JP2015534611A - Process for dyeing and processing BCF yarn - Google Patents

Abstract

Disclosed is a process for applying dyes, stain blockers, and antifouling compositions to BCF yarns prior to weaving, knitting, or tufting during a cable or air twist process or heat setting process. Further disclosed is a process for applying the dye, stain blocker, and antifouling composition to the BCF yarn prior to heat setting. This process abandons the need to dye carpet and other textile products made from BCF yarn using current methods or otherwise process. Also disclosed are carpets made from the system, BCF yarn, and BCF yarn treated by the disclosed process. [Selection figure] None

Description

  The present invention relates to a processing process for bulky continuous filament (BCF) carpets and related woven fabrics, in particular, prior to weaving, knitting, or tufting, a twisting process (cable or air), Or relates to a process for applying the dye and topical treatment composition to the BCF yarn during the heat setting process. This process abandons the need to dye carpet and other textile products made from BCF yarn using current methods, or otherwise process. The need for anti-stain treatment is also avoided by including fibers that are inherently stain resistant, such as cationic dyeable polyamides or polyesters. Thus, low inventory costs are achieved, and costly and environmentally unfavorable dyeing and low pH chemical treatment processes are excluded. Also provided herein are systems used to apply dyes and performance enhancing formulations to BCF yarns, and antifouling yarns, and carpets with improved antifouling properties made from BCF yarns of the disclosed process. To be disclosed.

  Carpets and other fabrics made from synthetic yarn are currently colored using two established processes. The first process involves processing colorless white yarn into a carpet and dyeing the carpet in a dye bath. This process is referred to as the “acid dyeing process”. The acidic dyeing process may be either a batch or continuous dyeing process. Each dyeing process requires a large amount of water, steam to fix the dye, and heat to dry the carpet. In addition, the recovery and disposal of excess dye and acidified performance enhancing solutions increases manufacturing costs and places additional burdens on waste management and water treatment facilities. In the second process, a colored pigment is added to the polymer during the melt spinning process. This process is referred to as the “solution dyeing process”. While the solution dyeing process is a low cost process, it imposes unnecessary inventory allocation strategies for fiber producers and carpet factories compared to the acid dyeing process. To meet consumer demand, fiber producers and carpet factories may then need to maintain an expensive inventory of colored yarns produced by solution dyeing processes. Fluctuating production demands and large inventory costs can affect inventory flexibility and can result in unnecessary limiting the color utilization of solution-dyed carpets.

  Topical chemicals are used to treat carpets and other fabrics to improve stain resistance and / or soil resistance. For nylon carpets, both stain blockers with fluorochemicals (eg, acid dye blockers) and antifouling agents are conventionally used. For polyester carpets such as polyethylene terephthalate (2GT) and polytrimethylene terephthalate (3GT) carpets and polypropylene carpets, antifouling chemicals are locally applied to the carpet that has been tufted as part of the carpet finishing process. Can be applied. Polyester and polypropylene carpets typically do not require a stain blocker treatment because of their inherent stain resistance to acid dyes and stains due to their lack of amine end groups that function as acid dye seats.

  Topical application in a carpet factory may be in the form of exhaust application and spray application. Exhaust application (i.e., a soft nipping process with high wet content (300-400 wt%)) improves effectiveness over spray application by spray with 10-20 wt% wet content of antifouling agent Is known to provide. Exhaust applications typically use more water and energy than spray applications use to dry and cure the carpet. Spray sprayed fluorochemical products are designed to use less water and energy than exhaust applications, but do not provide satisfactory antifouling properties.

  Various processes, some on a large scale and some on a small scale, are used in the carpet industry for carpet dyeing and finishing, but the majority of currently produced carpets are dyed over a continuous dyeing range. And finished. This is mainly done in one of two ways. That is, in one case, a two-step process is used, where the carpet is first steamed and dyed, steamed, rinsed, excess water is extracted, and then a stain blocker (SB) is used. Once applied, the carpet is again steamed and cleaned, then antifouling fluorochemical (FC) is applied with a foam or liquid spray, and the carpet is finally dried. (See, eg, US Pat. Nos. 5,853,814, 5,948,480, and WO 2000/000691). In the second somewhat improved case, called the co-application process, the carpet is also steamed and dyed, steamed again, rinsed and extracted, then the mixture of SB and FC has a high wet content Applied together in quantities, after which the carpet and chemicals are again exposed to steam to set the process followed by drying. (See, eg, US Pat. Nos. 6,197,378 and 5,520,962). In both cases, low pH solutions, extra water, and energy are required for SB and FC to penetrate the carpet and achieve a uniform coating. That is, a typical conventional process is as follows. BCF yarn-> twist-> heat setting-> tufting-> carpet-> dyeing-> stain block / antifouling.

  For environmental and cost reasons, there is a need to reduce the overall usage of dye liquors and stain blocker formulations. There is also a need to reduce the amount of water and low pH chemicals used to apply dye and anti-stain formulations. Accordingly, there is a need for a process that provides such beneficial compositions with less water, less pH chemicals, and less energy while providing less inventory requirements.

  While there is a need to develop a process that eliminates current carpet processing systems for applying anti-stain and anti-fouling compositions, current processes exist for good reasons. First, the appearance of carpets has historically depended on the ability to dye wool or nylon or even polyester tufted carpets to the desired shade, thus preventing stains or stains that can interfere with the uniform dyeing process. It is not allowed to pre-treat the carpet with a composition such as a fouling chemical. Furthermore, the dyeing process may tend to remove locally treated chemicals and make them ineffective.

  Second, as described above, treating yarn or fabric with a performance enhancing formulation for stain and soil resistance typically involves fixing with steam, and low pH is also This may be required especially for acid dyed fabrics. Thus, the sequence described above (in this case the carpet is formed and then steamed and dyed, steamed again, rinsed and extracted, then SB and FC applied, Processing the carpet, again with steaming and / or rinsing, was deemed most practical.

  Carpets have also been made with dyed or colored yarn for extended periods of time, but this production can be further dyed and stained and / or soiled by simultaneous use of steam and rinse water, as in the process described above. It is processed in a number of possible ways, including the option of applying a resistive composition.

  The invention disclosed herein does not require dyeing and subsequent application of stain and soil resistance chemicals, and thus costs associated with maintaining large stocks, as well as such large fabric applications. A process for producing woven fabrics, particularly tufted articles, that avoids the waste generated by steam fixing and rinsing associated with the process is provided. As disclosed herein, the process involves applying dye and topical chemicals to undyed yarn immediately after one or more such yarns are twisted or cabled together. The chemical is then heat set on the twisted yarn under dry conditions, and the twisted yarn is subsequently woven or tufted into a finished fabric or carpet. Also disclosed is a novel system that allows for the efficient application of dye liquor and topical chemicals to the yarn following twisting and prior to winding and heat setting.

  Specifically, the disclosed process uses a dye liquor or topical chemical composition applicator disposed within a mechanical twisting process downstream of the twist take-up reel and upstream of the winder. That is, the disclosed process moves the subsequent large and wasteful stain blocker application step forward, during or after yarn twisting. Therefore, the carpet manufacturing process will be BCF yarn → twisting → dyeing → arbitrary SB / FC → heat setting (optionally drying heat setting) → tufting → carpet. Surprisingly, the disclosed process is as effective or even more effective as prior art processes in terms of fabric soil resistance. In addition, a neutral pH staining solution (4-7.5 pH) can be used in place of the prior art low pH staining solution (pH 1-3). This reduces the environmental impact of prior art processes. Furthermore, the need for stain blocker application is not always necessary as it includes cationic dyeable polyamides or polyesters. In other words, stain blocker application can be consciously excluded without sacrificing stain resistance characteristics.

As noted above, the disclosed process of the present invention has the effect that treating the carpet yarn prior to heat setting and tufting, particularly during dyeing, affects the quality of the finished carpet. Is known and therefore counterintuitive. In addition, the process of the present invention also ensures that the soil resistance composition is applied uniformly to the twisted bundle at normal line speeds [30-80 yards / min (ypm)], without substantial waste. This is counterintuitive because it tends to be difficult. Furthermore, the disclosed process is counterintuitive because prior art twisting devices have not previously been adapted to the application of topical chemicals to the twisted yarn prior to winding. However, as will be shown below, nylon and polyester carpets produced using the treated BCF yarn exhibit one or more of the following desirable characteristics.
• At least equivalent staining characteristics to current technology processes.
-At least equivalent stain and dirt prevention performance to current technology processes.
• Desirable aesthetic qualities that cannot be generated by current technology processes.

  In one aspect, a process for treating BCF twist yarns with one or more dye compositions is disclosed. The process includes: (a) providing a BCF twist yarn; (b) winding the BCF yarn on a take-up reel; (c) while the BCF yarn is moving and pulling the BCF yarn to the draw. Contacting the BCF yarn with the dye composition prior to contacting the take-up reel and winding it thereon. The dye composition can comprise an acid dye composition or a disperse dye composition.

  In another aspect, a process for treating BCF twist yarns with one or more dye compositions is disclosed. The process includes: (a) providing a BCF twisted yarn; (b) contacting the BCF yarn with the dye composition while the BCF yarn is moving; and (c) applying the BCF yarn to the dye. Heat-setting the BCF yarn after contact with the composition. The dye composition can comprise an acid dye composition or a disperse dye composition.

  In a further aspect, a process for treating a BCF twist yarn with one or more dye compositions and performance enhancing compositions is disclosed. The process includes (a) providing a BCF twist yarn, (b) winding the BCF yarn on a take-up reel, (c) contacting the BCF yarn with the dye composition, (d) Optionally, contacting the BCF yarn with a first performance enhancing composition comprising a stain blocking composition, and (e) contacting the BCF yarn on the take-up reel and winding it there Contacting the BCF yarn with a second performance enhancing composition comprising an antifouling composition, wherein the BCF yarn comprises the dye, the optional first performance enhancing composition, and the second Moving while in contact with the two performance enhancing compositions. The dye composition can comprise an acid dye composition or a disperse dye composition. The stain blocking composition can comprise a species having an acidic moiety that binds to the amine end groups of the polymer and protects them from being stained by the acidic dye stain. A general class of chemicals suitable for the process of the present invention may include any chemical that blocks positively charged dye seats. Antifouling compositions have large specific surface energy chemicals or other materials, such as fluorochemicals that impart large specific surface energy properties, such as large contact angles for water and oil, or even similar properties, It can consist of non-fluorochemical particulate material. The antifouling composition can further comprise an antifouling component.

  In yet another aspect, a process for treating BCF twist yarns with one or more dye compositions and performance enhancing compositions is disclosed. The process includes (a) providing a BCF twisted yarn, (b) contacting the BCF yarn with the dye composition, and (c) optionally including a composition that blocks the stain on the BCF yarn. Contacting with the first performance enhancing composition; and (d) contacting the BCF yarn with a second performance enhancing composition comprising an antifouling composition, wherein the BCF yarn is the dye, Moving while in contact with the optional first performance-enhancing composition and the second performance-enhancing composition; and (e) the BCF yarn is the dye composition, the optional Heat-setting the BCF yarn after contacting the first performance enhancing composition and the second performance enhancing composition. Dye compositions and performance enhancing compositions are disclosed above.

  In a further aspect, an untufted BCF twist yarn comprising a dye component is disclosed and the dye component is present on the BCF twist yarn before tufting the BCF yarn. The dye component is selected from acidic and disperse dye materials. The yarn may include polyamide fibers and / or have a polymer component selected from polyester. Yarn can be tufted into a carpet or fabric.

  In yet another aspect, an untufted BCF twisted yarn comprising a dye component, an antifouling component, and an optional antifouling component is disclosed, wherein the dyeing component, antifouling component, and optional antifouling component are: It exists on the BCF twisted yarn before tufting the BCF yarn. The dye component is selected from acidic and disperse dye materials. The antifouling component and the optional antifouling component can be selected from the compositions disclosed above. The stain blocking component is optionally present in an amount of about 0.5 to about 40 ppm elemental sulfur content, based on the weight of the fiber. The antifouling component is present in an amount of elemental fluorine content of about 100 ppm to about 1000 ppm, based on the fiber weight. The yarn may include polyamide fibers and / or have a polymer component selected from polyester. Yarn can be tufted into a carpet or fabric.

  A still further aspect includes providing an untufted BCF twist yarn comprising a dye component, an optional stain blocker component, and an antifouling component, tufting the BCF yarn, and weaving into a carpet. A process for manufacturing the carpet is disclosed. Dye and performance enhancing components are present on the BCF yarn prior to tufting and weaving, so they are dyed or processed with acidified stain blocker and antifouling compositions according to the state of the art process This eliminates the need to process the finished carpet.

  In yet another aspect, a system for applying a dye composition to a BCF twisted fiber is disclosed. The system includes: (a) a first yarn take-up device that sends a single yarn member made from at least two individual yarn members; (b) downstream of the yarn take-up device that applies the dye composition to the single yarn member. And (c) a second yarn take-up device that receives the dyed single yarn member. The dyeing composition can consist of an acid dye or a disperse dye material.

  In still yet another aspect, a system for applying a dye composition and at least one performance enhancing composition to a BCF twisted fiber is disclosed. The system includes: (a) a first yarn take-up device that sends a single yarn member made from at least two individual yarn members; (b) downstream of the yarn take-up device that applies the dye composition to the single yarn member. A dye composition applicator disposed in (c) an optional anti-stain component applicator disposed downstream of the dye composition applicator for applying the anti-stain composition to the single yarn member; and (d) an anti-stain composition. An antifouling applicator disposed downstream of the dye composition applicator for application to the single yarn member, and (d) a second yarn take-up device that receives the dyed single yarn member. The dyeing composition can consist of an acid dye or a disperse dye material. The anti-stain composition can consist of a species having an acidic moiety that binds to the amine end groups of the polymer and protects them from staining by an acidic dye stain. Antifouling compositions have large specific surface energy chemicals or other materials, such as fluorochemicals that impart large specific surface energy properties, such as large contact angles for water and oil, or even similar properties, It can consist of non-fluorochemical particulate material. The antifouling composition can further comprise an antifouling component.

Definitions Those skilled in the art are largely familiar, but for clarity the following definitions are given.

  OWF (On weight of fiber): The amount of chemical applied as a weight percent of the fiber.

  WPU (wet content): The amount of water and solvent applied to the carpet prior to drying the carpet, expressed as weight percent of the fiber.

  Contacting the BCF yarn with the dye composition while the yarn is moving and before contacting the take-up reel or spooler to wind the yarn there to create a yarn package or cake. A process for processing a BCF twist yarn is disclosed. The process can also include contacting the BCF yarn with one or more performance enhancing compositions including a stain blocker and an antifouling composition. The dye composition comprises a dye component and is adapted to be applied continuously to the BCF twist yarn at 10-100 ypm, preferably 30-80 ypm. The stain blocker composition comprises an anti-stain component and is adapted to be continuously applied to the BCF twist yarn with a wet content of 10-50%, preferably 15-30%. The antifouling composition comprises an antifouling component and comprises about 10 wt% to about 30 wt%, about 20 wt% to about 30 wt%, and about 10 wt% to about 20 wt%, It is adapted to be applied continuously to BCF twist yarns with a wet content between about 50% by weight. The BCF twist yarn may optionally be heat set after contacting the yarn with the dye composition and one or more performance enhancing compositions. The heat setting temperature can range from about 125 ° C to about 200 ° C, including from about 160 ° C to about 195 ° C. The time to remain in the heat-set state can range from about 0.5 to about 4 minutes, including from about 0.5 to about 3 minutes and from about 0.5 to about 1 minute.

  The dye component for use in the disclosed dye composition is an acid dye or a disperse dye. Acid dye components are known to those skilled in the art and are water-soluble ionic species that contain one or more organic chromophore moieties. Acid dyes are typically provided in powder form, using different acid dyes, the usage rate of each selected dye component, the usage rate of one or more acidic adjuvants used, and the dyeing area. A well-defined color selection can be reached depending on process conditions such as substrate residence time. Examples of suitable acid dye compositions include Orange 3G, Red 2B, and Blue 4R. The disperse dye component is likewise a water-insoluble nonionic species that is known to those skilled in the art and contains one or more organic chromophore moieties. Disperse dyes are provided either in paste form combined with a dispersant or in powder form. Processes such as utilization of each selected disperse dye component, the specific dispersant (s) or dispersant (s) used, and the residence time of the substrate in the dyed area, using different disperse dyes in combination Depending on the conditions, a well-defined color selection can be reached. Examples of suitable disperse dye compositions include Disperse Red 60, Disperse Yellow 86, and Disperse Violet 33.

  Anti-stain components for use in the disclosed stain blocker compositions have components with acidic moieties associated with the polymeric amine end groups that protect them from staining with acidic dye stains. A general class of chemicals suitable for the process of the present invention may include any chemical that blocks positively charged dye seats. Stain blockers are syntans, sulfonated novolaks, sulfonated aromatic aldehyde condensation products (SACs) and / or formaldehyde reaction products, phenols, substituted phenols, thiophenols, sulfones, substituted sulfones, olefin polymers or copolymers , Branched olefins, cyclic olefins, sulfonated olefins, acrylates, methacrylates, maleic anhydride, and organic sulfonic acids are available. They are usually made by reacting formaldehyde, phenol, polymethacrylic acid, maleic anhydride, and sulfonic acid, depending on the particular chemical. In addition, stain blockers are typically water soluble and generally penetrate the fiber, while antifouling agents, usually fluorochemicals, are non-water soluble dispersions that coat the surface of the fiber. is there.

  Examples of stain blockers include, but are not limited to, CEASESTAIN and STAINAWAY (from American Emulsions Company, Inc., Dalton, Ga.), MESITOL (from Bayer Corporation, Rock Hill, NC), C ERIIONAL (from Corporation, Greensboro, NC), INTRATEX (from Crompton & Knowles Colors, Inc., Charlotte, NC), STAINKLLER (from Dyetech, Inc., Dalton, Ga.) LANOSTAIN (from Chemical Corporation, Dalton, Ga.) And phenol formaldehyde polymers or copolymers such as SR-300, SR-400, and SR-500 (from EI du Pont de Nemours and Company, Wilmington, Del.) (From 3M Company, St. Paul Minn. ) SCOTCHGARD FX series carpet protectors and other polymers of methacrylic acid, Rockland React-Rite, Inc. , Sulfonated fatty acids (from Rockmart, Ga), and stain resistant chemicals from ArrowStar LLC, Dalton and Tri-Tex, Canada.

  Antifouling ingredients for use in the disclosed antifouling compositions, such as large contact angles for water and oil (eg, water and oil "ball" on the surface treated thereby), Gives large specific surface energy characteristics. The antifouling component may comprise a fluorochemical dispersion, which is a fluorochemical allophanate, fluorochemical polyacrylate, fluorochemical urethane, fluorochemical carbodiimide, fluorochemical guanidine, non-telomer fluorochemical, and C2-C8 chemical Can be either primarily cationic or anionic, including those selected from the group consisting of fluorochemicals incorporating Alternatively, the fluorochemical can have one or more monomer repeat units that hear no more than 8 fluorinated carbons, including no more than 6 fluorinated carbons. Exemplary fluorochemical antifouling ingredients include DuPont TLF 10816 and 10894, Daikin TG 2511, and DuPont Capstone® RCP. Non-fluorinated antifouling components include silicones, silsesquioxanes and silane modified particles, organosilane modified particles and alkylated particles, anionic non-fluorinated surfactants, including sulfonates, sulfates, phosphates, and carboxylates, and An anionic hydrotrope non-fluorinated surfactant may be included. (See US Pat. No. 6,824,854, which is incorporated herein by reference).

  The dye composition is adapted to contact the BCF twist yarn while it is moving and before it contacts the take-up reel or spool. Further, the dye composition can be at a neutral pH (eg, 4-9, including 5.5-7.5), as the yarn can optionally be heat set after application of the composition. This process abolishes the need for vigorous low pH chemicals, and deionized water is suitable for use in the disclosed process.

  The stain blocker composition is adapted to contact the BCF twist yarn while it is moving and before it contacts the take-up reel or spool. Further, the stain blocker composition can be at a neutral pH (e.g., 6-8) since the yarn can optionally be heat set after application of the composition. This process abandons the need for intense low pH chemicals.

  The antifouling composition is adapted to contact the BCF twist yarn while it is moving and before it contacts the take-up reel or spool. Furthermore, the antifouling composition can be at a neutral pH (eg, 6-8) because the yarn can optionally be heat set after application of the composition. This process abandons the need for intense low pH chemicals.

  Contacting can be performed by any suitable device that applies wet material to a dry substrate, including but not limited to applicator pads, pinching rollers, wet wicks, dip tanks, sprayers, and sprayers.

  Another option is to transfer the dye liquor or other treatment agent to the yarn using one or more rotating rolls covered by a core. Here, the yarn may contact one roll or pass between two or more rotating rolls. The core on the surface of the roll may be supplied using a treatment with one or more radially oriented capillaries extending from the inside to the outside surface of the cylindrical roll. The wick may be located on a portion of the surface or may be uniformly distributed throughout the surface. If processing to a local portion of the yarn length is desired, a roll with a portion of the core is selected. If treatment along the entire length of the yarn is desired, a roll with cores uniformly distributed throughout the surface is selected.

  The amount of dye liquor or other treatment agent in contact with the yarn is metered and controlled by the use of a pump. This allows for the precise application of the desired amount of dye or chemical treatment. The amount may vary over the length of the yarn.

  Furthermore, a plurality of rolls may be used in succession. For example, one roll applies a first color to one side of a moving yarn and another roll applies a second color to the other side of the yarn to create a unique two-color yarn Can do. In addition, two sets of pinching rolls may be used. The first set may apply a first color to the yarn and the second set may apply a second color or performance enhancing chemical. Any combination of the above options can be used to produce yarns having multiple colors, color depths, and various performance chemicals.

  The wet content of the antifouling composition comprises from about 5% to about 50%, including from about 10% to about 30%, from about 20% to about 30%, and from about 10% to about 20%. Between weight percent. The resulting BCF twisted yarn contains about 100 to about 500 ppm elemental fluorine, about 200 to about 400 ppm, and about 100 ppm to about 300 ppm elemental fluorine, based on the weight of the fiber, when a fluorine-based antifouling component is used. Including from about 100 ppm to about 1000 ppm of elemental fluorine.

  The wet content of the stain blocker composition is about 500 ppm to about 3%, including about 1000 ppm to about 3%, about 0.5% to about 2%, and about 0.5% to about 1%, based on the weight of the fiber. Present at about 4%. Common stain blockers use sulfonated moieties as part of the chemical, resulting in the presence of sulfur on the treated fiber. The sulfur content can range from about 50 ppm with a 5% stain blocker to about 1 ppm with a 0.1% stain blocker, by weight of the fiber. Thus, based on the above stain blocker concentration, the sulfur content in the weight of the fiber ranges from about 0.5 ppm to about 40 ppm, including from about 1 ppm to about 30 ppm, from about 5 ppm to about 20 ppm, and from about 5 ppm to about 10 ppm. It extends to. The sulfur content can be measured by x-ray diffraction or other methods.

  The performance enhancing composition can further comprise one or more components selected from the group consisting of flavoring agents, antibacterial agents, antifungal agents, fragrances, bleach resistance agents, softeners, and UV stabilizers.

  BCF twist yarns are made from polyamide fibers such as those made from nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, copolymers thereof, and mixtures thereof. Can do. Furthermore, the BCF twist yarn can also have additional polymer components such as polyester. Additional polymer components can be incorporated with the polyamide (by melt blending or copolymerization) prior to making the polyamide fiber (eg, polyamide / polyester fiber) or with the polyamide fiber to make a BCF twisted yarn. It may be a single fiber that is twisted. However, cationic dyeable nylon, polyester, and acrylic fibers may also be used either together or exclusively.

  When only cationic dyeable nylon and / or polyester is present in the BCF yarn of the present invention, the use of a stain blocker is unnecessary. In other words, stain blockers are excluded from the process and further streamlined, reducing costs and exposure of these chemicals to the environment. Suitable cationic dyeable nylons are any of the above mentioned nylon compositions such as nylon 6 or nylon 66 modified with sulfoisophthalic acid, sodium salt as a comonomer, such as 5-sulfoisophthalic acid. There may be.

  As mentioned above, BCF yarns can be made using polyamide and / or polyester polymer components. Compared to known exhaustion processes, despite the fact that a small amount of antifouling composition is applied, a high antifouling component (eg fluorine) content is achieved on the surface of the yarn, An unexpected advantage of the disclosed process has been found. Further, the antifouling composition applied in the disclosed inventive process can be either a fluorochemical or non-fluorochemical system, or a mixture of a fluorochemical or fluoropolymer material and a non-fluorinated soil resistant material. .

  The disclosed process may be used with yarns that are dyed prior to twisting and optionally treated with one or more performance enhancing compositions that do not require subsequent dyeing or performance enhancing chemical treatments. Good. Yarns can be made with acid dyed fibers as well as disperse dyed fibers. Yarns suitable for use in the process are inherent stains, whether by a base composition as in the case of polyester or by including strong acid functionality in the polymer composition of the yarn as in nylon. A resistor may further be included. The use of a dye applicator with the disclosed process eliminates the need for subsequent dyeing and increases inventory flexibility and color options without the need for dyeing and performance enhancing chemical applications implemented under current technology. And enables the production of colored carpets that are both stain resistant and soil resistant.

  BCF twisted yarns made using various aspects of the disclosed process can be tufted and manufactured into carpets or fabrics by themselves or mixed with untreated fibers and yarns.

  The disclosed process can also be advantageously applied in certain processes where decorative style benefits can be derived from differential dyeing and finishing after carpet formation. For example, the disclosed soil or stain resistant twist yarns of the present invention are optionally tufted into carpet between untreated yarns before dyeing, thereby creating an aesthetic alternative.

  Alternatively, the disclosed process can be modified to include dye application, optional anti-stain application, and / or anti-stain application after the BCF twist yarn is woven and before heat setting. For example, the BCF twist yarn is unwound from the center core or package, contacts the dye applicator, contacts any anti-stain applicator, contacts the anti-stain applicator, and then passes through a heat setting process to dye the yarn into the yarn twist. Immobilize, antifouling, and optional stains.

  Further disclosed is a system for applying a dye composition and one or more performance enhancing compositions to a BCF twist yarn. The system includes: (a) a first yarn take-up device that sends a single yarn member made from at least two individual yarn members; (b) downstream of the yarn take-up device that applies the dye composition to the single yarn member. (C) an optional anti-stain blocker applicator disposed downstream of the dye composition applicator that applies the anti-stain composition to the single yarn member; and (d) an anti-stain composition. An antifouling applicator disposed downstream of the dye composition applicator for application to the single yarn member, and (e) a second yarn take-up device for receiving the dyed single yarn member. The first yarn take-up device can be a take-up roll or reel that can twist at least two individual yarn members into a single yarn member. Alternatively, the first yarn take-up device can receive an air twisted BCF yarn. The individual thread members can be single filaments or fibers, or threads composed of multiple filaments or fibers. Each applicator can be any suitable device that applies wet materials to a dry substrate, including but not limited to applicator pads, pinching rollers, wet wicks, dip tanks, sprayers, and sprayers. The wet content of the composition includes from about 10 wt% to about 30 wt%, from about 20 wt% to about 30 wt%, and from about 10 wt% to about 20 wt%, from about 5 wt% to about 50 wt% Between. When a stain blocker is used, the resulting BCF twist yarn comprises from about 1000 ppm to about 3%, from about 0.5% to about 2%, and from about 0.5% to about 1%, based on the weight of the fiber From about 500 ppm to about 4%. The resulting BCF twisted yarn contains about 100 to about 500 ppm elemental fluorine, about 200 to about 400 ppm, and about 100 ppm to about 300 ppm elemental fluorine, based on the weight of the fiber, when a fluorine-based antifouling component is used. Including from about 100 ppm to about 1000 ppm of elemental fluorine. The second yarn take-up device can be a spooler.

  In the cable twisting process, creel and bucket yarns fed at a spindle speed of 7000 rpm pass through the antiballoon device and onto the take-up roll. From here, the twisted yarn is wound up on a spool.

  In one aspect of the disclosed process, creel yarn and bucket yarn, fed at a spindle speed of 7000 rpm, pass through the anti-balloon device and onto the take-up roll. A dye applicator that applies a dye component or other treating agent to the twisted yarn is located downstream of the take-up roll. From here, the twisted and dyed yarn is wound up on a bobbin winder.

  Another aspect of the disclosed process involves two or more treatments, such as both a dye applicator and an antifouling / antifouling applicator. In this embodiment, creel and bucket yarns fed at a spindle speed of 7000 rpm pass through the antiballoon device and are connected onto the take-up roll. A first treating agent, i.e. a dye applicator for applying the dye component to the twisted yarn, is arranged downstream of the take-up roll. An antifouling / antifouling applicator that applies the antifouling / antifouling component to the dyed twisted yarn is located downstream of the dye applicator. From here, the twisted yarn is wound up on a winder.

  In a suitable heat setting process, the cable BCF twisted yarn enters a temporary twisting unit, followed by a winder or pusher chamber, a prebulker, and finally a heat setting chamber to produce heat set yarn.

  In one aspect of the disclosed process, if the cable BCF yarn is dyed before being heat set, the cable BCF yarn is dyed (or other processing applicator) followed by a temporary twisting unit, a winder or It enters the indentation chamber, pre-bulker, and finally the heat setting chamber to produce dyed and heat set yarns.

  The disclosed process is counter-intuitive and surprisingly yields yarns that contain acceptable dyed and performance enhancing properties when manufactured into carpets or fabrics. It can be expected that rearranging the process as described above will disrupt the downstream carpet manufacturing process and result in poor quality carpet. Thus, the results reported below are surprising and unexpected.

Examples The following are examples of carpets made from BCF fibers treated according to various aspects of the process disclosed above, and untreated similar fibers. The choice of alternative dyeing and performance enhancing components, fibers, and textile products with different surface chemistries requires minor adjustments to the variables described herein.

Test method
Stain test with acid dyes Stain resistance with acid dyes was modified based on a method based on American Association of Textile Chemists and Colorists (AATCC) Method 175-2003, "Stain Resistance: Pile Floor Covering". Mixing cherry-flavored KOOL-AID® powder (powder drink mix containing Kraft / General Foods, White Plains, NY, especially FD & C Red No. 40) according to manufacturer's guidelines To prepare a 9% by weight staining solution. Carpet samples (4 x 6 inches) are placed on a flat non-absorbent surface. A 2 inch (5.1 cm) diameter plastic hollow cup is placed firmly on the carpet sample. 20 ml of KOOL-AID® stain is poured into the cup and this solution is completely absorbed into the carpet sample. The cup is removed and the stained carpet sample is allowed to stand for 24 hours. After incubation, the stained sample is rinsed thoroughly under cold tap water, excess water is removed by centrifugation and the sample is dried in air. Carpet samples were visually inspected and FD & C Red No. described in AATCC Method 175-2003. Rating for staining according to 40 Stain Scale. Stain resistance is measured using steps 1-10. A rating of 10 is given to stains that cannot be detected in the test.

(Comparative example)
Two 920 denier white acid dyeable nylon 66BCF made from an acid dyeable polymer were cable twisted on a Volkman at 7000 rpm to form a 6.25 tpi twine. The winding speed was about 50 ypm. The cable twist was subsequently heat set on Superba using saturated steam at 129 ° C. The residence time in the channel was about 36 seconds. The heat treated yarn was converted to a cut pile carpet of 35 oz per square yard, 1/8 gauge, 22/32 inch pile height and dyed medium beige on a continuous dyeing machine. The finished carpet was tested for repellency and acid stain resistance. It was rated as having 1 (failure) in the 24 hour stain test and having 0 in both oil and water repellency.

(Invention)
Using the process described above, two 997 denier white nylon 66BCFs made from a cationic dyeable polymer were cable twisted on a Volkman at 7000 rpm to form a 6.25 tpi twine. The winding speed was about 50 ypm. A dye applicator was inserted between the take-up roll and the spool. Using a 1/2 inch wide, 1.5 inch thick cotton core (Wet Wick by Perperell MA), metallic dye (Yellow 2BRLSM by Greenville Colorants 24 gram / liter, Red B by huntsman 0.860 Gram / liter, Huntsman's Blue 3GL 9.1 gram / liter, Star technologies' wetting agent DOSS 15 gram / liter, pH 7.1) was applied to the cable twist. The cable twist passed through the wet core at about 50 ypm. The cable twist was subsequently heat set on Suessen using 200 ° C. dry air. The residence time in the channel was about 60 seconds. The heat-set yarn was processed into a 35 oz / yd, 22/32 inch pile height with a 1/8 gauge tufting machine. Latex and secondary support were added to the tufted carpet to protect the tuft. The finished carpet had a light beige color (Minota L63.34, a3.26, b12.56). (AATCC) Method 175-2003 was used to test the repellency and stain resistance of the finished carpet. It had a rating of 10 for both 24 hour stain and WAQE, but 0 for both oil and water repellency.

(Invention)
Two 997 denier white nylon 66BCF made from a cationic dyeable polymer were cable twisted on a Volkman at 7000 rpm to form a 6.25 tpi twin yarn. The winding speed was about 50 ypm. The cable twist was heat set on Suessen using 200 ° C. dry air. Two color center stations arranged in series were inserted between the creel and the temporary twisting unit. A 1/2 inch wide, 1.5 inch thick cotton wick is used at each wick station to produce a metallic dye (5.31 g / l Huntsman Yellow 3RL, 1.14 g / l Red B, 1.53 g). / L Blue 3GL, 15 g / l wetting agent Doss, pH 8.5) was applied to the cable twist. The processing speed was about 350 ypm. The residence time in the heat setting channel was about 60 seconds. The heat-set yarn was processed into a cut pile carpet of 35 oz, 22/32 inch pile height with a 1/8 gauge tufting machine. The finished carpet had a light beige color (Minota L70.76, a2.78, b10.66) and was tested for repellency and stain resistance using (AATCC) Method 175-2003. It had a rating of 9 for both 24 hour stain and WAQE, but 1 for water repellency and 0 for oil repellency.

(Invention)
Using the process described above, two 997 denier white nylon 66BCFs made from a cationic dyeable polymer were cable twisted on a Volkman at 7000 rpm to form a 6.25 tpi twine. The winding speed was about 50 ypm. A dye applicator was inserted between the take-up roll and the spool. Using a 0.5 "inch wide, 1.5 inch thick cotton core (Wet Wick by Perperell MA), metallic dyes (5.31 g / l Yellow 3RL, 1.14 g / l Red B, 1.51 g / l of Blue 3GL, 15 g / l of wetting agent Doss, pH 8.5) was applied to the cable twist, which passed through the wet core at about 50 ypm. The core unit was inserted between the creel and the temporary twist unit, and fluoro-chemical (50% A-201 antifouling chemical) was cabled through the core. Applied to the twisted yarn, the residence time in the channel was about 60 seconds, and the heat-set yarn was analyzed to have 390 ppm fluorine. The yarn was processed on a 1/8 gauge tufting machine to 35 oz / yd, 22/32 inch pile height Latex and secondary support were added to the tufted carpet to protect the tuft. The carpet had a light beige color and was tested for repellency and stain resistance using (AATCC) Method 175-2003, which had a 9 for both 24 hours and WAQE stain resistance, The evaluation was 3 for oil and 4 for oil repellency.

(Invention)
Using the process described above, two 997 denier white nylon 66BCFs made from a cationic dyeable polymer were cable twisted on a Volkman at 7000 rpm to form a 6.25 tpi twine. Two core stations arranged in series were inserted between the take-up roll and the spooler. A 1/2 inch wide, 1.5 inch thick cotton wick is used at the first wick station to produce metallic dyes (5.31 g / l Yellow 3RL, 1.14 g / l Red B, 1. 53 g / l Blue 3GL, 15 g / l wetting agent Doss, pH 8.5) were applied to the cable twist. Fluorochemicals (50% A-201) were applied to the cable twist using a 1/2 inch wide, 1.5 inch thick cotton core at the second station. The processing speed was about 50 ypm. The cable twist was heat-set on Suessen at 200 ° C. The residence time in the heat setting channel was about 60 seconds. The heat-set yarn was analyzed to have 170 ppm fluorine. It was processed into a 35 oz, 22/32 inch pile height cut pile carpet with a 1/8 gauge tufting machine. The finished carpet had a light beige color (Minota L70.46, a3.42, b10.39) and was tested for water / oil repellency and stain resistance using (AATCC) Method 175-2003. . It was rated as having 9 for both 24 hours and WAQE stain resistance, 4 for water repellency and 5 for oil repellency.

(Invention)
A 1245 denier, 64 filament nylon BCF made from a cationic dyeable polymer (294AT type) was processed on a winder. Two core stations, 1/2 inch wide and 1 inch thick, were inserted between the creel and the spool. Dye BCF yarn in medium blue using a metallic dye (2.52 g / l Isolan yellow NW, 2.54 g / l red S-RL, 27.57 g / l blue 3GL, pH 5) did. The winding speed was about 300 yards per minute. The test yarn was knitted on socks and treated with steam for 2 minutes. The treated socks had a medium blue color (L51.47, a-2.18, b-2.71).

(Invention)
This example uses a new dye formulation (23.0 g / l Dystar Isolan yellow NW, 6.03 g / l red S-RL, 2.359 g / l black 2S-CP, pH 5) Similar to Example 6 except that 1245-294AT yarn was dyed. The dyed yarn was processed into a 1/8 inch pile height, 12 oz / yd loop pile carpet on a 5/64 gauge machine. The tufted carpet was treated with steam for 2 minutes to fix the dye. It had a medium gold color (L45.30, a14.26, b26.59).

(Invention)
Using the process described above, two 1100 denier 6dpf white dyeable polyester BCFs (Item WS-1) were cable twisted at 6900 rpm on a Volkman cable twister to form 5.75 tpi twine. The winding speed was about 50 rpm. The cable twist was heat set on Suessen using 185 ° C. dry air. Two color center stations arranged in series were inserted between the creel and the temporary twisting unit. Disperse dyes (23.73 g / l Dianix yellow E-3GE, 13.74 g / l red E-FB, Dystar using a 1/2 inch wide, 1.5 inch thick cotton core at each core station. 6.16 g / l blue ER-AM from Dyetech Inc. and 5 g / l Techwet Spemia, pH 5.0) from Dyetech Inc. were applied to the moving cable twist. The processing speed was about 350 ypm. The residence time in the heat setting channel was about 60 seconds. The heat-set yarn was processed into a 45 oz, 22/32 inch pile height cut pile carpet with a 1/8 gauge tufting machine. The finished carpet had a medium brown color (Minota L44.83, a7.68, b17.11).

Claims (27)

A process for treating bulky continuous filament (BCF) twist yarns with a dye composition comprising:
a. Providing a BCF twisted yarn;
b. Winding the BCF yarn around a take-up reel;
c. Contacting the BCF yarn with the dye composition while the BCF yarn is moving and before contacting the BCF yarn with the take-up reel and winding it thereon.
The process wherein the BCF yarn is selected from the group consisting of cationic dyeable nylon and polyester.   The process of claim 1, further comprising heat setting the BCF yarn after contacting the BCF yarn with the dye composition.   The process of claim 1, wherein the dye composition comprises one or more acidic dye components.   The process of claim 1, wherein the dye composition comprises one or more disperse dye components.   The process of claim 1, wherein the dye composition comprises at least one performance enhancing composition. A process for treating a BCF twist yarn with a dye composition and at least one performance enhancing composition comprising:
a. Providing a BCF twisted yarn;
b. Winding the BCF yarn around a take-up reel;
c. Contacting the BCF yarn with the dye composition;
d. Contacting the BCF yarn with the take-up reel and contacting the BCF yarn with a performance-enhancing composition prior to winding the BCF yarn, wherein the BCF yarn comprises the dye composition and the first performance. A process that is moving while in contact with the enhancement composition.   The process of claim 6, wherein the performance enhancing composition excludes an antifouling component.   The process of claim 6, wherein the first performance enhancing composition comprises an anti-stain component.   The process of claim 6, wherein the first performance enhancing composition comprises both an antifouling component and an antifouling component.   Further contacting the BCF yarn with the second performance enhancing composition after contacting the first performance enhancing composition and before contacting the BCF yarn with the take-up reel and winding it thereon. The process of claim 6 comprising.   The process of claim 10, wherein the first performance enhancing composition comprises an antifouling component and the second performance enhancing composition comprises an antifouling component.   The process according to one of claims 6 to 9, further comprising heat setting the BCF yarn after contacting the BCF yarn with the first performance enhancing composition.   12. The process of claim 10 or 11, further comprising heat setting the BCF yarn after contacting the BCF yarn with the second performance enhancing composition.   The anti-stain component is a polymer of syntan, sulfonated novolak, sulfonated aromatic aldehyde condensation product (SAC) and / or formaldehyde reaction product, phenol, substituted phenol, thiophenol, sulfone, substituted sulfone, olefin Or one of one of the group consisting of a copolymer, a branched olefin, a cyclic olefin, a sulfonated olefin, an acrylate, a methacrylate, a maleic anhydride, and an organic sulfonic acid. The process described in the section.   The antifouling component is composed of fluorochemical, silicone, silsesquioxane, silane-modified particles, organosilane-modified particles, alkylated particles, anionic non-fluorinated surfactant, and anionic hydrotrope non-fluorinated surfactant. 12. A process according to one of claims 7, 9, and 11 selected from the group consisting of:   16. The fluorochemical of claim 15, wherein the fluorochemical is selected from the group consisting of fluorochemical allophanates, fluorochemical polyacrylates, fluorochemical urethanes, fluorochemical carbodiimides, fluorochemical guanidines, and fluorochemicals incorporating C2-C8 chemicals. process.   The process of claim 15, wherein the fluorochemical has one or more monomer repeat units having no more than 6 perfluorinated carbons.   The process of claim 15, wherein the fluorochemical is a fluorochemical urethane.   12. A process according to one of claims 8, 9 or 11 wherein the anti-stain component is present at 500 ppm to 4% based on the weight of the fiber.   The process according to one of claims 1 to 11, wherein the dye composition has a pH of 4 to 9.0.   7. The first performance enhancing composition according to claim 6, wherein the first performance enhancing composition comprises a component selected from the group consisting of flavoring agents, antibacterial agents, antifungal agents, fragrances, bleach resistance agents, softeners, and UV stabilizers. The process described.   The process of claim 6, wherein the first performance enhancing composition comprises a component selected from the group consisting of a dye adjuvant, a scavenger, a pH controller, and a surfactant.   12. A process according to one of claims 7, 9, or 11 wherein the antifouling component is present at 100 ppm elemental fluorine to 1000 ppm elemental fluorine, based on the weight of the fiber.   The process according to claim 2, wherein the heat setting is performed at a temperature of 125C to 200C.   The process of claim 1, wherein the polyester fiber is selected from the group consisting of poly (ethylene terephthalate), poly (propylene terephthalate), poly (butylene terephthalate), copolymers, and mixtures thereof.   The process according to claim 1 or 6, wherein the BCF yarn comprises a polyamide component and a polyester component.   27. The process according to any of claims 1 to 26, wherein the contacting is performed by a device selected from the group consisting of an applicator pad, a wet wick, a dip tank, a sprayer, and a sprayer.