WO1999013143A1 - Fil d'effet stylise pour tapis et son procede de fabrication - Google Patents

Fil d'effet stylise pour tapis et son procede de fabrication Download PDF

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Publication number
WO1999013143A1
WO1999013143A1 PCT/US1998/017957 US9817957W WO9913143A1 WO 1999013143 A1 WO1999013143 A1 WO 1999013143A1 US 9817957 W US9817957 W US 9817957W WO 9913143 A1 WO9913143 A1 WO 9913143A1
Authority
WO
WIPO (PCT)
Prior art keywords
yarn
core
yarns
carpet
length
Prior art date
Application number
PCT/US1998/017957
Other languages
English (en)
Inventor
William John Flynn
Original Assignee
E.I. Du Pont De Nemours And Company
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 E.I. Du Pont De Nemours And Company filed Critical E.I. Du Pont De Nemours And Company
Priority to CA002297689A priority Critical patent/CA2297689A1/fr
Priority to AU92111/98A priority patent/AU9211198A/en
Publication of WO1999013143A1 publication Critical patent/WO1999013143A1/fr

Links

Classifications

    • 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
    • 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
    • D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns
    • D02G3/346—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns with coloured effects, i.e. by differential dyeing process
    • 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
    • D02G3/38—Threads in which fibres, filaments, or yarns are wound with other yarns or filaments, e.g. wrap yarns, i.e. strands of filaments or staple fibres are wrapped by a helically wound binder yarn
    • D02G3/385—Threads in which fibres, filaments, or yarns are wound with other yarns or filaments, e.g. wrap yarns, i.e. strands of filaments or staple fibres are wrapped by a helically wound binder yarn using hollow spindles, e.g. making coverspun yarns
    • 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

Definitions

  • a popular feature of cut and loop pile carpets is the presence of randomly dispersed small regions or "islands" of color throughout.
  • This is accomplished by using space-dyed yarns m the tufting operation.
  • Space-dyeing refers to the process of dyeing white dyeable yarns m such a way that the color varies along the length of the yarn.
  • space- dyed yarns permits more colors to be placed into a tufte ⁇ carpet
  • Such yarns are consi ⁇ ered to be valuaole styling yarns Dy designers.
  • solution-dyed yarns also Known as producer- colored yarns, m lieu of dyed or dyeable yarns.
  • Solution-dyed yarns provide the advantages of not requiring dyeing, and generally having greater inherent resistance to stains, particularly acid type stains
  • U.S. Patent Number 4,542,619 discloses a yarn, and a process and apparatus for making it, for use in carpets with a space-dyed look.
  • the yarn contains a core of multicolor bulked continuous filament yarns wrapped with two wrapping yarns.
  • One of the wrapping yarns extends m the clockwise direction and the other wrapping yarn extends m the counterclockwise direction.
  • the length of the core is greater than the length of the wrapping yarns, and the core has a sinusoidal profile.
  • the present invention relates to a carpet styling yarn, to a method for fabricating the same, and to a carpet using the same.
  • the carpet styling yarn of the present invention comprises a core having at least two falsely twisted yarns, and a single wrapper yarn spirally wrapped about the core.
  • the length of the single wrapper yarn is greater than the length of the core for any given unit length of the carpet styling yarn.
  • the single wrapper yarn has a linear density m the range of about 20 to about 50 denier and is wrapped about the core at a frequency of about one (1) to about five (5) wraps per inch.
  • Each of the yarns m the core may be either a differently colored, solution-dyed bulked continuous filament yarn or a differently colored staple spun yarn.
  • each of the yarns m the core has a linear density m the range from about six hundred (600) to about thirteen hundred (1300) denier
  • the yarns in the core may either be nylon 6, nylon 6,6, polypropylene, poly (ethylene terephthalate) or poly (t ⁇ methylene terephthalate) .
  • the styling yarn is formed by falsely twisting the yarns of the core by passing the core yarns through a rotating hollow spindle, and spirally wrapping around the core a single wrapper yarn so that the length of the single wrapper yarn is greater than the length of the core for any given unit length of the carpet styling yarn.
  • the core yarns are passed through a yarn guide and maintained at a tension of preferably between about twenty (20) and about one hundred (100) grams.
  • the present invention relates to a carpet comprising a plurality of above- described carpet styling yarns tufted into a backing.
  • Figure 1 is a side elevational view of a carpet styling yarn in accordance with the present invention.
  • Figure 2 is a side elevational view entirely m section of an apparatus for fabricating the carpet styling yarn of Figure 1
  • the carpet styling yarn 10 of the invention is illustrated m Figure 1.
  • the carpet styling yarn 10 comprises a core, generally indicated by reference character 12, having a plurality of N number of yarns with a single wrapper yarn 14 spirally wound about the core.
  • the length of the wrapper yarn 14 is greater than the length of the core 12 for any given length of carpet styling yarn 10.
  • the number N of yarns in the core 12 is between two and eight
  • Each core yarn may be bulked continuous filament (BCF) yarn or, alternatively, staple spun yarn, or a mixture thereof.
  • Each core yarn preferably has a linear density m a range from about six hundred (600) to about thirteen hundred (1300) denier.
  • the core yarns may be any fiber-forming polymer suitable for textile applications, including, but not limited to, nylon 6, nylon 6,6, polypropylene, poly (trimethylene terephthalate) and poly (ethylene terephthalate) .
  • each of the core yarns is differently colored.
  • the embodiment of the yarn 10 shown m Figure 1 contains four such core yarns indicated by the reference characters 12A through 12D.
  • the color difference for the core yarns 12A-12D is shown by the various hatching styles of each yarn.
  • This slight amount of false twist in the core 12 results in low frequency alternation of the predominant color of the yarn 10 along its length.
  • the level of false twist within the core 12 may be considered to be equivalent to real twist in the range of about zero (0) to about one (1) turns per inch.
  • the styling yarn 10 of the present invention is held together by the single wrapper yarn 14 which is spirally wound around the core 12.
  • the wrapping frequency is between about one (1) and about five (5) wraps per inch, and more preferably, between about two-and-one-half (2.5) and about four (4) wraps per inch.
  • the wrapper yarn 14 may be any yarn having a linear density of about twenty (20) to about fifty (50) denier which is capable of wrapping around the core 12.
  • the wrapper yarn 14 should not have a noticeable appearance when the yarn 10 is used in the manufacture of a carpet.
  • the wrapper yarn 14 may be undyed, dyed or solution-dyed, and may be textured or untextured.
  • the wrapper yarn 14 is a forty (40) denier non-textured black dyed nylon yarn.
  • the carpet styling yarn 10 of the present invention combines the advantages of solution-dyed yarns with the aesthetics of space-dyed yarns in carpet.
  • each of the N yarns forming the core 12 is a solution- dyed, sulfonated nylon 6,6 BCF yarn such as Antron ® umena ® fiber available from E. I. Du Pont de Nemours &. Company, Incorporated, Wilmington, Delaware.
  • Antron ® umena ® fiber available from E. I. Du Pont de Nemours &. Company, Incorporated, Wilmington, Delaware.
  • core yarns which are differently colored and have a high degree of contrast with each other in terms of color and clarity.
  • carpets made according to the present invention with such a combination of core yarns in a tufted loop pile construction contain several colors randomly dispersed with good color separation and "color pop."
  • each of the N yarns of the core 12 is an undyed nylon BCF yarn, with each yarn having a different dyeability.
  • the carpet styling yarn 10 is initially a core 12 of white dyeable yarns wrapped by a single wrapper yarn 14. Such a carpet styling yarn 10 is dyed in subsequent processing, either in yarn or carpet form. After dyeing, the styling yarn 10 will exhibit low frequency color changes along its length, as described above.
  • Previously heathered, undyed yarns containing yarns of different dyeabilities may also be used as the core yarns 12 in order to achieve particular stylistic effects in carpet.
  • the core 12 may contain BCF yarns which have previously been skein or stock dyed.
  • each of the N yarns has been dyed a different color, so that once again, the resulting carpet styling yarn 10 exhibits low frequency color changes along its length.
  • differently colored staple spun yarns may be used in the core 12 to form a carpet styling yarn 10 with differently colored strands which exhibit low frequency color changes along the length.
  • the staple spun yarns may be either stock dyed or solution-dyed, and formed by conventional processing into spun yarns prior to being wrapped by a single light denier wrapper yarn 14.
  • each of the N yarns of the core 12 could be a combination of two or more of the different types of core yarns above discussed.
  • the length of the wrapper yarn 14 is greater than the length of the core 12 per given length of carpet styling yarn 10. This difference in length is determined by unwrapping the wrapper yarn 14 and measuring its length and the length of the core 12.
  • antistatic filaments may be included either in the core yarns of the core 12 and/or the wrapper yarn 14.
  • Carpet styling yarn 10 in accordance with the present invention can be used in conventional tufting processes to make a carpet .
  • the carpet may be tufted employing a "step-over" tufting pattern or, alternatively, a straight stitch tufting pattern.
  • the carpet may have a cut or loop pile construction.
  • the carpet using the yarn of the present invention exhibits space-dyed aesthetics. This carpet preferably has a randomly distributed multi-color pattern with good color separation and "color pop.”
  • the attributes of the selected core yarns are imparted to the carpet .
  • the carpet made with the above-described Antron ® Lumena ® fiber core yarn has an inherently high degree of stain resistance and durability, in addition to having the capacity for many colors in a space-dyed appearance without the need for dyeing, of either the yarns or the carpet.
  • a benefit of the present invention is that it may be used to make a multi-colored carpet having a space-dyed appearance without the need for dyeing and the associated expense and environmental concerns .
  • an apparatus 20 for implementing the process for making the carpet styling yarn 10 of the invention will now be discussed.
  • the N yarns 12-1 through 12 -N forming the core 12 are fed from a creel 22, through a tensioner 24 and a yarn guide 26, to the input end of the wrapping apparatus 20.
  • the wrapping apparatus 20 includes a hollow spindle 30 capable of holding a single Dobbin 32 of light denier wrapper yarn 14.
  • the hollow spindle 30 is preferably a commercially available spindle such as those available from Spmdelfab ⁇ k Suessen Schurr, Stahlecker & Grill GmbH, also known as Suessen,
  • the spindle 30 is mounted on bearings 34 for rotational movement with respect to a fixed plate 36.
  • One end of the spindle 30 is connected m driven relationship to a suitable motive source 38 by a drive belt 40.
  • the other end of the spindle 30 has a pair of axially spaced, radially extending openings 30A, 30B therein.
  • the exterior surface of the spindle 30, axially intermediate the openings 30A, 30B, preferably has a hook member 3 OH.
  • the creel 22 for use m the invention is a standard creel for use m textile operations which provides continuous supply of yarn to the wrapping apparatus 20.
  • the creel 22 must be capable of supplying the desired number N of yarns.
  • Suitable tensioners 24 are those commercially available from
  • the guide 26 is preferably located about two (2) to twenty (20) inches m advance of the spindle 30.
  • the guide 26 preferably is m the form of a plate having a plurality of holes 26H therein.
  • the resulting styling yarn 10 is pulled linearly through and from the wrapping apparatus 20 by an accumulator 42.
  • the accumulator 42 is commonly used m textile operations to interface between the pieces of equipment that carry out various operations, such as heat setting and winding.
  • Such accumulators are commercially available from Belmont Textile Machinery Company, Belmont, North Carolina Use of an accumulator is optional but is preferred in the present invention.
  • the yarns 12 may be pulled from the creel 22 through the wrapping apparatus 20 by other means, such as a winder or nip roll located after the wrapping apparatus 20.
  • the yarns are pulled from the accumulator 42 by a winder 44.
  • the winder 44 is a standard piece of equipment commercially available for use m textile operations.
  • the winder 44 pulls the finished carpet styling yarn 10 from the accumulator 42 and winds it onto an appropriately sized tube.
  • a suitable winder 44 is available from Belmont Textile Machinery Company, Belmont, North Carolina.
  • the yarns 12-1 through 12-N are manually guided from the creel 22 through the tensioners 24 and the guides 26.
  • the yarns 12-1 through 12-N are threaded through the bore of the spindle 30, radially outwardly through the lower radial opening 30A, and over the hook member 3 OH.
  • the yarns 12-1 through 12 -N are returned to the hollow bore of the spindle through the upper radial opening 30B.
  • the core yarns emanating from the upper end of the bore of the spindle 30 are fed to the accumulator 42 and then to the winder 44.
  • the single light denier wrapper yarn 14 from the bobbin 32 on the exterior of the spindle 30 is manually attached to the core yarns 12-1 through 12 -N prior to the entrance to the spindle 30 by lightly wrapping one or two wraps around the core yarns To form the styling yarn 10 the hollow spindle
  • the spindle 30 is rotated by the motive source 38 via the drive belt 40 at a predetermined speed, typically between about eight thousand (8,000) and about thirty thousand (30,000) rpm.
  • a predetermined speed typically between about eight thousand (8,000) and about thirty thousand (30,000) rpm.
  • the cohesion of the core 12 is attributed to the amount of false twist thus imparted. Because of its tendency to untwist the false twist propagates along the length of the core yarns 12-1 through 12 -N upstream of the spindle 30.
  • false twist is present in the core yarns before they enter the spindle 30.
  • the amount of false twist is determined by the combination of the linear yarn speed and the spindle rotational speed. Preferably, these speeds are selected to result in a false twist level approximated by about zero (0) to about one (1) turns per inch of real twist.
  • the single light denier wrapper yarn 14 is taken from the bobbin 32 and wrapped around the core 12.
  • the frequency of the wraps is determined by the combination of the linear speed of the feed yarns and the spindle speed.
  • the frequency of the wraps is preferably between about one (1) and about five (5) wraps per inch, and more preferably between about two- and-one-half (2.5) and about four (4) wraps per inch.
  • the single wrapper yarn 14 captures a portion of the false twist present in the core yarns at the entrance of the spindle 30.
  • the tension of each core yarn 12-1 through 12 -N as it is fed to the wrapping apparatus 20 is individually controlled by the tensioners 24.
  • the tension of each core yarn as measured between the creel 22 and the wrapping apparatus 20 is in the range of about twenty (20) to about oen hundred (100) grams. It has been found that different stylistic effects may be achieved in the carpet by having a tension differential between core yarns 12-1 through 12-N making up a single carpet styling yarn 10. Generally, a single core yarn that is fed to the wrapping apparatus 20 under lower tension than the other core yarns will have a more prominent appearance in the final carpet .
  • the yarn guide 26 maintains separation of the core yarns 12-1 through 12 -N as they are fed into the wrapping apparatus 20.
  • the core yarns 12-1 through 12- N are fed through the holes 26H in such a way that produces a desired effect in the resulting carpet yarn 10.
  • Each core yarn may be fed through its own unique hole 26H, or two yarns may be fed through the same hole 26H, for different effects in the resulting carpet.
  • an optical sensor 46 is provided in close proximity to the spindle 30 in order to detect the presence of the wrapper yarn 14 as it is fed from the bobbin 32. In the case of a break in the wrapper yarn 14 during the process of the invention, a signal from the optical sensor 46 will trigger an alarm and/or cause the process to shut down automatically.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Abstract

L'invention concerne un fil d'effet stylisé pour tapis (10), comprenant un noyau (12) constitué d'au moins deux fils texturés par fausse torsion, et un seul fil de guipage (14), enroulé en spirale autour dudit noyau. La longueur de ce fil de guipage est supérieure à celle du noyau, quelle que soit l'unité de longueur dudit fil d'effet stylisé pour tapis. L'invention concerne également un procédé de fabrication de ce fil stylisé pour tapis, ainsi qu'un tapis fabriqué avec un tel fil.
PCT/US1998/017957 1997-09-08 1998-08-31 Fil d'effet stylise pour tapis et son procede de fabrication WO1999013143A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CA002297689A CA2297689A1 (fr) 1997-09-08 1998-08-31 Fil d'effet stylise pour tapis et son procede de fabrication
AU92111/98A AU9211198A (en) 1997-09-08 1998-08-31 Carpet styling yarn and process for making

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US92588297A 1997-09-08 1997-09-08
US08/925,882 1997-09-08

Publications (1)

Publication Number Publication Date
WO1999013143A1 true WO1999013143A1 (fr) 1999-03-18

Family

ID=25452386

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1998/017957 WO1999013143A1 (fr) 1997-09-08 1998-08-31 Fil d'effet stylise pour tapis et son procede de fabrication

Country Status (3)

Country Link
AU (1) AU9211198A (fr)
CA (1) CA2297689A1 (fr)
WO (1) WO1999013143A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105401293A (zh) * 2015-11-25 2016-03-16 江南大学 一种新型花式纱及其生产方法
CN110592757A (zh) * 2019-10-08 2019-12-20 江苏海特服饰股份有限公司 多色变换接头纱及其制备方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105862209A (zh) * 2016-06-06 2016-08-17 寿光市嘉信生态科技有限公司 一种雪花竹节ab纱的制备方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4228640A (en) * 1976-04-07 1980-10-21 Fiber Industries, Inc. Simulated spun-like ingrain yarn
DE3126051A1 (de) * 1981-07-02 1983-01-20 Hacoba Textilmaschinen Gmbh & Co Kg, 5600 Wuppertal Mehrkomponenten-garn fuer mehrfarbige veloure und verfahren zu seiner herstellung
EP0232714A2 (fr) * 1986-01-09 1987-08-19 E.I. Du Pont De Nemours And Company Fil fausse torsion ayant des torsions variables
US4720943A (en) * 1986-11-03 1988-01-26 Monsanto Company Cord structure
JPH08260277A (ja) * 1995-03-23 1996-10-08 Toray Ind Inc 多色柄嵩高糸およびこの嵩高糸を用いた多色柄カーペット

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4228640A (en) * 1976-04-07 1980-10-21 Fiber Industries, Inc. Simulated spun-like ingrain yarn
DE3126051A1 (de) * 1981-07-02 1983-01-20 Hacoba Textilmaschinen Gmbh & Co Kg, 5600 Wuppertal Mehrkomponenten-garn fuer mehrfarbige veloure und verfahren zu seiner herstellung
EP0232714A2 (fr) * 1986-01-09 1987-08-19 E.I. Du Pont De Nemours And Company Fil fausse torsion ayant des torsions variables
US4720943A (en) * 1986-11-03 1988-01-26 Monsanto Company Cord structure
JPH08260277A (ja) * 1995-03-23 1996-10-08 Toray Ind Inc 多色柄嵩高糸およびこの嵩高糸を用いた多色柄カーペット

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 97, no. 2 28 February 1997 (1997-02-28) *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105401293A (zh) * 2015-11-25 2016-03-16 江南大学 一种新型花式纱及其生产方法
CN110592757A (zh) * 2019-10-08 2019-12-20 江苏海特服饰股份有限公司 多色变换接头纱及其制备方法

Also Published As

Publication number Publication date
CA2297689A1 (fr) 1999-03-18
AU9211198A (en) 1999-03-29

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