Note: Descriptions are shown in the official language in which they were submitted.
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HIGH WEAR RESILIENT SOFT YARN
BACKGROUND
[0001] Filaments having a low denier per filament are soft
but are more prone to
breaking. Filaments having a higher denier per filament are more durable, but
they are
not as soft as filaments having a lower denier per filament. Thus, there is a
need in the art
for a yarn that provides durability with softness.
BRIEF SUMMARY
[0002] According to a first aspect, a method of forming a
bulked continuous
filament (BCF) yarn comprises: (1) providing N molten streams of polymer,
wherein N is
an integer and is greater than or equal to 1; (2) providing M spinnerets,
wherein M is an
integer and is greater than or equal to one; (3) spinning the N molten streams
of polymer
through the M spinnerets, wherein at least a first group of filaments and a
second group of
filaments are spun through the M spinnerets, the first group of filaments each
having a first
average denier per filament along a length of the filaments and the second
group of
filaments each having a second average denier per filament along a length of
the filaments,
the first and second average denier per filament being different; (4)
combining the
filaments from the M spinnerets together; and (5) texturizing the spun
filaments.
[0003] In some implementations, the method further includes
winding the BCF
yarn after the spun filaments are texturized.
[0004] In some implementations, spinning the N molten
streams of polymer
through M spinnerets consists of spinning a first group of the plurality of
filaments having
a first average denier per filament and a second group of the plurality of
filaments having a
second average denier per filament, the first average denier per filament and
the second
average denier per filament being different.
[0005] In some implementations, the average denier per
filament of the first group
of filaments and the average denier per filament of the second group of
filaments vary less
than 10% along the lengths of the filaments.
[0006] In some implementations, the average denier per
filament of the first group
of filaments and the average denier per filament of the second group of
filaments vary 5%
or less along the lengths of the filaments.
[0007] In some implementations, each filament in the first
group of filaments and
the second group of filaments have a wavelike axial cross-sectional shape
along the
lengths of the filaments.
[0008] In some implementations, the first average denier per
filament is greater
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than the second average denier per filament.
[0009] In some implementations, the average denier per
filament of the first group
of filaments is at least 1.5 times larger than the average denier per filament
of the second
group of filaments.
[0010] In some implementations, the first group of filaments
are between 2% and
33% of a total number of filaments of the BCF yarn.
[0011] In some implementations, a total number of filaments
of the BCF yarn is
between 50 and 400.
[0012] In some implementations, the N molten streams of
polymer are extruded
from one extruder.
[0013] In some implementations, a radial cross-sectional
shape of each of the
filaments in the first group is the same as a radial cross-sectional shape of'
each of the
filaments in the second group.
[0014] In some implementations, a radial cross-sectional
shape of each of the
filaments in the first group is different from a radial cross-sectional shape
of each of the
filaments in the second group.
[0015] In some implementations, the N molten streams of
polymer includes a
single polymer.
[0016] In some implementations, M equals one, and the
spinneret defines a first
set of openings having a first diameter and a second set of openings having a
second
diameter, wherein the first diameter and the second diameter are different.
[0017] In some implementations, M is greater than one, and
wherein a first
spinneret defines a set of openings have a first diameter, and a second
spinneret defines a
set of openings having a second diameter, wherein the first diameter and the
second
diameter are different.
[0018] In some implementations, the spun filaments are
randomly texturized.
[0019] According to a second aspect, a bulked continuous
filament (BCF) yarn
comprises a plurality of filaments, each filament having an average denier
along its length,
the plurality of filaments comprising a first group of a plurality of
filaments having a first
average denier per filament, and a second group of a plurality of filaments
having a second
average denier per filament, the first average denier per filament and the
second average
denier per filament being different.
[0020] In some implementations, the average deniers of the
filaments in the BCF
yarn vary between 2 denier per filament and 25 denier per filament.
[0021] In some implementations, the first average denier per
filament and the
second average denier per filament vary less than 10% along the lengths of the
filaments.
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[0022] In some implementations, the average denier per
filament of the first group
of filaments and the average denier per filament of the second group of
filaments vary 5%
or less along the lengths of the filaments.
[0023] In some implementations, the plurality of filaments
comprising the first
group of the plurality of filaments and the plurality of filaments comprising
the second
group of the plurality of filaments have a wavelike axial cross-sectional
shape along the
lengths of the filaments.
[0024] In some implementations, the first average denier per
filament is greater
than the second average denier per filament.
[0025] In some implementations, the first average denier per
filament is at least
1.5 times larger than the second average denier per filament.
[0026] In some implementations, the first group of filaments
are between 2% and
33% of a total number of filaments of the BCF yarn.
[0027] In some implementations, a total number of filaments
of the BCF yam is
between 50 and 400.
[0028] In some implementations, the filaments have the same
radial cross-
sectional shape.
[0029] In some implementations, the first group of the
plurality of filaments has a
first radial cross-sectional shape, and the second group of the plurality of
filaments has a
second radial cross-sectional shape, wherein the first and the second radial
cross-sectional
shapes are different.
[0030] In some implementations, all of the filaments are
spun from one molten
polymer stream.
[0031] In a third aspect, a carpet has a pile formed from a
BCF yam, and the BCF
yarn comprises a plurality of filaments, wherein each filament has an average
denier along
its length, the plurality of filaments comprising a first group of a plurality
of filaments
having a first average denier per filament, and a second group of a plurality
of filaments
having a second average denier per filament, the first average denier per
filament and the
second average denier per filament being different.
[0032] In some implementations, the average deniers of the
filaments in the BCF
yarn vary between 2 denier per filament and 25 denier per filament.
[0033] In some implementations, the first average denier per
filament and the
second average denier per filament vary less than 10% along the lengths of the
filaments.
[0034] In some implementations, the average denier per
filament of the first group
of filaments and the average denier per filament of the second group of
filaments vary 5%
or less along the lengths of the filaments.
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[0035] In some implementations, the plurality of filaments
comprising the first
group of the plurality of filaments and the plurality of filaments comprising
the second
group of the plurality of filaments have a wavelike axial cross-sectional
shape along the
lengths of the filaments.
[0036] In some implementations, the first average denier per
filament is greater
than the second average denier per filament.
[0037] In some implementations, the first average denier per
filament is at least
1.5 times larger than the second average denier per filament.
[0038] In some implementations, the first group of filaments
are between 2% and
33% of a total number of filaments of the BCF yarn.
[0039] In some implementations, a total number of filaments
of the BCF yam is
between 50 and 400.
[0040] In some implementations, the filaments have the same
radial cross-
sectional shape.
[0041] In some implementations, the first group of the
plurality of filaments has a
first radial cross-sectional shape, and the second group of the plurality of
filaments has a
second radial cross-sectional shape, wherein the first and the second radial
cross-sectional
shapes are different.
[0042] In some implementations, all of the filaments are
spun from one molten
polymer stream.
BRIEF DESCRIPTION OF DRAWINGS
[0043] Example features and implementations are disclosed in
the accompanying
drawings. However, the present disclosure is not limited to the precise
arrangements and
instrumentalities shown. Similar elements in different implementations are
designated
using the same reference numerals.
[0044] FIG. 1 is schematic diagram of a system for producing
bulked continuous
filament (BCF) yarn, in accordance with one implementation.
[0045] FIG. 2 is a cross-sectional view of the filaments of
a BCF yarn.
[0046] FIG. 3 is schematic diagram of a system for producing
BCF yarn, in
accordance with another implementation.
[0047] FIG. 4 is schematic diagram of a system for producing
BCF yarn, in
accordance with another implementation.
[0048] FIG. 5 is a schematic diagram of a texturizer
according to one
implementation.
[0049] FIG. 6A is a side view of BCF yarn that has been
produced by the
system ofFIG. 1.
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[0050] FIG. 6B is a side view of yarn produced by the
traditional false twist
methodof the prior art.
[0051] FIG. 7 shows BCF yarn produced by the system of FIG.
1 as tufted pile in
a carpet according to one implementation.
[0052] FIG. 8 shows a filament from the first group of
filaments and a filament
from the second group of filaments having a wavelike axial cross-sectional
shape,
according toone implementation.
DETAILED DESCRIPTION
[0053] According to a first aspect, a method of forming a
bulked continuous
filament (BCF) yarn comprises: (I) providing N molten streams of polymer,
wherein N is
an integer and is greater than or equal to 1; (2) providing M spinnerets,
wherein M is an
integer and is greater than or equal to one; (3) spinning the N molten streams
of polymer
through the M spinnerets, wherein at least a first group of filaments and a
second group of
filaments are spun through the M spinnerets, the first group of filaments each
having a first
average denier per filament along a length of the filaments and the second
group of
filaments each having a second average denier per filament along a length of
the filaments,
the first and second average denier per filament being different; (4)
combining the
filaments from the M spinnerets together; and (5) texturizing the spun
filaments. In some
implementations, the filaments are texturizcd randomly.
[0054] According to a second aspect, a BCF yarn including a
plurality of filaments
is provided. Each filament has an average denier along its length. The
plurality of
filaments includes a first group of a plurality of filaments having a first
average denier per
filament and a second group of a plurality of filaments having a second
average denier per
filament. The first average denier per filament and the second average denier
per filament
are different. Clearly such BCF yarn may be obtained, but is not necessarily
obtained,
through the method of forming a BCF yarn of the first aspect. Nevertheless,
the BCF yarn
of the second aspect may show various preferred features similar or equal to
the features
obtained through the method of the first aspect.
[0055] According to a third aspect, a carpet, rug, or carpet
tile (collectively
referred to herein as "carpet") comprising the yarn obtained through the first
aspect and/or
in accordance with the second aspect is provided. Herein this may relate to a
flooring
product with a tufted or woven pile.
[0056] FIGS. 1, 3, and 4 show various implementations of
systems for forming
bulked continuous filament (BCF) yarn. Each system includes at least one
extruder, at
least one pump, a spin pack including at least one spinneret, and a
texturizer. The BCF
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yarn produced by the systems and methods disclosed herein are texturized in
three
dimensions and can be produced at a higher speed than traditional false twist
methods. In
some implementations, the yarn is randomly texturized. The BCF yarn produced
by the
disclosed systems and methods produces a yarn with filaments that are
differently bulked
than with the traditional false twist method. For comparison, FIG. 6A shows a
side view of
BCF yam that has been produced by the methods disclosed herein, and FIG. 6B
shows a
side view of yarn produced by the traditional false twist method. The
resulting BCF yarn
exhibits a softer and more durable yarn than yam produced by the traditional
false twist
method.
[0057]
FIG. 1 shows a system 100 including one extruder 110, one pump 120, a
spin pack 140 including one spinneret 152, and a texturizer 180. The extruder
110
provides a molten stream of polymer 190 to the pump 120. The pump 120 has a
pump inlet
122 and a pump outlet 124. The pump inlet 122 is in fluid communication with
the
extruder 110, and the pump outlet 124 is in communication with the spinneret
152 of the
spin pack 140. The pump 120 creates a pressure differential across the pump
inlet 122 and
the pump outlet 124 to cause the molten stream of polymer 190 to flow from the
extruder
110, through a plurality of openings 162, 164 defined by the spinneret 152 of
the spin pack
140. As the molten stream of polymer 190 flows out of the plurality of
openings 162, 164
defined by the spinneret 152, the molten stream of polymer 190 is spun into a
plurality of
filaments 172, 174.
The filaments 172, 174 are then quenched by a quencher and
combined and texturized by the texturizer 180, forming the BCF yarn 199. The
system 100
in FIG. 1 produces the yarn 199 (extrusion, drawing, and texturing)
continuously, but in
other implementations, the yarn may be extruded and taken up in one step and
is then later
unwound, drawn, and textured in another step, or extruded, drawn, and textured
in one or
more operations.
[0058]
The molten stream of polymer 190 can include any thermoplastic polymer
material, for example, poly-amide (PA) such as PA6, PA6.6, PA6.10, polyether
sulfone
(PES) such as PTT, polybutylene terephthalate (PBT), polyethylene
terephthalate (PET) or
recycled PET, polyolefin (PO) such as polyethylene (PE), or polypropylene
(PP).
[0059]
The spinneret 152 shown in FIG. 1 defines a first set of openings 162 and a
second set of openings 164. The first set of openings 162 are sized to produce
a first group
of filaments 172 having a first average denier per filament along a length of
the filaments,
and the second set of openings 164 are sized to produce a second group of
filaments 174
having a second average denier per filament along a length of the filaments.
FIG. 2 shows
a cross-section of the filaments 172, 174 spun by the spinneret 152 that
comprise the BCF
yam 199 shown in FIG. 1. As seen in FIG. 2, filaments spun through the first
set of
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openings 162 have a first average denier per filament, and the first average
denier per
filament is greater than the second average denier per filament of filaments
spun through
the second set of openings 164. However, in other implementations, the first
average
denier per filament is less than the second average denier per filament. In
some
implementations, the spinneret defines more than two groups of openings, and
each set of
openings produces a group of filaments having an average denier per filament
that is
different than the average denier per filament for the group(s) of filaments
produced by the
other set(s) of openings.
[0060]
The first set of openings 162 defined by the spinneret 152 are shaped
such that the first group of filaments 172 exiting the first set of openings
162 have a
first radial cross-sectional shape, and the second set of openings 164 defined
by the
spinneret 152 areshaped such that the second group of filaments 174 exiting
the second
set of openings 164 have a second radial cross-sectional shape. The first
group of
filaments 172 and second group of filaments 174 produced by the first set of
openings
162 and second set of openings 164, respectively, produce the same cross-
sectional shape,
as shown in FIG. 2. The radial cross-sectional shape shown in FIG. 2 is
trilobal, but
the radial cross-sectional shape in other implementations may be circular,
oval, fox, or
other suitable radial cross-sectional shape. And, in other implementations,
the first group
of filaments and second group of filaments produced by the first set of
openings and
second set of openings, respectively, produce different radial cross-sectional
shapes. In
addition, the filaments may be solid or define at least one hollow void.
[0061]
The spun filaments 172, 174 are then combined to form a BCF yarn 199
and are texturized by the texturizer 180 to texturize the BCF yarn 199.
Texturizing
may result in the length of the filament shrinking by 3-25%, for example.
Other aspects
measuring the extent to which the filaments arc texturized include crimping,
total
recovery, bulking, and shrinkage. The texturizer 180, which is shown in FIG.
5, includes a
slotted tube 182, a plurality of jets 188, and a heat source 192. The slotted
tube 182
defines an inner surface 184, and a plurality of fins 186 extending radially
inward from
the inner surface 184. The plurality of jets 188 introduces air jets that
cause the filaments
172, 174 to flow through the slotted tube 182. The size of the slotted tube
182 and the fins
186 extending from the inner surface 184 of the slotted tube 182 form a
sufficiently
narrow passage such that the filaments 172, 174 do not pass straight through
the slotted
tube 182, but are, e.g., randomly, texturized within the slotted tube 182 due
to the pushing
of the filaments 172, 174 by the plurality of jets 188 upstream of the slotted
tube 182. As
the filaments 172, 174 are forced through the slotted tube 182 by the air jets
created by the
plurality of jets 188, the filaments 172, 174 are heated by the heat source
192. The heat
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and the dynamics of the filaments 172, 174 passing through the slotted tube
182
texturize the resulting BCF yarn 199, causing it to shrink in length. The
number of fins
186 extending from the inner surface 184 of the slotted tube 182 can be varied
to change
the ratio of surface area to volume of the slottedtube 182. An increase in the
ratio of
surface area to volume of the slotted tube 182 increases the amount of surface
area
with which the filaments 172, 174 come in contact, which affects the overall
appearance
of the texturized yarn 199. The heat source 192 shownin FIG. 5 is a heater
that creates
hot air, but in other implementations, the heat source is a steam generator.
After the spun
filaments 172, 174 have been texturized, the BCF yarn 199is wound. Thus, the
filaments
172, 174 are processed in a single stage, which increases the speed of
manufacturing and
creates a softer yarn. in contrast, two stage manufacturing for yarns includes
a first
stage of extruding, finishing, and spooling the filaments then a second stage
of drawing,
texturing, and winding the filaments.
[0062] FIG. 3 shows another implementation of a system 300
including one
extruder 310, three pumps 320a, 320b, 320c, a spin pack 340 including three
spinnerets
352, 354, 356, and a texturizer 380. The extruder 310 provides a molten stream
of polymer
390 to each of the three pumps 320. The pumps 320a, 320b, 320c each have a
pump inlet
322 and a pump outlet 324. The pump inlet 322 of each pump 320a, 320b, 320c is
in
communication with the extruder 310, and the pump outlet 324 each pump 320a,
320b,
320c is in communication with one of the three spinnerets 352, 354, 356 of the
spin pack
340. The pumps 320a, 320b, 320c create a pressure differential across the pump
inlets
322 and the pump outlets 324 to cause the molten stream of polymer 390 to flow
from the
extruder 310, through a plurality of openings 362, 364, 366 defined by the
spinnerets 352,
354, 356 of the spin pack 340. As the molten stream of polymer 390 flows out
of the
plurality of openings 362, 364, 366 defined by the spinnerets 352, 354, 356,
the molten
stream of polymer 390 is spun into a plurality of filaments 372, 374, 376. The
filaments
372, 374, 376 spun from each of the three spinnerets 352, 354, 356 are then
combined and
texturized by the texturizer 380 to texturize the resulting BCF yarn 399.
Because the
system 300 shown in FIG. 3 includes three pumps 320a, 320b, 320c, the output
of each of
the pumps 320a, 320b, 320c to each of the spinnerets 352, 354, 356 in the spin
pack 340
can be adjusted as necessary to change the denier of the filaments 372, 374.
376 that are
output by the spinnerets 352, 354, 356.
[0063] The molten stream of polymer 390 can include any
thermoplastic polymer
material, for example, polyamide (PA) such as PA6, PA6.6, PA6.10, polyether
sulfone
(PES) such as PTT, polybutylene terephthalate (PBT), polyethylene
terephthalate (PET) or
recycled PET, polyolefin (PO) such as polyethylene (PE), or polypropylene
(PP).
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[0064] The spin pack 340 shown in FIG. 3 includes a first
spinneret 352, a second
spinneret 354, and a third spinneret 356. The first spinneret 352 defines a
first set of
openings 362, the second spinneret 354 defines a second set of openings 364,
and the third
spinneret 356 defines a third set of openings 366. The first set of openings
362 are sized to
produce a first group of filaments 372 having a first average denier per
filament along a
length of the filaments, the second set of openings 364 are sized to produce a
second group
of filaments 374 having a second average denier per filament along a length of
the
filaments, and the third set of openings 366 are sized to produce a third
group of filaments
376 having a third average denier per filament along a length of the
filaments. The first
average denier per filament produced by the first set of openings 362 is
greater than the
second average denier per filament produced by the second set of openings 364,
and the
second average denier per filament produced by the second set of openings 364
is greater
than the third average denier per filament produced by the third set of
openings 366.
However, in other implementations, the first average denier per filament,
second average
denier per filament, and third average denier per filament are different sizes
in relation to
each other. In other implementations, the first average denier per filament,
second average
denier per filament, or third average denier per filament is different from
one of the other
average deniers per filament, but two of the average deniers per filament can
be the same.
In some implementations, the spinnerets define more than one set of openings,
and each
set of openings produces a group of filaments having an average denier per
filament that is
different than the group of filaments produced by any other set of openings.
[0065] The first set of openings 362 defined by the first
spinneret 352 are shaped
such that the first group of filaments 372 exiting the first set of openings
362 have a first
radial cross-sectional shape, the second set of openings 364 defined by the
second
spinneret 354 are shaped such that the second group of filaments 374 exiting
the second
set of openings 364 have a second radial cross-sectional shape, and the third
set of
openings 366 defined by the third spinneret 356 are shaped such that the third
group of
filaments 376 exiting the third set of openings 366 have a third radial cross-
sectional
shape. The first group of filaments 372, second group of filaments 374, and
third group of
filaments 376 spun through the first set of openings 362, second set of
openings 364, and
third set of openings 366, respectively, produce the same cross-sectional
shape. However,
in other implementations, the first group of filaments, second group of
filaments, and third
group of filaments have different cross-sectional shapes.
[0066] The filaments 372, 374, 376 spun by each of the
spinnerets 352, 354, 356
are then combined to form a BCF yarn 399 and are texturized by the texturizer
180 shown
in FIG. 5. After the spun filaments 372, 374, 376 have been texturized, the
BCF yam 399
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is wound. Thus, the filaments 372, 374, 376 are processed in a single stage,
which
increases the speed of manufacturing and creates a softer yarn. In contrast,
two stage
manufacturing for yarns includes a first stage of extruding, finishing, and
spooling the
filaments then a second stage of drawing, texturing, and winding the
filaments.
[0067] FIG. 4 shows another implementation of a system 400
including three
extruders 410a, 4 lob, 410c, three pumps 420a, 420b, 420c, a spin pack 440
including three
spinnerets 452, 454, 456, and a texturizer 480. Each of the three extruders
410a, 410b,
410e provide a molten stream of polymer 490a, 490b, 490c to one of the three
pumps
420a, 420b, 420c. The pumps 420a, 420b, 420c each have a pump inlet 422 and a
pump
outlet 424. The pump inlet 422 of each pump 420a, 420b, 420c is in
communication with
one of the extruders 210, and the pump outlet 424 of each pump 420a, 420b,
420c is in
communication with one of the three spinnerets 452,454, 456 of the spin pack
440. The
pumps 420a, 420b, 420c create a pressure differential across the pump inlets
422 and the
pump outlets 424 to cause the molten stream of polymer 490a, 490b, 490c to
flow from
each of the extruders 410a, 410b, 410c, through a plurality of openings 462,
464, 466
defined by the spinnerets 452, 454, 456 of the spin pack 440. As the molten
stream of
polymer 490a, 490b, 490c flows out of the plurality of openings 462, 464, 466
defined by
the spinnerets 452, 454, 456, the molten stream of polymer 490a, 490b, 490c is
spun into a
plurality of filaments 472, 474, 476. The filaments 472, 474, 476 from each of
the three
spinnerets 452, 454, 456 are then combined and texturized by the texturizer
480. Each of
the three extruders 410a, 410b, 410e can contain a molten stream of a
different polymer
490a, 490b, 490c than, or the same polymer as, any of the other extruders
410a, 410b,
410c. Because the system 400 shown in FIG_ 4 includes three pumps 420a, 420b,
420c, the
pressure provided by each of the pumps 420a, 420b. 420c to each of the
spinnerets 452,
454, 456 in the spin pack 440 can be adjusted to as necessary to cause an even
flowrate of
the molten stream of polymer 490a, 490b, 490e through spinnerets 452, 454,
456, and
thus, an even flowrate of filaments 472, 474, 476.
[0068] The molten stream of polymer 490a, 490b, 490e can
include any
thermoplastic polymer material, for example, polyamide (PA) such as PA6,
PA6.6,
PA6.10, polyether sulfone (PES) such as PTT, polybutylene terephthalate (PBT),
polyethylene terephthalate (PET) or recycled PET, polyolefin (PO) such as
polyethylene
(PE), or polypropylene (PP).
[0069] The spin pack 440 shown in FIG. 4 includes a first
spinneret 452, a second
spinneret 454, and a third spinneret 456. The first spinneret 452 defines a
first set of
openings 462, the second spinneret 454 defines a second set of openings 464,
and the third
spinneret 456 defines a third set of openings 466. The first set of openings
462 are sized to
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produce a first group of filaments 472 having a first average denier per
filament along a
length of the filaments, the second set of openings 464 are sized to produce a
second group
of filaments 474 having a second average denier per filament along a length of
the
filaments, and the third set of openings 466 are sized to produce a third
group of filaments
476 having a third average denier per filament along a length of the
filaments. The first
average denier per filament produced by the first set of openings 462 is
greater than the
second average denier per filament produced by the second set of openings 464,
and the
second average denier per filament produced by the second set of openings 464
is greater
than the third denier per filament produced by the third set of openings 466.
However, in
some implementations, the first average denier per filament, second average
denier per
filament, and third denier per filament are different sizes in relation to
each other. In other
implementations, the first average denier per filament, second average denier
per filament,
or third denier per filament is different from one of the other average
deniers per filament,
but two of the average deniers per filament can be the same. In some
implementations, the
spinnerets define more than one set of openings, and each set of openings
produces a
group of filaments having a denier per filament that is different than the
group of filaments
produced by any other set of openings.
[0070] The first set of openings 462 defined by the first
spinneret 452 are shaped
such that the first group of filaments 472 exiting the first set of openings
462 have a first
radial cross-sectional shape, the second set of openings 464 defined by the
second
spinneret 454 are shaped such that the second group of filaments 474 exiting
the second
set of openings 464 have a second radial cross-sectional shape, and the third
set of
openings 466 defined by the third spinneret 456 are shaped such that the third
group of
filaments 476 exiting the third set of openings 466 have a third radial cross-
sectional
shape. The first group of filaments 472, second group of filaments 474, and
third group of
filaments 476 produced by the first set of openings 462, second set of
openings 464, and
third set of openings 466, respectively, produce the same cross-sectional
shape. However,
in other implementations, the first group of filaments, second group of
filaments, and third
group of filaments produced by the first set of openings, second set of
openings, and third
set of openings, respectively, produce different cross-sectional shapes.
[0071] The filaments 472, 474, 476 spun by each of the
spinnerets 452, 454, 456
are then combined to form a BCF yarn 499 and are texturized by the textarizer
180 shown
in FIG. 5. After the spun filaments 472, 474, 476 have been texturized, the
BCF yarn 499
is wound. Thus, the filaments 472, 474, 476 are processed in a single stage,
which
increases the speed of manufacturing and creates a softer yam. In contrast,
two stage
manufacturing for yarns includes a first stage of extruding, finishing, and
spooling the
filaments then a second stage of drawing, texturing, and winding the
filaments.
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[0072] The implementations of systems shown in FIGS. 1, 3,
and 4 include
different numbers of extruders, pumps, and spinnerets. In other
implementations, the
system can include any number of extruders producing N molten streams of
polymer and
M spinnerets, where N is an integer and is greater than or equal to 1 and M is
an integer
and is greater than or equal to one. In some implementations, the N molten
streams of
polymer are extruded from one extruder, but in other implementations, the N
molten
streams of polymer are extruded from a plurality of extruders. The N molten
streams of
polymer can include a single polymer or different polymers. The N molten
streams of
polymer are spun through the M spinnerets to form groups of filaments. The
filaments
produced by the M spinnerets are combined together and, e.g., randomly,
texturized to
form a BCF yarn.
[0073] In some implementations, M equals one. The one
spinneret defines a first
set of openings having a first diameter and a second set of openings having a
second
diameter that is different than the first diameter. In some implementations, M
is greater
than one. A first spinneret defines a set of openings that have a first
diameter, a second
spinneret defines a set of openings that have a second diameter that is
different than the
first diameter.
[0074] The M spinnerets spin at least a first group of
filaments and a second group
of filaments. The first group of filaments each have a first average denier
per filament
along a length of the filaments, and the second group of filaments each have a
second
average denier per filament along a length of the filaments. The first and
second average
denier per filament are different. In some implementations, the first average
denier per
filament is greater than the second average denier per filament. The radial
cross-sectional
shape of each of the filaments in the first group can be the same as or
different than a
radial cross-sectional shape of each of the filaments in the second group.
[0075] Clearly, the BCF yarn obtained through the method of
the first aspect
described in the figures also shows the features of the second and third
aspects.
[0076] In some implementations of the first, second, and/or
third aspects, the total
number of filaments of the BCF yarn is between 50 and 400, and the first group
of
filaments, which have a larger denier per filament than one or more other
groups of
filaments, are between 2% and 33% of a total number of filaments of the BCF
yarn. In
some implementations, the average deniers of the filaments in the BCF yarn
vary between
2 denier per filament and 25 denier per filament. In some implementations, the
average
denier per filament of the first group of filaments and the average denier per
filament of
the second group of filaments vary less than 10% along the lengths of the
filaments. In
some implementations, the average denier per filament of the first group of
filaments and
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the average denier per filament of the second group of filaments vary less
than 5% along
the lengths of the filaments.
[0077] It is not excluded that the first and/or the second
group would include less
than 2% of the filaments of the yam, or even as few as only 1 filament. For
example, in
some implementations, the BCF yarn obtained through the first, second, and/or
third
aspect contains a plurality of, e.g., up to 50 or 100, groups of filaments of
all different
denier per filament.
[0078] In some implementations, the difference in DPF
between the respective
groups of filaments is such that the filaments of the first group along their
length always
have a denier value that is smaller, or larger as the case may be, than the
denier the
filaments of the second group have along their length. In other words, the
filaments of the
first group, at any radial cross-section, are thicker/thinner, than any
segment along the
length of the filaments of the second group. As aforestated, in some
implementations, the
DPF of each filament is constant along its length and/or varies less than 10%
or less than
5% along its length.
[0079] In some implementations of the first, second, and/or
the third aspect, each
filament in the first group of filaments and/or the second group of filaments
have a
wavelike axial cross-sectional shape along the lengths of the filaments.
Wavelike refers to
a change in the DPF of the filament in different segments along the length of
the filament.
For example, one segment along the length of the filament may have a DPF that
is larger
than the DPF of another segment along the length of the filament. The change
in DPF for
each filament may vary between 10% and 40%, for example. As shown in FIG. 8,
filament
172' from the first group of filaments has a first segment 178 that has a
higher DPF than a
second segment 179 that is axially spaced from and axially adjacent the first
segment 178.
And, filament 174' from the second group of filaments has a first segment 176
that has a
higher DPF than a second segment 177 that is axially spaced from the first
segment 176.
The segment of filament 172' with the smallest DPF (e.g., segment 179 shown in
FIG. 8)
has a higher DPF than the DPF of the segment of filament 174' with the largest
DPF (e.g.,
segment 176).
[0080] In some implementations of the first, second, and/or
the third aspect, the
average denier per filament of the first group of filaments is at least 1.5
times larger than
the average denier per filament of the second group of filaments.
[0081] The BCF yarn is texturized such that the overall
length of the yarn is
reduced by between 3% and 25%, depending on the processing speeds, conditions,
and
desired output of the yarn. For example, a higher percentage of reduction in
length yields a
bulkier yarn. The amount of texturizing is measured by using ASTM D4031-01;
which
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includes heating the BCF yarn and measuring an increase in tension or an
increase in
linear density of the BCF yarn in response to the heating. The heating of the
BCF yarn can
be performed with an oven or with a designated measurement tool, such as a
textured yarn
tester (TYT).
[0082]
In some implementations of the first, second, and/or the third aspect, the
distribution of the filaments of the first and second group in the cross-
section of the yarn is
such that they are equally, or at least more or less equally, distributed, for
example such
that the inner 50% area of the yarn contains not more than 1.25 times (100/G)%
filaments
of a group, where G is the number of groups of filaments having different
denier. Thus,
filaments of the first and second group are present at the outer surface of
the yarn, as well
as in the center of the yarn. The more or less equal distribution leads to a
softer feeling of
the yarn and the carpet containing the yarn.
[0083]
FIG. 7 shows BCF yarn 799 manufactured by the systems and methods
disclosed herein included as the tufted pile 794 in a carpet 796. The BCF yarn
799
includes a first group of filaments 772 and a second group of filaments 774,
and each
filament 772, 774 has an average denier along its length. The first group of
filaments 772
has a first average denier per filament, and the second group of filaments 774
has a second
average denier per filament. The first average denier per filament is larger
than the second
average denier per filament. The filaments in the first group of filaments 772
and the
filaments in the second group of filaments 774 shown in FIG. 7 have the same
radial
cross-sectional shape. However, in other implementations, the first group of
filaments has
a first radial cross-sectional shape, and the second group of filaments has a
second radial
cross-sectional shape that is different than the first cross-sectional shape.
All of the
filaments 772, 774 shown in FIG. 7 are spun from one molten polymer stream,
but in other
implementations, the filaments are spun from two or more molten polymer
streams.
[0084]
In some implementations of the first, second, and/or the third aspect, the
total number of filaments of the BCF yarn is between 50 and 400, and the first
group of
filaments, which have a larger denier per filament than one or more other
groups of
filaments, are between 2% and 33% of a total number of filaments of the BCF
yarn. In
some implementations, the average deniers of the filaments in the BCF yarn
vary between
2 denier per filament and 25 denier per filament. In some implementations, the
average
denier per filament of the first group of filaments and the average denier per
filament of
the second group of filaments vary less than 10% along the lengths of the
filaments. In
some implementations, the average denier per filament of the first group of
filaments and
the average denier per filament of the second group of filaments vary less
than 5% along
the lengths of the filaments. In some implementations, such as described above
in relation
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to FIG. 8, each filament in the first group of filaments and the second group
of filaments
have a wavelike axial cross-sectional shape along the lengths of the
filaments. In some
implementations, the average denier per filament of the first group of
filaments is at least
1.5 times larger than the average denier per filament of the second group of
filaments.
[0085] A number of implementations have been described.
Nevertheless, it will be
understood that various modifications may be made without departing from the
spirit and
scope of the claims. Accordingly, other implementations are within the scope
of the
following claims.
[0086] Certain terminology is used herein for convenience
only and is not to be
taken as a limitation on the present claims. In the drawings, the same
reference numbers
are employed for designating the same elements throughout the several figures.
A number
of examples are provided, nevertheless, it will be understood that various
modifications
can be made without departing from the spirit and scope of the disclosure
herein. As used
in the specification, and in the appended claims, the singular forms "a,"
"an," "the"
include plural referents unless the context clearly dictates otherwise. The
term
-comprising" and variations thereof as used herein is used synonymously with
the term
"including" and variations thereof and are open, non-limiting terms. Although
the terms
comprising" and "including" have been used herein to describe various
implementations,
the terms "consisting essentially of' and "consisting of' can be used in place
of
comprising" and "including" to provide for more specific implementations and
are also
disclosed. As used herein, when a value is given as "between" a first and
second number,
the range includes the first and second numbers.
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