Note: Descriptions are shown in the official language in which they were submitted.
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PROCESSES TO DYE AND TREAT BCF YARN
FIELD OF THE INVENTION
[0001] The invention relates to treatment processes for bulk continuous
filament (BCF) carpet
and related textile fabrics, and specifically, to processes for applying dyes
and topical treatment
compositions on BCF yarns during twisting processes (cable or air) or
heatsetting process prior
to weaving, knitting or tufting. The process foregoes the need to dye and
otherwise treat
carpets and other textiles made from the BCF yarn using current methods. The
need for an anti-
stain treatment is also avoided by the inclusion of an inherently stain
resistant fiber, such as
cationic dyeable polyamide or polyester. Thus, low inventory overhead is
achieved and costly
and environmentally unfavorable dyeing and low pH chemical treatment processes
are
eliminated. Also disclosed herein are systems used to apply the dye and
performance
enhancement formulations to the BCF yarn, and soil repellent yarns, and
carpets with improved
anti-soil properties made from the BCF yarn of the disclosed process.
BACKGROUND OF THE TECHNOLOGY
[0002] Carpets and other fabrics made from synthetic yarns are currently
colored using two
well-established processes. The first process involves converting colorless
white yarns into
carpet, and dyeing the carpet in a dye bath. This process is referred to as
the "acid dye
process." The acid dye process can be either a batch or a continuous dyeing
operation. Each
dyeing operation requires a large volume of water, steam to set the dyes, and
heat to dry the
carpet. In addition, collection and disposal of excess dye and acidified
performance enhancing
solutions add manufacturing cost and place additional burden on waste
management and water
treatment facilities. The second process adds color pigments into the polymer
during the melt
spinning process. This process is referred to as the "solution dye process."
The solution dye
process is a low cost operation, but in comparison to the acid dye process it
imposes
undesirable inventory allocation measures on the fiber producer and the carpet
mill. In order to
meet consumer demand, then, the fiber producer and carpet mill may need to
keep a costly
inventory of colored yarns produced by the solution dye process. Variable
production demands
and large inventory costs can affect inventory flexibility with the result
being the color availability
of solution dyed carpets is undesirably limited.
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[0003] Topical chemistries are used to treat carpets and other fabrics for
improved stain
resistance and/or soil resistance. For nylon carpets, both stain blocker (e.g.
acid dye blocker)
and anti-soil with fluorochemicals are traditionally used. For polyester
carpets, such as such as
polyethylene terephthalate (2GT) and polytrimethylene terephthalate (3GT)
carpets, and
polypropylene carpets, anti-soil chemistry may be applied topically to the
tufted carpet as part of
the carpet finishing process. Polyester and polypropylene carpets typically do
not require a
stain blocker treatment because of inherent stain resistance to acid dyes and
stains owing to
their lack of amine end groups that function as acid dye sites.
[0004] Topical application at the carpet mill can be in the form of exhaust
application and
spray application. Exhaust application (i.e. flex-nip process at high (300 ¨
400 wt.%) wet pick-
up), is known to provide an improvement in efficacy over spray-on applications
at 10-20 wt.%
wet pick-up of anti-soil. Exhaust applications typically use greater amounts
of water and energy
to dry and cure the carpet than do spray applications. Spray-on fluorochemical
products are
designed to use less water and energy than exhaust applications, but do not
impart satisfactory
anti-soil properties.
[0005] While various processes are in use in the carpet industry for the
dyeing and finishing of
carpets, some large scale and some small, most of the carpet made today is
dyed and finished
on a continuous dye range. This is done mainly in one of two ways: In one
case, a two stage
process is employed, where the carpet is steamed and dyed first, steamed,
rinsed, and excess
water extracted; then stain blocker (SB) is applied, the carpet is again
steamed and washed,
and then anti-soil fluorochemical (FC) is applied in the form of a foam or
liquid spray and the
carpet is finally dried. (See e.g. U.S. Patent Nos. 5,853,814; 5,948,480 and
W02000/000691).
In the second, somewhat improved case, called the co-application process, the
carpet is also
steamed and dyed first, steamed again, rinsed and extracted; and then a blend
of SB and FC is
applied together at high wet pick up, after which the carpet and chemicals are
exposed once
again to steam to fix the treatment, followed by drying. (See e.g. U.S. Patent
Nos. 6,197,378
and 5,520,962). In both cases, low pH solutions, excess water, and energy are
required for the
SB and FC to penetrate the carpet and achieve uniform coverage. In sum, the
typical prior art
process is as follows: BCF yarn ¨*Twist ¨> heat set ¨> tufting --> carpet --
dye ¨> stain block /
anti-soil.
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SUMMARY OF THE INVENTION
[0006] There is a desire to reduce the overall usage of dyeing solutions and
stain blocker
formulations for environmental and cost reasons. Further, there is also a
desire to reduce the
amount of water and low pH chemicals used to apply the dyeing and anti-stain
formulations.
Thus, processes which provide for low inventory needs while applying such
beneficial
compositions using less water, nominal pH chemicals, and less energy are in
demand.
[0007] While the development of a process that eliminates the current carpet
treatment
systems for applying anti-stain and anti-soil compositions is desirable,
current processes do
exist for good reasons. First, because the appearance of carpet has
historically depended on
the ability to dye wool or nylon or even polyester tufted carpets to the
desired shade, it would
not be permissible to treat the carpet with compositions such as anti-stain or
anti-soil
chemistries beforehand that might interfere with the process of uniform
dyeing. Further, the
dyeing process would tend to remove the topical treatment chemistries,
rendering them
ineffective.
[0008] Second, as mentioned above, treatment of yarn or fabric with
performance
enhancement formulations for stain and soil resistance typically involves
fixing with steam, and
low pH may also be required especially for acid dyed fabrics. Therefore, it
was deemed most
practical to process carpets in the order described above, where carpet is
formed, then steamed
and dyed, steamed again, rinsed and extracted; and then SB and FC is applied,
again involving
steaming and/or rinsing in the various processes of the prior art.
[0009] Carpets have also long been constructed of dyed or pigmented yarns,
which
constructions are treated in numerous possible ways, including the options of
further dyeing,
and the application of stain and/or soil resistant compositions with the
concomitant use of steam
and rinse water, as in the processes described above.
[0010] The invention disclosed herein provides a process to make textile
fabrics, especially
tufted articles, without the requirements for dyeing and subsequent stain and
soil resistant
chemistry application, thus avoiding the costs associated with maintaining
large inventories as
well as waste generated by steam fixation and rinsing attendant with such
large-scale fabric
applications. As disclosed herein, the process involves application of dyes
and topical
chemistries to undyed yarns immediately after twisting or cabling one or more
such yarns
together. The chemistries are then heat-set onto the twisted yarn under dry
conditions, and the
twisted yarn subsequently weaved or tufted into a finished fabric or carpet.
Novel systems that
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enable the efficient application of dye solutions and topical chemistries to
yarn subsequent to
twisting and prior to winding and heat-setting are also disclosed.
[0011] Specifically, the disclosed process uses a dye solution or topical
chemistry
composition applicator positioned within a mechanical twisting process
downstream of the
twisted yarn take-up reel and upstream of the yarn winder. In sum, the
disclosed process
moves the back end, large scale and wasteful stain blocker application step up
front during or
after yarn twisting. Thus, the carpet manufacturing process now becomes: BCF
yarn ¨> twist
--) dye --- optional SB/FC --> heat set (optionally dry heat set) --* tufting
¨> carpet. Surprisingly,
the disclosed process is as effective, or even more effective, than processes
of the prior art in
terms of fabric soil resistance. Additionally, neutral pH dye solutions (4-7.5
pH) can be used
instead of the prior art low pH dye solutions (1-3 pH). This reduces the
environmental impact of
prior art processes. Moreover, the need for a stain blocker application is not
necessary due to
the inclusion of a cationic dyeable polyamide or polyester. In other words,
the stain blocker
application can be consciously excluded while not sacrificing stain resistant
properties.
[0012] As described above, the process of the disclosed invention is
counterintuitive since
treating the carpet yarn prior to heat setting and tufting is known to affect
the quality of the
finished carpet, particularly during dyeing. Further, the inventive process is
also counter
intuitive because soil resistant compositions tend to be very difficult to
apply uniformly to twisted
yarn bundles at the usual line speed without substantial waste [30 to 80 yards-
per-minute
(ypm)]. Moreover, the disclosed process is counter intuitive because the prior
art yarn twisting
apparatuses have not previously accepted topical chemistry applications to
twisted yarn prior to
winding. However, as shown below, nylon and polyester carpets manufactured
with the treated
BCF yarn show one or more of the following desirable characteristics:
= At least equivalent dyeing characteristics vs. the current state of the
art
processes.
= At least equivalent stain and soil repellant performance vs. the current
state of
the art processes.
= Desirable aesthetic attributes otherwise not generated by the current
state of the
art processes.
[0013] In one aspect, a process for treating twisted BCF yarn with one or more
dye
compositions is disclosed. The process comprises: (a) providing twisted BCF
yarn; (b) winding
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said BCF yarn on a take-up reel; and (c) contacting said BCF yarn with said
dye composition
while said BCF yarn is in motion and prior to said BCF yarn contacting and
winding up on said
take-up reel. The dye composition can be comprised of an acid dye composition
or a disperse
dye composition.
[0014] In another aspect, a process for treating twisted BCF yarn with one or
more dye
compositions is disclosed. The process comprises: (a) providing twisted BCF
yarn; (b)
contacting said BCF yarn with said dye composition while said BCF yarn is in
motion; and (c)
heat setting said BCF yarn after contacting said BCF yarn with said dye
composition. The dye
composition can be comprised of an acid dye composition or a disperse dye
composition.
[0015] In a further aspect, a process for treating twisted BCF yarn with one
or more dye
compositions and performance enhancing compositions is disclosed. The process
comprises:
(a) providing twisted BCF yarn; (b) winding said BCF yarn on a take-up reel;
(c) contacting said
BCF yarn with said dye composition; (d) optionally contacting said BCF yarn
with a first
performance enhancing composition comprising a stain blocking composition; and
(e)
contacting said BCF yarn with a second performance enhancing composition
comprising an
anti-soil composition and prior to said BCF yarn contacting and winding up on
said take-up reel,
wherein said BCF yarn is in motion while contacted with said dye, said
optional first
performance enhancing composition, and said second performance enhancing
composition.
The dye composition can be comprised of an acid dye composition or a disperse
dye
composition. The stain blocking composition can be comprised of species having
acidic
moieties that associate with polymer amine end groups and protect them from
staining by acidic
dye stains. The general category of chemicals suitable to the process of the
instant invention
can comprise any chemical that blocks positively charged dye sites. The anti-
soil composition
can be comprised of a high specific surface energy chemical or other material,
for example a
fluorochemical that imparts high specific surface energy properties such as
high contact angles
for water and oil, or even a non-fluorochemical particulate material having
similar properties.
The anti-soil composition can further comprise an anti-stain component.
[0016] In even another aspect, a process for treating twisted BCF yarn with
one or more dye
compositions and performance enhancing compositions is disclosed. The process
comprises:
(a) providing twisted BCF yarn; (b) contacting said BCF yarn with said dye
composition; (c)
optionally contacting said BCF yarn with a first performance enhancing
composition comprising
a stain blocking composition; (d) contacting said BCF yarn with a second
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enhancing composition comprising an anti-soil composition, wherein said BCF
yarn is in motion
while contacted with said dye, said optional first performance enhancing
composition, and said
second performance enhancing composition and; (e) heat setting said BCF yarn
after contacting
said BCF yarn with said dye composition, said optional first performance
enhancing
composition, and said second performance enhancing composition. The dye
compositions and
performance enhancing compositions are disclosed above.
[0017] In a further aspect, an untufted, twisted BCF yarn comprising a dye
component is
disclosed, wherein said dye component is present on said twisted BCF yarn
prior to tufting the
BCF yarn. The dye component is selected from acid and disperse dye
ingredients. The yarn
can comprise polyamide fiber and/or have polymer components selected from
polyester. The
yarn can be tufted and manufactured into carpet or fabrics.
[0018] In yet another aspect, an untufted, twisted BCF yarn comprising a dye
component, an
anti-soil component, and an optional anti-stain component is disclosed,
wherein said dyeing
component, anti-soil component and optional anti-stain component are present
on said twisted
BCF yarn prior to tufting the BCF yarn. The dye component is selected from
acid and disperse
dye ingredients. The anti-soil component and optional anti-stain component can
be selected
from the compositions disclosed above. The stain blocking component is
optionally present at
an amount on weight of fiber of about 0.5 to about 40 ppm elemental sulfur
content. The anti-
soil component is present at an amount on weight of fiber from about 100 ppm
to about 1000
ppm elemental fluorine content. The yarn can comprise polyamide fiber and/or
have polymer
components selected from polyester. The yarn can be tufted and manufactured
into carpet or
fabrics.
[0019] In yet a further aspect, a process for manufacturing carpet is
disclosed comprising
providing an untufted, twisted BCF yarn comprising a dye component, an
optional stain blocker
component, and an anti-soil component, tufting said BCF yarn, and weaving into
said carpet.
Because of the dye and performance enhancing components present on the BCF
yarn prior to
tufting and weaving, there is no need to process the finished carpet by dyeing
or treating with an
acidified stain blocker composition and an anti-soil composition under the
current state of the art
processes.
[0020] In yet even another aspect, a system for applying a dye composition to
twisted BCF
fiber is disclosed. The system comprises: (a) a first yarn take-up device that
transmits a single
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yarn member made from at least two individual yarn members; (b) a dye
composition applicator
disposed downstream of said yarn take-up device that applies said dye
composition to said
single yarn member; and (c) a second yarn take-up device that receives a dyed
single yarn
member. The dyeing composition can be comprised of acid dye or disperse dye
ingredients.
[0021] In yet even a further aspect, a system for applying a dye composition
and at least one
performance enhancing composition to twisted BCF fiber is disclosed. The
system comprises:
(a) a first yarn take-up device that transmits a single yarn member made from
at least two
individual yarn members; (b) a dye composition applicator disposed downstream
of said yarn
take-up device that applies said dye composition to said single yarn member;
(c) an optional
anti-stain component applicator disposed downstream of said dye composition
applicator that
applies anti-stain composition to said single yarn member; (d) an anti-soil
applicator disposed
downstream of said dye composition applicator that applies anti-soil
composition to said single
yarn member; and (d) a second yarn take-up device that receives a dyed single
yarn member.
The dyeing composition can be comprised of acid dye or disperse dye
ingredients. The anti-
stain composition can be comprised of species having acidic moieties which
associate with
polymer amine end groups and protect them from staining by acidic dye stains.
The anti-soil
composition can be comprised of a high specific surface energy chemical or
other material, for
example a fluorochemical that imparts high specific surface energy properties
such as high
contact angles for water and oil, or even a non-fluorochemical particulate
material having similar
properties. The anti-soil composition can further comprise an anti-stain
component.
DEFINITIONS .
[0022] While mostly familiar to those versed in the art, the following
definitions are provided in
the interest of clarity.
[0023] OWF (On weight of fiber): The amount of chemistry that was applied as a
% of weight
of fiber.
[0024] WPU (Wet pick-up): The amount of water and solvent that was applied on
carpet
before drying off the carpet, expressed as a % of weight of fiber.
DETAILED DESCRIPTION OF THE INVENTION
[0025] A process for treating twisted BCF yarn is disclosed comprising
contacting the BCF
yarn with a dye composition while said yarn is in motion and prior to
contacting and winding the
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yarn onto a take-up reel or winder to create a yarn package or cake. The
process can also
include contacting the BCF yarn with one or more performance enhancing
compositions
comprising stain blockers and anti-soil compositions. The dye composition
comprises a dye
component and is adapted to be continuously applied onto twisted BCF yarn at
10 to 100 ypm,
preferably, 30 to 80 ypm. The stain blocker composition comprises an anti-
stain component
and is adapted to be continuously applied onto twisted BCF yarn at a wet pick-
up of 10 to 50%,
preferably 15 to 30%. The anti-soil composition comprises an anti-soil
component and is
adapted to be continuously applied onto twisted BCF yarn at a wet pick-up of
between about 5
wt.% and about 50 wt.%., including between about 10 wt.% and about 30 wt%,
about 20 wt.%
to about 30 wt.%, and about 10 wt.% to about 20 wt.%. The twisted BCF yarn can
be optionally
heat set after contacting the yarn with the dye composition and the one or
more performance
enhancing compositions. Heat setting temperatures can range from about 125 C
to about
200 C, including from about 160 C to about 195 C. Heat setting dwell times can
range from
about 0.5 to about 4 minutes, including from about 0.5 to about 3 minute and
from about 0.5 to
about 1 minute.
[0026] Dye components for use in the disclosed dye compositions are acid dyes
or disperse
dyes. Acid dye components are well known to those skilled in the art and are
water-soluble
ionic species containing one or more organic chromophore moieties. Acid dyes
are typically
provided in powder form and different acid dyes can be used in combinations to
arrive at a
precisely defined color choice depending on process conditions such as the use
rate of each
selected dye component, the use rate of the one or more acid auxiliaries
employed, and the
residence time of the substrate in the dyeing zone. Examples of suitable acid
dye compositions
are Orange 3G, Red 2B and Blue 4R. Disperse dye components are likewise well
known to
those skilled in the art and are water-insoluble nonionic species containing
one or more organic
chromophore moieties. Disperse dyes are either provided in paste form in
combination with a
dispersing agent or in powder form. Different disperse dyes can be used in
combinations to
arrive at a precisely defined color choice depending on process conditions
such as the use rate
of each selected disperse dye component, the specific dispersing agent or
agents employed,
and the residence time of the substrate in the dyeing zone. Examples of
suitable disperse dye
compositions are Disperse Red 60, Disperse Yellow 86 and Disperse Violet 33.
[0027] Anti-stain components for use in the disclosed stain blocker
compositions have a
component bearing an acidic moiety which associates with polymer amine end
groups and
protects them from staining by acidic dye stains. The general category of
chemicals suitable to
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the process of the instant invention can comprise any chemical that blocks
positively charged
dye sites. Stain blockers are available in various forms such as syntans,
sulfonated novolacs,
sulfonated aromatic aldehyde condensation products (SACs) and/or reaction
products of
formaldehyde, phenolics, substituted phenolics, thiophenolics, sulfones,
substituted sulfones,
polymers or copolymers of olefins, branched olefins, cyclic olefins,
sulfonated olefins, acrylates,
methacrylates, maleic anyhydride, and organosulfonic acids. They are usually
made by
reacting formaldehyde, phenol, polymethacrylic acid, maleic anyhydride, and
sulfonic acid
depending on specific chemistry. Further, the stain blocker is typically water
soluble and
generally penetrates the fiber while the anti-soil, usually a fluorochemical,
is a non-water soluble
dispersion that coats the surface of fiber.
[0028] Examples of stain blockers include, but are not limited to: phenol
formaldehyde
polymers or copolymers such as CEASESTAIN and STAINAWAY (from American
Emulsions
Company, Inc., Dalton, Ga.), MESITOL (from Bayer Corporation, Rock Hill,
N.C.), ERIONAL
(from Ciba Corporation, Greensboro, N.C.), INTRATEX (from Crompton & Knowles
Colors, Inc.,
Charlotte, N.C.), STAINKLEER (from Dyetech, Inc., Dalton, Ga.), LANOSTAIN
(from Lenmar
Chemical Corporation, Dalton, Ga.), and SR-300, SR-400, and SR-500 (from E. I.
du Pont de
Nemours and Company, Wilmington, Del.); polymers of methacrylic acid such as
the
SCOTCHGARD FX series carpet protectors (from 3M Company, St. Paul Minn.);
sulfonated
fatty acids from Rockland React-Rite, Inc., Rockmart, Ga); and stain resist
chemistries from
ArrowStar LLC, Dalton and Tri-Tex, Canada.
[0029] Anti-soil components for use in the disclosed anti-soil compositions
impart high
specific surface energy properties such as high contact angles for water and
oil (e.g. water and
oil "beads up" on surfaces treated by it). The anti-soil component can
comprise a fluorochemical
dispersion, which dispersion may be predominantly either cationic or anionic,
including those
selected from the group consisting of fluorochemical allophanates,
fluorochemical polyacrylates,
fluorochemical urethanes, fluorochemical carbodiimides, fluorochemical
guanidines, non-
telomeric fluorochemicals, and fluorochemicals incorporating C2 to C8
chemistries.
Alternatively, the fluorochemical can have one or more monomeric repeat units
hearing less
than or equal to eight fluorinated carbons, including less than or equal to
six fluorinated carbons.
Example fluorochemical anti-soil components include: DuPont TLF 10816 and
10894; Daikin
TG 2511, and DuPont Capstone RCP. Non-fluorinated anti-soil components can
include:
silicones, silsesquioxanes and silane-modified particulates, organosilane-
modified particulates
and alkylated particulates, anionic non-fluorinated surfactants and anionic
hydrotrope non-
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fluorinated surfactants, including sulfonates, sulfates, phosphates and
carboxylates. (See U.S.
Patent No. 6,824,854, herein incorporated by reference).
[0030] The dye composition is adapted to contact the twisted BCF yarn while it
is in motion
and prior to contacting the take-up reel or winder. Further, the dye
composition can be at a
neutral pH (e.g. 4 to 9, including 5.5 to 7.5) because the yarn can be
optionally heat set after
application of the composition. The process foregoes the need for harsh low pH
chemicals;
deionized water is suitable for use in the disclosed process.
[0031] The stain blocker composition is adapted to contact the twisted BCF
yarn while it is in
motion and prior to contacting the take-up reel or winder. Further, the stain
blocker composition
can be at a neutral pH (e.g. 6 to 8) because the yarn can be optionally heat
set after application
of the composition. The process foregoes the need for harsh low pH chemicals.
[0032] The anti-soil composition is adapted to contact the twisted BCF yarn
while it is in
motion and prior to contacting the take-up reel or winder. Further, the anti-
soil composition can
be at a neutral pH (e.g. 6 to 8) because the yarn can be optionally heat set
after application of
the composition. The process foregoes the need for harsh low pH chemicals.
[0033] The contacting can be performed by any suitable device that applies wet
ingredients to
a dry substrate, including, but not limited to: applicator pad, nip rollers,
wet-wick, dip-tank,
sprayer, and mister.
[0034] Another option is to transport dye solution or other treatment to the
yarn using one or
more rotating rolls covered with wicks. Here, the yarn may contact one roll or
pass between two
or more rotating rolls. The wicks on the surface of the rolls may be supplied
with the treatment
by one or more radially oriented capillaries extending from the inside to the
outer surface of the
cylindrical roll. The wicks may be located in a portion of of the surface or
be distributed evenly
throughout the surface. Where treatment to a localized portion of the yarn
length is desired, a
roll with a portion of wicks will be selected. Where treatment is desired
along the entire length
of the yarn, a roll with the wicks evenly distributed throughout the surface
will be selected.
[0035] To control the amount of dye solution or other treatment that contacts
the yarn is
metered by the use of a pump. This permits precise application of the dye or
chemical
treatment to the desired amount. The amount may be varied over the length of
the yarn.
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[0036] Further, multiple rolls can be used in series. For example, one roll
can apply a first
color onto one side of the moving yarn and another roll to apply a second
color onto the other
side of the yarn to create a unique two color yarn. Further, two sets of nip
rolls can be used.
The first set can apply the primary color and the second set can apply a
second color or
performance enhancing chemical onto the yarn. Any combination of the above
options can be
used to make yarn with multiple colors, color depth and with various
performance chemicals.
[0037] The wet pick-up of the anti-soil composition is between about 5 wt.%
and about 50
wt.%., including between about 10 wt.% and about 30 wt%, about 20 wt.% to
about 30 wt.%,
and about 10 wt.% to about 20 wt.%. The resulting twisted BCF yarn, if a
fluorine based anti-
soil component is used, can have an on weight of fiber from about 100 ppm to
about 1000 ppm
elemental fluorine, including from about 100 to about 500 ppm elemental
fluorine, from about
200 to about 400 ppm, and from about 100 ppm to about 300 ppm elemental
fluorine.
[0038] The wet pick-up of the stain blocker composition is present on weight
of fiber from
about 500 ppm to about 4%, including from about 1000 ppm to about 3%, from
about 0.5% to
about 2%, and from about 0.5% to about 1%. Common stain blockers use
sulfonated moieties
as part of the chemistry, which results in the presence of sulfur on the
treated fiber. The sulfur
content can range from about 50 ppm with 5% stain blocker to about 1 ppm with
0.1% stain
blocker on weight of fiber. Thus, based on the above stain blocker
concentrations, the sulfur
content on weight of fiber will range 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. Sulfur content can be determined by x-ray diffraction or other methods.
[0039] The performance enhancing compositions can further comprise one or more
components selected from the group consisting of: odor control agents, anti-
microbial agents,
anti-fungal agents, fragrance agents, bleach resist agents, softeners, and UV
stabilizers.
[0040] The twisted BCF yarn can be 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, its
copolymers, and blends
thereof. Further, the twisted BCF yarn can also have additional polymer
components, such as
polyester. The additional polymer components can be incorporated with the
polyamide (by
melt-blend or co-polymerization) prior to making a polyamide fiber (e.g. a
polyamide/polyester
fiber), or can be stand-alone fibers that are twisted with the polyamide
fibers to make the twisted
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BCF yarn. However, cationic dyeable nylon, polyester, and acrylic fiber may
also be used either
together or exclusively.
[0041] 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,
a stain blocker is
excluded from the process, further streamlining and reducing costs and
environmental exposure
of these chemicals. A suitable cationic dyeable nylon may be any of the nylon
compositions
mentioned above, such as nylon 6 or nylon 66, that has been modified with
sulfoisophthalic
acid, sodium salt as a co-monomer, such as 5-sulfoisophthalic acid.
[0042] As stated above, the BCF yarn can be manufactured with polyamide and /
or polyester
polymer components. An unexpected benefit of the disclosed process has been
discovered in
that, whereas a small amount of anti-soil composition is applied compared to
known exhaust
processes, a high anti-soil component content, such as fluorine, is achieved
on the surface of
the yarn. Further, the anti-soil composition applied in the process of the
disclosed invention can
be either fluorochemical or non-fluorochemical based, or a mixture of
fluorochemical or
fluoropolymer material with non-fluorinated soil resistant materials.
[0043] The disclosed process may be used with yarns that do not require
subsequent dyeing
or performance enhancing chemical treatments, having been dyed and optionally
treated with
one or more performance enhancing compositions prior to twisting. The yarns
can be made by
acid dyed as well as disperse dyed fibers. Yarns suitable for use in the
process may further
comprise inherent stain resistance, whether by base composition as in the case
of polyester, or
by the inclusion of strong acid functionality in the polymer composition of
the yarn, as in the
case of nylon. Use of a dye applicator with the disclosed process eliminates
the need for
subsequent dyeing and enables the creation of colored carpets that improve
inventory flexibility,
improve color options, are stain resistant, and are soil resistant without the
need for dyeing and
performance enhancing chemical applications as practiced under the current
state of the art.
[0044] The twisted BCF yarn made with the various aspects of the disclosed
process, by itself
or blended with non-treated fibers and yarns, can be tufted and manufactured
into carpets or
fabrics.
[0045] The disclosed process can also be advantageously applied in certain
processes where
a styling advantage might be derived from differential dyeing and finishing
after carpet
formation. For example, a soil resistant or stain resistant twisted yarn of
the disclosed invention
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could optionally be tufted into a carpet among untreated yarns prior to
dyeing, thus creating an
aesthetic alternative.
[0046] Alternatively, the disclosed process can be modified to include dye
application,
optional anti-stain application and/or anti-soil application after the twisted
BCF yarn is wound
and prior to heat setting. For example, the twisted BCF yarn is unwound from a
core or
package, contacts the dye applicator, contacts the optional anti-stain
applicator, and contacts
the anti-soil applicator, then goes through a heat setting process to lock in
the yarn twist, dye,
anti-soil, and optional anti-stain.
[0047] Further disclosed is a system for applying a dye composition and one or
more
performance enhancing compositions to the twisted BCF yarn. The system
includes: (a) a first
yarn take-up device that transmits a single yarn member made from at least two
individual yarn
members; (b) a dye composition applicator disposed downstream of said yarn
take-up device
that applies said dye composition to said single yarn member; (c) an optional
anti-stain blocker
applicator disposed downstream of said dye composition applicator that applies
anti-stain
composition to said single yarn member; (d) an anti-soil applicator disposed
downstream of said
dye composition applicator that applies anti-soil composition to said single
yarn member; and
(e) a second yarn take-up device that receives a dyed single yarn member. The
first yarn take-
up device can be a take-up roll or reel that can twist the at least two
individual yarn members
into a single yarn member. Alternatively, the first yarn take-up device can
receive BCF yarn that
has been air twisted. The individual yarn members can be single filaments or
fibers, or yarns
made from a plurality of filaments or fibers. Each applicator can be any
suitable device that
applies wet ingredients to a dry substrate, including, but not limited to:
applicator pad, nip
rollers, wet-wick, dip-tank, sprayer, and mister. The wet pick-up of
composition is between
about 5 wt.% and about 50 wt.%., including between about 10 wt.% and about 30
wt%, about
20 wt.% to about 30 wt.%, and about 10 wt.% to about 20 wt.%. The resulting
twisted BCF
yarn, if a stain blocker is used, is present on weight of fiber from about 500
ppm to about 4%,
including from about 1000 ppm to about 3%, from about 0.5% to about 2%, and
from about
0.5% to about 1%. The resulting twisted BCF yarn, if a fluorine based anti-
soil component is
used, can have an on weight of fiber from about 100 ppm to about 1000 ppm
elemental fluorine,
including from about 100 to about 500 ppm elemental fluorine, from about 200
to about 400
ppm, and from about 100 ppm to about 300 ppm elemental fluorine. The second
yarn take-up
device can be a winder.
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[0048] In a cable twisting process, a creel yarn and a bucket yarn, which is
fed at a spindle
speed of 7000 rpm, pass through an anti-balloon device and onto a take-up
roll. From here, the
twisted yarn is wound up on a winder.
[0049] In one aspect of the disclosed process, a creel yarn and bucket yarn,
which is fed at a
spindle speed of 7000 rpm, pass through anti-balloon device and onto a take-up
roll. A dye
applicator is disposed downstream of take-up roll, which applies a dye
component or other
treatment to the twisted yarn. From here, the twisted and dyed yarn is wound
up on a winder.
[0050] Another aspect of the disclosed process includes two or more treatments
such as both
a dye applicator and anti-stain / anti-soil applicator. In this aspect, a
creel yarn and bucket yarn,
which is fed at a spindle speed of 7000 rpm, pass through an anti-balloon
device and onto a
take-up roll. A dye applicator is disposed downstream of take-up roll, which
applies a first
treatment, namely a dye component to the twisted yarn. An anti-soil / anti-
stain applicator is
disposed downstream of the dye applicator, which applies an anti-soil / anti-
stain component to
the dyed, twisted yarn. From here, the twisted and treated yarn is wound up on
a winder.
[0051] In a suitable heat setting process, cable twisted BCF yarn enters a
false twisting unit,
followed by a coiler or stuffer box, prebulker, and finally a heatset chamber
to produce a heatset
yarn.
[0052] In an aspect of the disclosed process, where the cable twisted BCF yarn
is dyed prior
to heat setting, the cable twisted BCF yarn enters the dye applicator (or
other treatment
applicator), followed by a false twisting unit, a coiler or stuffer box,
prebulker, and finally a
heatset chamber to produce a dyed, heatset yarn.
[0053] The disclosed process is counterintuitive and surprisingly results in
yarn that contains
acceptable dyed and performance enhancement properties when manufactured into
a carpet or
fabric. One would expect that rearranging the process as described above would
fowl up down-
stream carpet manufacturing processes and lead to poor quality carpet. Thus,
the results
reported below are surprising and unexpected.
EXAMPLES
[0054] The following are examples of carpets made from BCF fibers that have
been treated
according to various aspects of the process disclosed above, and similar
fibers with no
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treatment. Selection of alternative dyeing and performance enhancing
components, fibers and
textiles having different surface chemistries will necessitate minor
adjustments to the variables
herein described.
Test Methods
Acid Dye Stain Test.
[0055] Acid dye stain resistance is evaluated using a procedure modified from
the American
Association of Textile Chemists and Colorists (AATCC) Method 175-2003, "Stain
Resistance:
Pile Floor Coverings." 9 wt % of aqueous staining solution is prepared,
according to the
manufacturer's directions, by mixing cherry-flavored KOOL-AID powder
(Kraft/General Foods,
White Plains, N.Y., a powdered drink mix containing, inter alia, FD&C Red No.
40). A carpet
sample (4x6-inch) is placed on a flat non-absorbent surface. A hollow plastic
2-inch (5.1cm)
diameter cup is placed tightly over the carpet sample. Twenty ml of the KOOL-
AID staining
solution is poured into the cup and the solution is allowed to absorb
completely into the carpet
sample. The cup is removed and the stained carpet sample is allowed to sit
undisturbed for 24
hours. Following incubation, the stained sample is rinsed thoroughly under
cold tap water,
excess water is removed by centrifugation, and the sample is dried in air. The
carpet sample
was visually inspected and rated for staining according to the FD&C Red No. 40
Stain Scale
described in AATCC Method 175-2003. Stain resistance is measured using a 1-10
scale. An
undetectable test staining is accorded a value of 10.
Examplel (Comparative)
[0056] Two 920 denier white acid dyeable Nylon 66 BCF made from acid dyeable
polymer
were cable twisted on Volkman at 7000 rpm to form a 6.25 tpi two ply yarn. The
winding speed
was about 50 ypm. The cable twisted yarn as subsequently heatset on Superba
with 129 C
saturated steam. The holdup time in the channel was about 36 seconds. The heat
treated yarn
was converted into a 35 oz per square yard, 1/8 gauge, 22/32" pile height cut
pile carpet and
dyed on a continuous dyer to medium beige color. The finished carpet was
tested for repellence
and acid stain resistance. It was rated to have 1 (failed) on 24 hour stain
test and 0 for both oil
and water repellence.
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Example 2 (inventive)
[0057] Two 997 denier white Nylon 66 BCF made from cationic dyeable polymer
were cable
twisted on Volkman at 7000 rpm to form a 6.25 tpi two ply yarn using the
process described
above. The winding speed was about 50 ypm. A dye applicator was inserted
between the take
up roll and the winder. A 1/2 inch wide, 1.5" thick cotton wick (Wet Wick by
Perperell MA) was
used to apply premet dyes (Yellow 2BRLSM by Greenville Colorants 24
grams/liter, Red B by
huntsman 0.860 grams/liter, Blue 3GL by huntsman 9.1 grams/liter, wetting
agent DOSS by Star
technologies 15 grams/liter, pH 7.1) onto the cable twisted yarn. The cable
twisted yarn went
through the wet wick about 50 ypm. The cable twisted yarn was subsequently
heatset on
Suessen with 200 C dry air. The holdup time in the channel was about 60
seconds. The
heatset yarn was converted into 35 oz/yd, 22/32" pile height on a 1/8 gauge
tufting machine.
Latex and secondary backing were added to the tufted carpet to secure tufts.
The finished
carpet had a light beige color (Minota L 63.34, a 3.26, b 12.56). The finished
carpet was tested
for repellence and stain resistance using (AATCC) Method 175-2003. It was
rated to have 10
for both 24 hour stain and WAQE, but 0 for water and oil repellence.
Example 3 (inventive)
[0058] Two 997 denier white Nylon 66 BCF made from cationic dyeable polymer
were cable
twisted on Volkman at 7000 rpm to form a 6.25 tpi two ply yarn. The winding
speed was about
50 ypm. The cable twisted yarn was heatset on Suessen with 200 C dry air. Two
color wicking
stations arranged in series were inserted between the creel and the false
twisting unit. A 1/2"
wide, 1.5" thick cotton wick was used in each wicking station to apply premet
dyes (Huntsman
Yellow 3RL 5.31 g/I, Red B 1.14 g/I, Blue 3GL 1.53 WI, wetting agent Doss 15
g/I, pH 8.5) onto
the cable twisted yarn. The processing speed was about 350 ypm. The holdup
time inside the
heatset channel was about 60 seconds. The heatset yarn was converted into 35
oz, 22/32" pile
height cut pile carpet on a 1/8 gauge tufting machine. The finished carpet had
light beige color
(Minota L 70.76, a 2.78, b 10.66) and was tested for repellence and stain
resistance using
(AATCC) Method 175-2003. It was rated to have 9 for both 24 hour stain and
WAQE, but 1 for
water and 0 for oil repellence.
Example 4 (inventive)
[0059] Two 997 denier white Nylon 66 BCF made from cationic dyeable polymer
were cable
twisted on Volkman at 7000 rpm to form a 6.25 tpi two ply yarn using the
process described
above. The winding speed was about 50 ypm. A dye applicator was inserted
between the take
up roll and the winder. A 0.5" inch wide, 1.5" thick cotton wick (Wet Wick by
Perperell MA) was
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used to apply premet dyes (Yellow 3RL 5.31 g/I, Red B 1.14 WI, Blue 3GL 1.51
WI, wetting
agent Doss 15 WI, pH 8.5) onto the cable twisted yarn. The cable twisted yarn
went through
the wet wick about 50 ypm. The cable twisted yarn was subsequently heatset on
Suessen with
200 C dry air. A wicking unit was inserted between the creel and the false
twisting unit.
Fluoro-chemical (50% A-201 anti-soil chemical) was applied to the cable
twisted yarn through
the wick. The holdup time in the channel was about 60 seconds. The heatset
yarn was
analyzed to have 390 ppm Fluorine. The heatset yarn was converted into 35
oz/yd, 22/32" pile
height on a 1/8 gauge tufting machine. Latex and secondary backing were added
to the tufted
carpet to secure tufts. The finished carpet had a light beige color and was
tested for repellency
and stain resistance using (AATCC) Method 175-2003. It was rated to have 9 for
both 24 hour
and WAQE stain resistance and 3 for water, 4 for oil repellence.
Example 5 (inventive)
[0060] Two 997 denier white Nylon 66 BCF made from cationic dyeable polymer
were cable
twisted on Volkman at 7000 rpm to form a 6.25 tpi two ply yarn using the
process described
above. Two wicking stations arranged in series were inserted between the
take up roll and
the winder. A 1/2" wide, 1.5" thick cotton wick was used in the first wicking
station to apply
premet dyes (Yellow 3RL 5.31 WI, Red B 1.14 g/I, Blue 3GL 1.53 g/I, wetting
agent Doss 15 g/I,
pH 8.5) onto the cable twisted yarn. A 1/2" wide, 1.5" thick cotton wick was
used in the second
station to apply Fluoro chemical (50% A-201) onto the cable twisted yarn. The
processing
speed was about 50 ypm. The cable twisted yarn was heatset on Suessen at 200
C. The
holdup time inside the heatset channel was about 60 seconds. The heatset yarn
was analyzed
to have 170 ppm Fluorine. It was converted into 35 oz, 22/32" pile height cut
pile carpet on a
1/8 gauge tufting machine. The finished carpet had light beige color (Minota L
70.46, a 3.42, b
10.39) and was tested for water/oil repellence and stain resistance using
(AATCC) Method 175-
2003. It was rated to have 9 for 24 hour and WAQE stain resistance, 4 for
water and 5 for oil
repellence.
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Example 6 (inventive)
[0061] A 1245 denier, 64 filament nylon BCF made from cationic dyeable polymer
(Type
294AT) was processed on a rewinding machine. Two wicking stations with W wide,
1" thick
were inserted between the creel and winder. Pre-metalized dyes (Isolan yellow
NW 2.52 g/I,
red S-RL 2.54 WI, blue 3GL 27.57 g/I, pH 5) were used to dye the BCF yarn to
medium blue
color. The winding speed was about 300 yards per minute. The test yarn was
knitted into sock,
treated with steam for two minutes. The treated sock had a medium blue color
(L51.47, a -2.18,
b -2.71)
Example 7 (inventive)
[0062] This example was similar to example 6, except new dye formulation
(Dystar Isolan
yellow NW 23.0 g/I, red S-RL 6.03 WI, black 2S-CP 2.359 g/I, pH 5) was used to
dye 1245-
294AT yarn. The dyed yarn was converted into a 1/8" 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
set the dye. It
had a medium gold color (L 45.30, a 14.26, b 26.59)
Example 8 (inventive)
[0063] Two 1100 denier 6 dpf white dyeable polyester BCF (item WS-1) were
cable twisted
on Volkman cable twisting machine at 6900 rpm to form 5.75tpi two ply yarn
using the process
described in above. The winding speed was about 50 rpm. The cable twisted yarn
was heatset
on Suessen with 185 C dry air. Two color wicking stations arranged in series
were inserted
between the creel and the false twisting unit. A1/2" wide, 1.5" thick cotton
wick was used in each
wicking station to apply disperse dyes (Dianix yellow E-3GE 23.73 WI, red E-FB
13.74 g/I, blue
ER-AM 6.16 g/I by Dystar, Techwet Spmia 5 g/I by Dyetech Inc. pH 5.0) onto the
moving cable
twisted yarn. The processing speed was about 350 ypm. The holdup time inside
the heatset
channel was about 60 seconds. The heatset yarn was converted into 45 oz,
22/32" pile height
cut pile carpet on a 1/8 gauge tufting machine. The finished carpet had a
medium
brown color (Minota L44.83, a 7.68, b17.11).
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