EP4200467A1 - Fil bcf torsadé et thermofixé comprenant un filament à deux composants côte à côte, procédé de formation d'un tel fil et matériau de revêtement de sol comprenant un tel fil - Google Patents

Fil bcf torsadé et thermofixé comprenant un filament à deux composants côte à côte, procédé de formation d'un tel fil et matériau de revêtement de sol comprenant un tel fil

Info

Publication number
EP4200467A1
EP4200467A1 EP21778216.8A EP21778216A EP4200467A1 EP 4200467 A1 EP4200467 A1 EP 4200467A1 EP 21778216 A EP21778216 A EP 21778216A EP 4200467 A1 EP4200467 A1 EP 4200467A1
Authority
EP
European Patent Office
Prior art keywords
yarn
component
bcf
yam
filament
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
EP21778216.8A
Other languages
German (de)
English (en)
Inventor
Abhishek Rajesh Mandawewala
Khushboo Abhishek Mandawewala
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.)
Aym Syntex Ltd
Original Assignee
Aym Syntex Ltd
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 Aym Syntex Ltd filed Critical Aym Syntex Ltd
Publication of EP4200467A1 publication Critical patent/EP4200467A1/fr
Pending legal-status Critical Current

Links

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 the textile industry, and, more particularly, to a bulked continuous side-by-side bi-component filament (BCF) yarn, a method for making such BCF yam, and a floor covering material made from such BCF yarn.
  • BCF bi-component filament
  • Continuous filament yam comprises a group of filaments, wherein each such filament is made of a polymer material that is extruded as a long fiber.
  • Such yarn is also referred to as continuous multi-filament yarn although for the sake of the present disclosure, the fact that there are multiple filaments in the respective yams will be assumed, where not specifically mentioned.
  • Continuous filament yam may be a continuous mono-component filament yam 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 yam are chosen for respective purposes.
  • the continuous bi-component filament yarn may be available in various arrangements, such as a sheath-core arrangement and a side-by- side arrangement.
  • each filament of the continuous bi- component filament yarn includes one of the two polymers forming a core while the other forms a sheath.
  • each filament of the continuous bi-component filament yam includes the two polymers arranged side-by-side to each other. While both types of continuous bi-component filament yams are widely used and have specific requirements in the textile industry, the present disclosure relates to continuous side-by-side bi-component filament yam 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 e.g. 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 and resilience performance, prior to making the carpet therefrom.
  • the articles, such as, the carpets, made from such continuous side-by-side bi-component filament yams 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 levels of wear and tear, affecting integrity and long-term durability of such articles.
  • the general purpose of the present disclosure is to provide a twisted and heat-set bulked continuous side-by-side bi-component filament (BCF) yarn, a method for making such twisted and heatset BCF yarn, and a floor covering material made from such twisted and heat-set 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 yams that may be able to withstand high levels 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 levels 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 levels of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.
  • a twisted and heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yam 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 25 and up to 75 volume percent of the filament in the BCF yam.
  • 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 most 75 and down to 25 volume percent of the filament in the BCF yarn.
  • the BCF yarn may be obtained by a single-step continuous process which is subsequently followed by steps of cabling and heat-setting at predetermined parameters to form the twisted and heat-set BCF yam.
  • the BCF yam as obtained may exhibit an elongation to break in a range of 40% to 65%, and carpet or floor covering formed therefrom may exhibit a Hexapod rating after 12000 cycles of more than 2.
  • PET may be the first component
  • PBT may be the second component
  • polyesters such as PET and PBT for the first and second components ensures that they can be intimately coextruded together without requiring a binding or compatibilitising agent or third component.
  • other equivalent polyesters may also be used as first and second polymer components, including aliphatic polyesters and aromatic or semiaromatic polyesters.
  • a single-step continuous process is intended to refer to a process that takes place without intermediate winding e.g. to a bobbin. Nevertheless, the single step process may be terminated by winding the BCF yarn to a roll or bobbin. It will be well understood that twisting and/or cabling will generally take place at a far lower speed than that of extmsion and spinning. In the above, the single step process may include winding of the yarn prior to performing the cabling and/or twisting. The cabled and/or twisted BCF yarn may then again be wound to a bobbin or reel prior to being heat set.
  • twisting in the context of the present invention may refer to twisting alone or steps of twisting and cabling. Twisting may thus include twisting a single yarn comprising a plurality of filaments, or twisting a plurality of yams around each other.
  • the term ‘cabling’ means twisting at least one yam comprising at least one filament around at least one other yarn comprising at least one filament. Cabling usually requires filaments or yams wound on at least two bobbins to be combined together. Further, one bobbin can comprise a plurality of individual filaments or yams bundled together. In the following, a bobbin, reel, roll, tube and the like are all referred to as bobbin.
  • a method for forming a twisted and heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yam may include: extruding the first polymer component and the second polymer component e.g. 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 e.g. 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 25 and up 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 (PEA) in at most 75 and down to 25 volume percent of the filament in the BCF yam.
  • PET polyethylene terephthalate
  • PEA 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 other ply to obtain the continuous side-by-side bi-component filament yam having twists.
  • TPM Transmission Per meter
  • the twisted BCF yam is heat set, preferably in a range of 100°C to 200°C to obtain a twisted and heat set BCF yam
  • Such twisted and heat-set BCF yarns have been shown to exhibit an elongation to break in a range of 40% to 65%, and floor coverings manufactured therefrom exhibit a Hexapod rating after 12000 cycles of more than 2.
  • a floor covering material may include a base backing and a plurality of twisted and heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yams configured on the base backing.
  • BCF bi-component Filament
  • the twisted and heat-set BCF yarns 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 least25 and up 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 most 75 and down to 25 volume percent of the filament in the BCF yarn.
  • PET polyethylene terephthalate
  • PLA polylactic acid
  • the floor covering as obtained may exhibit a Hexapod rating after 12000 cycles of more than 2.
  • FIG. 1 illustrates a cross-sectional perspective view of a twisted and heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yarn, in accordance with an exemplary embodiment of the present disclosure
  • FIGS. 2A to 2L illustrate various cross-sectional views of side-by-side bi-component filaments, in accordance with exemplary embodiments of the present disclosure
  • FIG. 3 illustrates a block diagram of a method for forming a Bulked Continuous side-by-side bi-component Filament (BCF) yarn, in accordance with an exemplary embodiment of the present disclosure
  • FIG. 4 illustrate an article, such as a floor covering material made from Bulked Continuous side-by-side bi-component Filament (BCF) yarns, in accordance with an exemplary embodiment of the present disclosure.
  • BCF Bulked Continuous side-by-side bi-component Filament
  • the exemplary embodiments described here in 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 yam, and a floor covering material made from such BCF yarn.
  • BCF bi-component filament
  • the present disclosure is not limited to floor covering materials and methods 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 twisted and heat-set 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 25 and up 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 most 75 and down to 25 volume percent of the filament in the BCF yarn.
  • PET polyethylene terephthalate
  • PLA polylactic acid
  • the BCF yam may be obtained by a single-step continuous process which is subsequently followed by steps of cabling and heat-setting at predetermined parameters.
  • the twisted and heat- set BCF yarn as obtained may exhibit an elongation to break in a range of 40% to 65%.
  • Floor covering produced from the yam may exhibit a Hexapod rating after 12000 cycles of more than 2.
  • FIGS. 1 to 4 A twisted and heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yarn will now be explained in conjunction with FIGS. 1 to 4 as below, in accordance with various exemplary embodiments of the present disclosure.
  • BCF bi-component Filament
  • FIG. 1 a cross-sectional perspective view of a twisted and heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yarn 100 is illustrated in accordance with an exemplary embodiment of the present disclosure.
  • the 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. 2 A, 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 25 and up 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 most 75 and down to 25 volume percent of the filament 110 in the BCF yarn 100.
  • PET polyethylene terephthalate
  • PLA polylactic acid
  • recycled PET recycled PET in at most 75 and down to 25 volume percent of the filament 110 in the BCF yarn 100.
  • the first and second polymer components 112, 114 may be any suitable polyesters, in any desired volume percent of the filament 110 in the BCF yam 100 depending upon the requirement.
  • the twisted and heat-set 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 includes a side-by-side full tri-lobal cross-sectional shape and a side-by-side hollow tri-lobal cross-sectional shape, respectively. Further, as shown in FIGS.
  • the side-by-side bi-component filament 110 includes a side-by-side full delta cross-sectional shape and a side-by-side hollow delta cross-sectional shape, respectively. Further, as shown in FIGS. 2G and 2H, the side-by-side bi-component filament 110 includes a side-by-side full concave cross-sectional shape and a side-by-side hollow concave cross-sectional shape, respectively. Further, as shown in FIGS. 21 and 2J, the side-by-side bi-component filament 110 includes a side-by-side full octa-lobal cross-sectional shape and a side-by-side hollow octa-lobal cross-sectional shape, respectively.
  • the side-by-side bi-component filament 110 includes a side-by-side full elliptical cross-sectional shape and a side-by-side hollow elliptical cross-sectional shape, respectively.
  • 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 side together as a whole comprise a side-by-side full circle cross sectional shape, a side-by-side hollow circular cross-sectional shape.
  • the filament 110 may include a third or fourth component, also in a side-by-side relation and the term bi-component may be understood to include at least two components intimately bonded together.
  • the twisted and heat-set BCF yarn 100 may be obtained by a single-step continuous process.
  • processes may generally include steps of extruding, spinning, quenching, spin finish application, drawing, texturizing, cooling, intermingling and winding at the predetermined parameters. These steps, sub-steps or process elements are all generally performed without intermediate winding to a bobbin.
  • the yarn or filament may be buffered or taken- up temporarily but that the process is otherwise continuous.
  • the output of the single-step continuous process will be referred to as BCF yarn, for the purpose of distinguishing it from the twisted and heat set product of the subsequent process steps.
  • the BCF yarn is at least bulked by the further described texturizing process.
  • the BCF yams according to the invention are preferably one, two, three, or four ply where two, three, or four ply yams are twisted or cabled.
  • the term ‘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 extmder El and the second polymer component 114 via a second extmder E2.
  • the first polymer component 112 and the second polymer component 114 are extruded under predetermined conditions, such as gradual temperature and pressure to obtain a plurality of side-by-side bicomponent filaments 110. These may be grouped together to obtain a continuous side-by-side bi-component filament yam.
  • the first polymer component 112 and the second polymer component 114 may be extruded by conventional means at a gradual temperature having a range of 240°C to 305°C through a plurality of temperature zones (tl . . .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 is performed. Further, at 330, the continuous side-by-side bi-component filament 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. Imps 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 may also be otherwise conventional.
  • the spin finish application yarn is sequentially drawn under predetermined conditions, such as drawing speed and drawing temperature.
  • the drawing speed may be in a range of 760mpm to 3500mpm and even up to 4000mpm or 5000mpm, and the drawing temperature range may be in a range of 75 °C to 200°C.
  • the drawn yarn is texturized at a texturizing temperature range of 130°C to 200°C and a texturizing vacuum pressure range of -50 mbars to -150 mbars.
  • Various conventional texturizing processes may be employed.
  • the continuous side- by-side bi-continuous filament yam is cooled at a cooling drum speed having a range of 10 mpm to 60 mpm and a cooling drum vacuum having a range of -20mbars to -80mbars.
  • the cooled continuous side-by-side bi-continuous filament may further be optionally intermingled at 380 and wound at 390.
  • the yam may be referred to as BCF yarn.
  • At least one of the first and second polymer components 112, 114 is provided with a dye, either before or after being extruded.
  • the first and/or second polymer components 112, 114 may be solution-dyed, either using pigments or solvent dyes or a combination thereof.
  • the at least one of the first and second polymer components is 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 they are extruded.
  • the BCF yarn is cabled and/or twisted at step 210.
  • This is understood to be a separate step i.e. it does not take place in line and at the same speed as the single-step process and is performed from one or more bobbins of the BCF yarn.
  • individual filaments may be twisted or plied together or that groups of filaments or bundles of yarns may be cabled by a combination of individual twists and collective rotations. Reference to twisting is thus intended to encompass all alternatives of such twisting, plying and cabling operations.
  • the BCF yarn is imparted with permanent 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 is 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 and/or twisting of the continuous side-by-side bi-component filament yarn may be done in a range of 40 TPM to 350 TPM; preferably 100 TPM-300 TPM; more preferably 200 TPM-250 TPM, for example about 230 TPM, to obtain the continuous side-by-side bi-component filament yarn having such twists.
  • Cabling or twisting parameters with respect the combination of types of the first and second polymer components 112, 114 are shown in Table 1.
  • twist direction refers to a yarn spun in clockwise direction and is normally used to create left-handed twill.
  • spindle rpm refers to the speed of the spindle where the twisting takes place. Subsequent to cabling and/or twisting, the yarn may again be wound to a bobbin or the like for subsequent processing in the next step of the process.
  • the twisted BCF yam is heat set.
  • Heat treating of the fibers, filaments or yam 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 yam as it continuously travels through a heat setting device. It should be noted that the heat set is performed while the filaments or yam are in relaxed state. The temperature of such fluid must be such that the yam does not melt.
  • This step of heat setting utilizes such fluid stream capable of transferring heat to the twisted BCF yarn as it continuously travels through the heat setting device, at a temperature of 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 BCF yam 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 1* minutes; for example, about 1 minute.
  • the twisted BCF yam is heated to a temperature sufficiently above the glass transition temperature of the respective materials for heat setting to occur.
  • heat setting above the glass transition temperature relieves the stress in the filaments resulting from the drawing and twisting. Bonds created as linkages and entanglements between the molecular chains that have been frozen-in during processing can be overcome by the supply of heat, giving rise to greater freedom for the bonds to revert to states of lower energy. Subsequent cooling, will result in a state of lower stress and the yam will be heat-set in its new configuration and will not draw back or untwist once released.
  • Table 2 illustrates cabling or heat setting parameters used on the Power-Heat-Set type machine (operating with superheated steam at atmospheric pressure) with respect to the combination of types of the first and second polymer components 112, 114.
  • twist direction as “S” represents a yarn is twisted in clockwise and is normally used to create left-handed twill.
  • the twist direction may also be “Z”, which represents that a yarn is twisted in counter-clockwise and is normally used to create right-handed twill.
  • “Over feed Speed” represents the speed in m/min at which the overfeed rollers in the heat set machine run. This is normally 10-30% more than the delivery speed, to keep the yarn slack before entering the actual heat set process, ensuring that heat setting takes place in the relaxed condition of the yarn.
  • “Delivery Speed” represents the feed speed in m/min 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 frieze) 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 in m/min of the yam outlet from the heat setting tunnel.
  • “Accumulator jump speed” represents the higher optional speed of the yam 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 BCF yarns stabilizes the twist and causes the BCF yarn 100 to lock in the twists and gain volume in the BCF yarn 100. This volume growth may be described as "bulk development”. Heat setting also retains the twist during use and there is not such a loss of resilience and of overall appearance due to matting.
  • the unique yam 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 twisted and heat-set BCF yarn is produced having the number of the side-by-side bi-component filaments in the range of 25 filaments to 1000 filaments.
  • the twisted and heat-set BCF yarn 100 exhibits a denier per filament (DPF) ratio in the range of 0.5 DPF to 50 DPF, and a linear density in a range of 600 denier to 6000 denier.
  • the denier value is obtained for the BCF yarn after the one-step process and before the heat set. The skilled person understands that this value may change upon heat setting the BCF yam 100.
  • the yam may also be subjected to a frieze process prior to heat setting.
  • this involves introducing the twisted BCF yam into a stuffing box subsequent to it being removed from the bobbin and prior to introduction into the heat setting machine. This bunching up of the yam creates crinkles in the yarn, which is then set in place during the heat set process. Heat setting is thus a necessary step to produce such frieze yarn.
  • the twisted and heat-set BCF yam 100 that is produced using the above process has an elongation to break in a range of 40% to 65%.
  • elongation to break is determined according to ASTM D 2256 (2015) using a gauge length of 500 mm, a test speed of 500 mm/min, a pretension of 0.5 cN/tex and break identified by a 90% drop in peak force.
  • carpet produced with twisted and heat-set BCF yam 100 comprising the 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 commercial carpet performance and found to have a Hexapod rating after 12000 cycles of more than 2.
  • Such Hexapod rating of more than 2 after 12000 cycles is obtained due to the unique combination of the first polymer component 112 forming the first side 110a in at least 25 and up to 75 volume percent, and the second polymer component 114 forming the second side 110a in at most 75 and down to 25 volume percent of the filament in the BCF yam, along with the heat setting of such yarn.
  • Table 3 presented below, illustrates various combinations of the first and second polymer components 112, 114 and resulting properties including “elongation to break” and “Hexapod rating” as obtained in the BCF heat set yarns 100 and carpets made from such yarns, in comparison to other conventionally available yarns.
  • the parameters of the carpets are chosen to be as close as possible to each other in order to provide a fair comparison between different yarns.
  • the filaments are circular cross- section.
  • the table clearly shows that the items made from twisted and heat-set BCF yarns exhibit higher Hexapod rating compared to the items that were made from mono-component heat-set yarns or bi-component BCF yarns that were not heat set.
  • the Hexapod rating as referenced throughout the present specification is obtained using the D 5252 - 98a (2003) standard for the operation of the Hexapod tumble drum tester of 3.8 Kg weight. The test was performed using a standard, upright type vacuum cleaner as supplied with the Hexapod drum tester. As can be seen from the results, the Hexapod rating for carpets made with the bi-component filament yarns of the invention is considerably higher than that for either 100 % PET or 100% PBT. Furthermore, the Hexapod rating for carpets made with the bi-component filament yarns without heat set is also far lower than that of the invention. Also, in the case of cold drawing the cabled yarn and subsequent relaxation in warm water at 80 C, no improvement is apparent in the Hexapod rating.
  • the floor covering material 400 may include a base backing 410, and a plurality of twisted and heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yams 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 to avoid repetition of the subject matter.
  • the floor covering material 400 may include, but is not limited to, carpets, rugs, mats and so forth.
  • the twisted and heat-set BCF yams 100 are tufted on the base backing 410 to form the floor covering material 400.
  • the twisted and heat-set 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 twisted and heat-set 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 twisted and heat-set 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 yams 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)

Abstract

L'invention concerne un fil à filaments à deux composants côte à côte continus gonflants (BCF) torsadé et thermofixé comprenant une pluralité de filaments à deux composants côte à côte, comprenant chacun des premier et deuxième composants polymères. Le premier composant polymère forme un premier côté des filaments à deux composants côte à côte, et comprend du polybutylène téréphtalate (PBT) avec une proportion d'au moins 25 % et jusqu'à 75 % en volume du filament dans le fil BCF. En outre, le deuxième composant polymère forme un deuxième côté des filaments à deux composants côte à côte, et comprend un composé parmi le polyéthylène téréphtalate (PET) et l'acide polylactique (PLA) avec une proportion d'au plus 75 % et descendant jusqu'à 25 % en volume du filament dans le fil BCF. Le fil BCF torsadé et thermofixé est obtenu par un procédé continu en une seule étape suivi par des étapes de torsion et/ou de câblage et de thermofixage. Le fil BCF torsadé et thermofixé de l'invention présente un allongement à la rupture dans une plage de 40 % à 65 %, et le revêtement de sol fabriqué à partir du fil présente un score d'essai à l'hexapode après 12000 cycles supérieur à 2.
EP21778216.8A 2020-08-21 2021-08-20 Fil bcf torsadé et thermofixé comprenant un filament à deux composants côte à côte, procédé de formation d'un tel fil et matériau de revêtement de sol comprenant un tel fil Pending EP4200467A1 (fr)

Applications Claiming Priority (2)

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IN202021036119 2020-08-21
PCT/IB2021/057668 WO2022038570A1 (fr) 2020-08-21 2021-08-20 Fil bcf torsadé et thermofixé comprenant un filament à deux composants côte à côte, procédé de formation d'un tel fil et matériau de revêtement de sol comprenant un tel fil

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EP4200467A1 true EP4200467A1 (fr) 2023-06-28

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EP20202322.2A Withdrawn EP3957782A1 (fr) 2020-08-21 2020-10-16 Fil de filament bicomposant continu côte à côte en vrac, procédé de fabrication et matériel de revêtement de sol fabriqué à partir de celui-ci
EP21778216.8A Pending EP4200467A1 (fr) 2020-08-21 2021-08-20 Fil bcf torsadé et thermofixé comprenant un filament à deux composants côte à côte, procédé de formation d'un tel fil et matériau de revêtement de sol comprenant un tel fil

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EP20202322.2A Withdrawn EP3957782A1 (fr) 2020-08-21 2020-10-16 Fil de filament bicomposant continu côte à côte en vrac, procédé de fabrication et matériel de revêtement de sol fabriqué à partir de celui-ci

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US (1) US20230304219A1 (fr)
EP (2) EP3957782A1 (fr)
AU (1) AU2021327176A1 (fr)
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WO (1) WO2022038570A1 (fr)

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WO2023195964A2 (fr) * 2022-04-05 2023-10-12 Küçükçalik Teksti̇l Sanayi̇i̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇ Procédé de production de fil pes bi-composant recyclé auto-coloré compatible avec des conditions météorologiques extrêmes

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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 (fr) * 1997-12-05 2002-10-02 Basf Corporation Fil d'autofixage
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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CA3187836A1 (fr) 2022-02-24
WO2022038570A1 (fr) 2022-02-24
AU2021327176A1 (en) 2023-03-02
EP3957782A1 (fr) 2022-02-23
US20230304219A1 (en) 2023-09-28

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