US3458986A - Composite yarn - Google Patents

Composite yarn Download PDF

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Publication number
US3458986A
US3458986A US720858A US3458986DA US3458986A US 3458986 A US3458986 A US 3458986A US 720858 A US720858 A US 720858A US 3458986D A US3458986D A US 3458986DA US 3458986 A US3458986 A US 3458986A
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United States
Prior art keywords
fibers
fiber
poly
yarn
heatset
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Expired - Lifetime
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US720858A
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English (en)
Inventor
Louie J Allison
Richard F Dyer
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Eastman Kodak Co
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Eastman Kodak Co
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    • 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
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/26—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre with characteristics dependent on the amount or direction of twist
    • D02G3/28—Doubled, plied, or cabled threads
    • 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]

Definitions

  • This invention relates to composite carpet yarns comprising at least two diiferent types of polyester fiber. This invention further relates to a method of treating poly(ethylene terephthalate) fiber to improve the resilience and crush resistance thereof and to lower the atfinity of the fiber for disperse dyes.
  • pile fabrics such as carpets, rugs and fur fabrics
  • poly(ethylene terephthalate) fibers have been made from yarns containing poly(ethylene terephthalate) fibers.
  • poly(ethylene terephthalate) fiber for use in pile fabrics has been its poor resilience and recovery from crushing.
  • the poly(ethylene terephthalate) fiber is inferior to polyester fiber made from poly(l,4-cyclohexylene dimethylene terephthalate) which fiber is characterized by having excellent crush resistance and excellent aflinity for disperse dyes.
  • a general object of this invention is to provide a composite polyester fiber yarn which has good crush resistance and crimp retention and which when dyed with a disperse dye will exhibit a tone-on-tone color efiect.
  • the treated fibers are then blended or plied as desired with fibers of poly(l,4-cyclohexylene dimethylene terephthalate), heatset at about 215 C., and having an I.V. of at least about .60 and a density of about 1.225 g./cc. to about 1.235 g./cc.
  • density is defined as the weight in grams of a cubic centimeter of fiber, corrected to base polymer for any additives such as TiO or other pigments, dulling agents, catalysts, etc.
  • FIGURE 1 is a graph illustrating the change in density of poly(ethylene terephthalate) fibers when subjected to heat while in a relaxed condition.
  • FIGURE 2 is a graph illustrating the ratio of percent dye takeup of poly( 1,4-cyclohexylene dimethylene terephthalate) fiber heatset at 215 C. to poly(ethylene terephthalate) fiber heatset at temperatures ranging from to 200 C.
  • the practice of the present invention requires that the fibers or yarns to be treated are first melt extruded, drafted to obtain the required physical properties, crimped or texturized and then heatset in a tensionless state at C. or higher for a sufiicient time to insure complete penetration of heat into the fiber.
  • the fiber is dealt with in a manner which depends upon the desired final yarn structure.
  • the heatset fiber may be cut into staple lengths for processing into carpet yarns on conventional staple processing equipment. If a textured continuous filament yarn is required, the fiber may be extruded, drafted, texturized in a manner such as is described in US. Patent 3,099,064 or by other suitable texturizing means, then heatset at 165 C. or higher, depending on the particular polyester polymer composition of the filaments. It is possible to accomplish the heatsetting after the yarn has been processed into carpeting.
  • the carpeting may, prior to any latex application to the carpet backing, be beatset in an oven, apron dryer, or the like.
  • the manner in which the heat is applied is not critical. It is only required that the temperature be at least 0.60 times the melt temperature, the yarns or fibers be in a tensionless state, the duration of the heat application be sufficient to insure complete penetration, equilibrium, and maximum crystallization of the fiber, and the heatsetting step follow extrusion, drafting and crimping or texturizing. It is important that the heat be applied uniforrnly to avoid variation in dye take-up due to variations in the crystalline structure of the heatset yarn.
  • the improving of fiber resilience by heatsetting appears to be attained when the ratio of the heatset temperature in degrees centigrade to the melt temperature in degrees centigrade falls in the range of 0.65 to 0.80. Higher temperatures may result in discoloration of the fibers while lower temperatures result in loss of resilience, texture retention, and appearance of carpets made from these fibers. In general, polyester fibers with higher melting or softening points require higher heatsetting temperatures to achieve maximum fiber crystallinity and the resultant maximum resilience in carpet piles. It appears that the heatset temperature should be equal to or greater than about 0.65 times the melt temperature and less than 0.80 times the melt temperature. The time of application of the heatsetting treatment should be suificient to insure that all the fibers in a yarn or carpet pile are affected and achieve maximum crystallization.
  • Heatsetting may be performed in an oven, apron dryer, heated tube, or other suitable device.
  • the fabric is formed from strands of poly(ethylene terephthalate) fiber and strands of poly(1,4-cyclohexylene dimethylene terephthalate) fiber, and dye it with a disperse dye to obtain a tone-on-tone color effect.
  • the density of polyethylene terephthalate fibers is one measure of the degree of crystallinity of the fiber, high density fibers having a higher degree of crystallinity than low density fibers.
  • FIGURE 1 depicts the change in density, and degree of crystallinity, which is effected when extruded, drawn, and crimped polyethylene terephthalate fiber is subjected to increasing levels of heatset temperature while the fiber is free to relax. It will be noted that at the conventional heatset temperature of 130 C. to 150 C. the crystallinity of the fiber is relatively low as indicated by the low density measurements in the range of 1.378 to 1.384 g./cc.
  • the highly crystalline poly(ethylene terephthalate) fibers which have been subjected to the high temperature heat treatments to impart improved carpet crush resistance have a high degree of crystallinity as reflected by their densities in the range of 1.385 to 1.395 when subjected to heatsetting temperatures in the range of 170 to 210 C.
  • EXAMPLE II A quantity of 15 d./ f. fiber poly (ethylene terephthalate) was melt extruded, drafted, and crimped in a stuffer box crimper. One portion was heatset at room temperature (22 C.-25 C.); one at 125 C., and one at 180 C., on an apron dryer for five minutes. After heatsetting, the three portions were cut to 4-inch staple, and processed into 2.5/3 ply cotton counts yarns. The three yarns heatset at different temperatures were then tufted into 25 ounces per square yard loop pile carpeting. The carpeting was piece dyed and tested on the floor for 20,000 steps or walkovers. The following table shows the degree of improvement obtained with the 180 C. heatset sample as compared to the room temperature, and the 125 C. heatset samples.
  • Carrier assistant 10 Calgon 1 Monosodium phosphate 1 Navy formula Color index name Eastman Polyester Blue BLF (2.7%) -Disperse Blue 120. Eastman Polyester Yellow W (2.7 -Disperse Yellow 42. Eastman Polyester Violet R (2.4%) -Disperse Violet 27. Eastman Polyester Brilliant Red FFBL (9%) Disperse Red 60.
  • Percent Dye carrier assistant (Carolid) 21 Calgon 1 Monosodium phosphate 1 Wetting agent (Standapon) .75
  • Methylene chloride extractions were used to determine the total amount of dye absorbed by the fibers.
  • Results show that as the heatsetting temperature of the polyester terephthalate samples is increased from C. to C., the difference in dye rate between the two types of fiber increased linearly from a ratio of about 1:1 at 130 C. to a ratio of about 4:1 at 180 C., with the polyester terephthalate fibers dyeing lighter. As the heatset temperature was increased further (from 180 C. to 200 0.), the contrast between fibers decreased. The same results were obtained with both dye furmulae as shown in FIGURE 2.
  • the novel yarns of this invention are particularly useful for the production of carpets.
  • the yarn exhibits good covering power and is more resistant to crushing and matting when heavy objects are placed on carpets made with the yarns.
  • the crush resistance of the yarn is due in partto the excellent crush resistance of the poly(1,4- cyclohexylene dimethylene terephthalate) fiber and in part to the improved crush resistance of the poly(ethylene terephthalate) fiber.
  • the novel yarn of this invention being composed of two different polyester fibers, each having been treated to possess desired disperse dye take-up characteristics make possible the manufacture of carpets, fur fabrics, sweaters, woven fabrics and the like which will retain their bulk characteristics and which can be easily :dyed to tone-on-tone colors with a disperse dye.
  • Textile yarn having good crush resistance and crimp retention properties comprising at least two plied strands of fibers, the fibers of at least one of said strands being poly(ethylene terephthalate) fibers characterized by having an I.V. of at least .55 and a density of 1.385 to about 1.395 g./cc.
  • Fibers of the other of said strands are poly(1,4-cyclohexylene dimethylene terephthalate) fibers having an I.V. of at least .60 and a density of 1.225 to about 1.235.
  • Textile yarn having a good crush resistance and crimp retention properties comprising a blend of at least two kinds of polyester fibers, one of said polyester fibers being poly(ethylene terephthalate) fibers having an I.V. of at least .55 and a density of 1.385 to about 1.395 g./cc. and the other of said polyester fibers being poly(1,4-cyclohexylene dimethylene terephthalate) fibers having an I.V. of at least .60 and a density of 1.225 to about 1.235 g./cc.
  • Textile fabric having good crush resistance and bulk characteristics said fabric including yarn made from poly(ethylene terephthalate) fibers having an I.V. of at least .55 and a density of 1.385 g./cc. to about 1.395 g./cc., and yarn made from poly(1,4-cyclohexylene dimethylene terephthalate) fibers having an I.V. of at least .60 and a density of 1.225 g./cc.
  • the ratio of disperse dye take-up of said poly(1,4-cyc1ohexylene dimethylene terephthalate) fiber to said poly (ethylene terephthalate) fibers is at least three to one, whereby said fabric when dyed with disperse dye will exhibit a tone-on-tone color effect.
  • said yarn comprises a blend of said poly(ethylene terephthalate) fibers and said poly(1,4-cyclohexylene dimethylene terephthalate) fibers.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Artificial Filaments (AREA)
US720858A 1968-04-12 1968-04-12 Composite yarn Expired - Lifetime US3458986A (en)

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US72085868A 1968-04-12 1968-04-12

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2089237A5 (it) * 1970-04-06 1972-01-07 Teijin Ltd
US3676906A (en) * 1967-09-13 1972-07-18 Ici Ltd Process for making a patterned fabric by using differential shrinkage yarns
US3936999A (en) * 1970-04-06 1976-02-10 Teijin Ltd. False twist-crimped polyester yarns production
US3988108A (en) * 1973-04-09 1976-10-26 Kanebo, Ltd. Process for coloring fibrous structures

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2880057A (en) * 1958-01-22 1959-03-31 Du Pont Treatment of filaments to improve strength in tension
US2926065A (en) * 1956-04-18 1960-02-23 Fabric Res Lab Inc Method of shrinkproofing oriented, crystallized polyethylene terephthalate yarns at elevated temperatures by heat tensioning and heat relaxing said yarns
US2952879A (en) * 1957-03-27 1960-09-20 Du Pont Process of preparing spontaneously extensible structures
US2979883A (en) * 1957-08-12 1961-04-18 Du Pont Composite yarn and process of producing bulked fabric therefrom
US2980492A (en) * 1958-05-27 1961-04-18 Du Pont Process for preparing textile yarns
US3159964A (en) * 1960-01-12 1964-12-08 Hoechst Ag Process for working up stretched filaments of aromatic polyesters of high molecular weight
US3188714A (en) * 1963-03-22 1965-06-15 Eastman Kodak Co Process of producing self-crimping fibers

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2926065A (en) * 1956-04-18 1960-02-23 Fabric Res Lab Inc Method of shrinkproofing oriented, crystallized polyethylene terephthalate yarns at elevated temperatures by heat tensioning and heat relaxing said yarns
US2952879A (en) * 1957-03-27 1960-09-20 Du Pont Process of preparing spontaneously extensible structures
US2979883A (en) * 1957-08-12 1961-04-18 Du Pont Composite yarn and process of producing bulked fabric therefrom
US2880057A (en) * 1958-01-22 1959-03-31 Du Pont Treatment of filaments to improve strength in tension
US2980492A (en) * 1958-05-27 1961-04-18 Du Pont Process for preparing textile yarns
US3159964A (en) * 1960-01-12 1964-12-08 Hoechst Ag Process for working up stretched filaments of aromatic polyesters of high molecular weight
US3188714A (en) * 1963-03-22 1965-06-15 Eastman Kodak Co Process of producing self-crimping fibers

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3676906A (en) * 1967-09-13 1972-07-18 Ici Ltd Process for making a patterned fabric by using differential shrinkage yarns
FR2089237A5 (it) * 1970-04-06 1972-01-07 Teijin Ltd
US3797221A (en) * 1970-04-06 1974-03-19 Teijin Ltd False twist-crimped polyester yarns and process for their production
US3936999A (en) * 1970-04-06 1976-02-10 Teijin Ltd. False twist-crimped polyester yarns production
US3988108A (en) * 1973-04-09 1976-10-26 Kanebo, Ltd. Process for coloring fibrous structures

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