-by-side bi-component filament (BCF) yarn, a method for making such BCF yarn, and a floor covering material made from such BCF yarn.
  • BCF bi-component filament
  • the present disclosure is not limited to an antiviral and antibacterial textile material and method for preparing the same. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the present disclosure.
  • the present disclosure provides a Bulked Continuous side-by-side bi-component Filament (BCF) yarn.
  • the BCF yarn may include a plurality of side-by-side bi-component filaments.
  • Each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments may include a first polymer component and a second polymer component.
  • the first polymer component may form a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn.
  • PBT polybutylene terephthalate
  • the second polymer component may form a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn.
  • PET polyethylene terephthalate
  • PLA polylactic acid
  • the BCF yarn may be obtained by a single-step continuous process, and subsequently, after the single-step continuous process, is followed by steps of cabling and heat-setting at predetermined parameters.
  • the BCF yarn as obtained may include an elongation in a range of 40% to 65%, and a Hexapod rating after 12000 cycles is of more than 2.
  • FIGS. 1A to 4 A Bulked Continuous side-by-side bi-component Filament (BCF) yarn will now be explained in conjunction with FIGS. 1A to 4 as below, in accordance with various exemplary embodiment of the present disclosure.
  • the drawings as shown herein are only for better understanding of the disclosure and may not be in anyway considered to be limiting only to the diagrams as disclosed herein. There may be various other forms that may be covered by the claims of the present disclosure.
  • the BCF yarn 100 may include a plurality of side-by-side bi-component filaments 110.
  • Each side-by-side bi-component filament 110, as shown in FIG. 2A , of such plurality of side-by-side bi-component filaments may include a first polymer component 112 and a second polymer component 114.
  • the first polymer component 112 may form a first side 110a of the side-by-side bi-component filaments 110.
  • the second polymer component 114 may form a second side 110b of the side-by-side bi-component filaments 110.
  • the first polymer component 110 may include polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament 110 in the BCF yarn 100.
  • the second polymer component 114 may include one of polyethylene terephthalate (PET) or polylactic acid (PLA) or recycled PET in at least about 75 to 25 volume percent of the filament 110 in the BCF yarn 100.
  • PET polyethylene terephthalate
  • PLA polylactic acid
  • recycled PET polylactic acid
  • the first and second polymer components 112, 114 may be in any desired volume percent of the filament 110 in the BCF yarn 100 depending upon the requirement.
  • the BCF yarn 100 may include various shapes of the side-by-side bi-component filament 110, such as shown in FIGS. 2A to 2L .
  • the side-by-side bi-component filament 110 respectively, include a side-by-side full semi-circular cross-sectional shape, a side-by-side hollow semi-circular cross-sectional shape.
  • the side-by-side bi-component filament 110 respectively, include a side-by-side full tri-lobal cross-sectional shape and a side-by-side hollow tri-lobal cross-sectional shape.
  • the side-by-side bi-component filament 110 respectively, include a side-by-side full delta cross-sectional shape and a side-by-side hollow delta cross-sectional shape.
  • the side-by-side bi-component filament 110 respectively, include a side-by-side full concave cross-sectional shape and a side-by-side hollow concave cross-sectional shape. Further, as shown in FIGS.
  • the side-by-side bi-component filament 110 include a side-by-side full octa-lobal cross-sectional shape and a side-by-side hollow octa-lobal cross-sectional shape.
  • the side-by-side bi-component filament 110 include a side-by-side full elliptical cross-sectional shape and a side-by-side hollow elliptical cross-sectional shape.
  • the side-by-side bi-component filament 110 may include various other shapes, such as, a side-by-side full multi-lobal cross-sectional shape, a side-by-side hollow multi-lobal cross-sectional shape, or any other shape as required.
  • the first and the second sides together as a whole comprises a side by side full circle cross sectional shape, a side by side hollow circular cross-sectional shape.
  • the BCF yarn 100 may be obtained by a single-step continuous process that may include steps of extruding, spinning, quenching, spin finish application, drawing, and/or texturing, cooling, intermingling and winding at the predetermined parameters. Subsequently, after the single-step continuous process, steps of cabling and heat-setting at predetermined parameters are followed.
  • Single-step process means that all such steps are performed on a single machine having various machine sections, and may also be referred to as single machine process. Referring now to FIG. 3 , to describe a method 200 of making the BCF yarn 100 via the single-step continuous process 300, and subsequently followed by steps of cabling or twisting 210 and heat-setting 220.
  • the method 200 includes the single-step continuous process 300, which starts at 310 by extruding the first polymer component 112 via a first extruder E1 and the second polymer component 114 via a second extruder E2.
  • the first polymer component 112 and the second polymer component 114 are extruded at a predetermined parameter, such as gradual temperature and pressure to obtain a plurality of side-by-side bi-component filaments 110 grouped together to obtain a continuous side-by-side bi-component filament yarn.
  • the first polymer component 112 and the second polymer component 114 are extruded at the gradual temperature having a range of 240°C to 305°C through a plurality of temperature zones (t1...tn), and at the pressure range of 60 bars to 130 bars. Further, at 320 spinning of the continuous side-by-side bi-component filament yarn is performed. Further, at 330, the continuous side-by-side bi-component filament yarn is gradually quenched, at the predetermined parameters, via, an air flow.
  • the predetermined parameters of the quenching air flow may include: a quenching air flow temperature in a range of 10°C to 25°C, quenching air flow rate in a range of 0.1mps to 0.8mps, and quenching air flow pressure in a range of 1 mbars to 4 mbars.
  • spin finish application is performed at 340 on the continuous side-by-side bi-component filament yarn.
  • the spin finish application yarn is sequentially drawn at predetermined parameters, such as drawing speed and drawing temperature.
  • the drawing speed may be in a range of 760mpm to 3500mpm
  • the drawing temperature range may be in a range of 75°C to 200°C.
  • the drawn yarn may be optionally textured at a texturing temperature range of 130°C to 200°C and a texturing vacuum pressure range of -50 mbars to -150 mbars.
  • the continuous side-by-side bi-continuous filament yarn is cooled at a cooling drum speed having a range of 10rpm to 60rpm and a cooling drum vacuum having a range of -20mbars to -80mbars.
  • the cooled continuous side-by-side bi-continuous filament may further be intermingled at 380 and wounded at 390.
  • the at least one of the first and second polymer components 112, 114 are solution-dyed, either using pigments or solvent dyes or a combination thereof. Further, in one embodiment of the present disclosure, the at least one of the first and second polymer components are one of hank-dyed, space-dyed or yarn-dyed. One way to dye the at least one of the first and second polymer components 112, 114 is to dip them in a vat of dye after or before they are extruded.
  • the continuous side-by-side bi-continuous filament yarn is cabled or twisted at step 210.
  • the continuous side-by-side bi-component filament yarn is imparted with parament and distinctive texture in the form of twists.
  • cabling or twisting improves tip definition and integrity.
  • the tip is that end of the yarn which are extending vertically from the carpet backing and visually and physically apparent to the consumer. Twists are generally expressed as twists per meter or TPM.
  • Such cabling/twisting of the continuous side-by-side bi-component filament yarn may be done in a range of 40TPM to 350 TPM; preferably 100TPM-300TPM; more preferably 200TPM-250TPM, for example about 230TPM, to obtain the continuous side-by-side bi-component filament yarn having such twists.
  • One of the example table is presented below to illustrate cabling or twisting parameters with respect the combination of types of the first and second polymer components 112, 114: Polymer PET-50% & PBT-50% PET-33% & PBT-67% PET-67% & PBT-33% TPM 230 230 230 Twist Direction "s" "s” "s” Spindle Rpm 5000 5000 5000
  • 'Twist direction' "S" refers a yarn spun in counter-clockwise direction and is normally used to create right-handed twill. Further, 'spindle rpm' refers to speed to spindle where the twisting is done.
  • the continuous side-by-side bi-component filament yarn with the twists is heat set.
  • Heat treating of the fibers, filaments or yarn of the present invention is carried out by a fluid, such as air, steam, or any other compressible liquid or vapor capable of transferring heat to the twisted yarn as it continuously travels through a heat setting device.
  • the temperature of such fluid must be such that the yarn does not melt. If the temperature of the yarn is above the melting point of the yarn it is necessary to shorten the time in which the yarn dwells in the heat setting device.
  • This step of heat setting utilizes such stream capable of transferring heat to the twisted yarn as it continuously travels through the heat setting device, at a temperature 85°C to 200°C; preferably 100°C to 190°C; more preferably 130°C to 180°C, for example about 130°C or 140°C.
  • This process is affected by the length of time during which the twisted yarn is exposed to the heating medium (time/temperature effect). Generally, useful exposure times are from 30 seconds to 3 minutes; preferably from 45 seconds to 11 ⁇ 2 minutes; for example, about 1 minute.
  • twist direction As defined above in the table: "Twist direction” as “S” represents a yarn is twisted in counter-clockwise and is normally used to create right-handed twill. However, without departing from the scope of the present disclosure, the twist direction may also be "Z", which represents that a yarn is twisted in clockwise and is normally used to create left-handed twill.
  • “Over feed Speed” represents the speed at which the overfeed rollers in the heat set machine runs. This is normally 10-30% more than the delivery speed, to keep the yarn slack before entering the actual heat set process.
  • “Delivery Speed” represents the feed speed of the yarn at the heat set machine.
  • “Dwell time” represents the total time yarn stays inside the actual heat setting process.
  • “Stuffing pressure 1" represents the level of additional crimp (known as friese) given in the yarn during the heat setting process.
  • GKK temp 1&2 represents the actual temperature yarn is exposed for heat setting.
  • Dew point set 1&2 represents the moisture level inside the actual heat setting tunnel.
  • “Accumulator basic speed” represents the normal speed of the yarn outlet from the heat setting tunnel.
  • No of ends per tunnel represents total number of yarns which are heat set together in each heat setting tunnel.
  • Heat setting for the twisted yarns stabilizes the twist and often causes the BCF yarn 100 to lock in the twists and gain volume in the PCF yarn 100. This volume growth is may be described as "bulk development”. Heat setting also retains the twist during use and there is no such a loss of resilience and of overall appearance due to matting.
  • the unique yarn and carpet made therefrom based on the side-by-side bi-component filaments disclosed herein results in an ability to thermally lock in the twist structure and enables to gain volume in the BCF yarn 100.
  • the BCF yarn is produced have number of the side-by-side bi-component filaments in in the range of 25 filaments to 1000 filaments. Further, the BCF yarn 100 exhibits a denier per filament (DPF) ratio measuring in the range of 0.5 DPF to 50 DPF, and a linear density in a range of 600denier to 6000denier.
  • DPF denier per filament
  • the BCF yarn 100 that is produced using above process have an elongation in a range of 40% to 65%.
  • BCF yarn 100 and/or carpet produced with compositions of the first and second polymers 112, 114 arranged in side-by-side arrangements of the invention were tested for performance in a Hexapod Tumble Test typically used in the art to evaluate carpet performance and found to have a Hexapod rating after 12000 cycles to be more than 2.
  • Such Hexapod rating of more than 2 after 12000 cycles of the BCF yarn 100 are obtained due to the unique combination the first polymer component 112 forming the first side 110a in at least about 25 to 75 volume percent, and the second polymer component 114 forming the second side 110a in at least about 75 to 25 volume percent of the filament in the BCF yarn, along with the heat setting of such yarn.
  • the floor covering material 400 may include a base backing 410, and the plurality of Bulked Continuous side-by-side bi-component Filament (BCF) yarn 100 configured on the base backing 410, as described above and excluded from the description herein for the sake of brevity of the disclosure and avoid reputation of the subject matter.
  • the floor covering material 400 may include, but not limited to, carpets, rugs, mats and so forth.
  • the BCF yarns 100 are tufted on the base backing 410 to form the floor covering material 400.
  • the BCF yarns 100 are knitted on the base backing 410 to form the floor covering material 400. In one embodiment of the present disclosure, the BCF yarns 100 are woven on the base backing 410 to form the floor covering material 400. In one embodiment of the present disclosure, the BCF yarns 100 are knotted on the base backing 410 to form the floor covering material 400.
  • the present disclosure is advantageous in providing such bulk continuous side-by-side bi-component filament yarns or carpets that may be able to withstand high level of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
EP20202322.2A 2020-08-21 2020-10-16 Bauschgarn mit kontinuierlichem nebeneinanderliegendem zweikomponentenfilament, verfahren zur herstellung und daraus hergestelltes bodenbelagsmaterial Withdrawn EP3957782A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IN202021036119 2020-08-21

Publications (1)

Publication Number Publication Date
EP3957782A1 true EP3957782A1 (de) 2022-02-23

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EP20202322.2A Withdrawn EP3957782A1 (de) 2020-08-21 2020-10-16 Bauschgarn mit kontinuierlichem nebeneinanderliegendem zweikomponentenfilament, verfahren zur herstellung und daraus hergestelltes bodenbelagsmaterial
EP21778216.8A Pending EP4200467A1 (de) 2020-08-21 2021-08-20 Verdrilltes und wärmefixiertes bcf-garn mit nebeneinander angeordnetem bikomponentenfilament, verfahren zur herstellung dieses garns und bodenbelagmaterial mit solch einem garn

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US (1) US20230304219A1 (de)
EP (2) EP3957782A1 (de)
AU (1) AU2021327176A1 (de)
CA (1) CA3187836A1 (de)
WO (1) WO2022038570A1 (de)

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WO2023195964A2 (en) * 2022-04-05 2023-10-12 Küçükçalik Teksti̇l Sanayi̇i̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇ A method for the production of self-colored recycled bicomponent pes yarn compatible with harsh weather conditions

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US5958548A (en) * 1996-08-14 1999-09-28 Nyltec Inc. Carpet tufted with bulked continuous filament carpet face yarns utilizing new sheathed core filaments and related selection techniques to produce cost savings
EP0921219B1 (de) * 1997-12-05 2002-10-02 Basf Corporation Selbstfixierender Faden
KR100629813B1 (ko) * 1999-06-08 2006-09-29 도레이 가부시끼가이샤 소프트 스트레치사 및 제조 방법
US10760186B2 (en) * 2017-03-29 2020-09-01 Welspun Flooring Limited Manufacture of bi-component continuous filaments and articles made therefrom

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EP4200467A1 (de) 2023-06-28
WO2022038570A1 (en) 2022-02-24
AU2021327176A1 (en) 2023-03-02
CA3187836A1 (en) 2022-02-24
US20230304219A1 (en) 2023-09-28

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