Note: Descriptions are shown in the official language in which they were submitted.
WO 2022/038570 PCT/IB2021/057668
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TWISTED AND HEAT-SET BCF YARN COMPRISING SIDE-BY-SIDE BI-COMPONENT
FILAMENT, METHOD FOR FORMING SUCH YARN AND A FLOOR COVERING MATERIAL
COMPRISING SUCH YARN
FIELD OF THE DISCLOSURE
[0001] The
present disclosure relates to the textile industry, and, more
particularly, to a bulked continuous side-by-side bi-component filament (BCF)
yarn, a method
for making such BCF yarn, and a floor covering material made from such BCF
yarn.
BACKGROUND OF THE DISCLOSURE
[0002]
Continuous filament yarn comprises a group of filaments, wherein each
such filament is made of a polymer material that is extruded as a long fiber.
Such yarn is also
referred to as continuous multi-filament yarn although for the sake of the
present disclosure,
the fact that there are multiple filaments in the respective yarns will be
assumed, where not
specifically mentioned. Continuous filament yarn may be a continuous mono-
component
filament yarn or a continuous bi-component filament yarn. Depending upon the
requirements
and usages, the continuous mono-component filament yarn or the continuous bi-
component
filament yarn are chosen for respective purposes. The continuous bi-component
filament yarn
may be available in various arrangements, such as a sheath-core arrangement
and a side-by-
side arrangement. In the sheath-core arrangement, each filament of the
continuous bi-
component filament yarn includes one of the two polymers forming a core while
the other forms
a sheath. In the side-by-side arrangement, each filament of the continuous bi-
component
filament yarn includes the two polymers arranged side-by-side to each other.
While both types
of continuous hi-component filament yarns are widely used and have specific
requirements in
the textile industry, the present disclosure relates to continuous side-by-
side hi-component
filament yarn and articles made therefrom.
[0003]
The continuous side-by-side bi-component filament yarns arc used for
making various kinds of articles, including, but not limited to, carpets, as
an alternative e.g. to
carpets made using spun yarn comprised of staple fibers. Generally, such
continuous side-by-
side hi-component filament yarns are texturized for increasing bulkiness and
for better wear
resistance and resilience performance, prior to making the carpet therefrom.
However, the
articles, such as, the carpets, made from such continuous side-by-side bi-
component filament
yarns may undergo delamination over time, a degradation process wherein the bi-
component
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polymers begin to separate from one another, particularly, when such carpets
are subject to high
levels of wear and tear, affecting integrity and long-term durability of such
articles.
[0004]
Accordingly, there exists a need to provide such bulk continuous side-
by-side hi-component filament yarns or articles made therefrom that may be
able to withstand
high levels of wear and tear and avoid delamination of hi-components from each
other over the
maximum period of time.
SUMMARY OF THE DISCLOSURE
[0005]
In view of the foregoing disadvantages inherent in the prior art, the
general purpose of the present disclosure is to provide a twisted and heat-set
bulked continuous
side-by-side hi-component filament (BCF) yarn, a method for making such
twisted and heat-
set BCF yarn, and a floor covering material made from such twisted and heat-
set BCF yarn, to
include all advantages of the prior art, and to overcome the drawbacks
inherent in the prior art.
[0006]
Therefore, an object of the present disclosure is to provide such bulk
continuous side-by-side bi-component filament yarns that may be able to
withstand high levels
of wear and tear and avoid delamination of bi-components from each other over
the maximum
period of time.
[0007]
Another object of the present disclosure is to provide a method for
making such bulk continuous side-by-side hi-component filament yarns that may
be able to
withstand high levels of wear and tear and avoid delamination of hi-components
from each
other over the maximum period of time.
[0008]
Yet another object of the present disclosure is to provide a floor
covering
material, such as, carpets that may be able to withstand high levels of wear
and tear and avoid
delamination of hi-components from each other over the maximum period of time.
[0009] In light
of the above objects, in one aspect of the present disclosure, a
twisted and heat-set Bulked Continuous side-by-side bi-component Filament
(BCF) yam is
provided. The BCF yarn may include a plurality of side-by-side bi-component
filaments. Each
side-by-side bi-component filament of the plurality of side-by-side bi-
component filaments
may include a first polymer component and a second polymer component. The
first polymer
component may form a first side of the side-by-side hi-component filaments,
wherein the first
polymer component comprises polybutylene terephthalate (PBT) in at least 25
and up to 75
volume percent of the filament in the BCF yarn. Further, the second polymer
component may
form a second side of the side-by-side bi-component filaments, wherein the
second polymer
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component comprises one of polyethylene terephthalate (PET) or polylactic acid
(PLA) in at
most 75 and down to 25 volume percent of the filament in the BCF yarn. The BCF
yarn may
be obtained by a single-step continuous process which is subsequently followed
by steps of
cabling and heat-setting at predetermined parameters to form the twisted and
heat-set BCF yarn.
The BCF yam as obtained may exhibit an elongation to break in a range of 40%
to 65%, and
carpet or floor covering formed therefrom may exhibit a Hexapod rating after
12000 cycles of
more than 2.
[0010]
Although the invention is disclosed in the context of PBT and PET or
PLA as the respective first and second polymer components, it will be
understood that PET
may be the first component and PBT may be the second component. The use of
polyesters such
as PET and PBT for the first and second components ensures that they can be
intimately co-
extruded together without requiring a binding or compatibilitising agent or
third component.
The skilled person will also understand that other equivalent polyesters may
also be used as
first and second polymer components, including aliphatic polyesters and
aromatic or semi-
aromatic polyesters.
[0011]
In the present context, reference to a single-step continuous process is
intended to refer to a process that takes place without intermediate winding
e.g. to a bobbin.
Nevertheless, the single step process may be terminated by winding the BCF
yarn to a roll or
bobbin. It will be well understood that twisting and/or cabling will generally
take place at a far
lower speed than that of extrusion and spinning. In the above, the single step
process may
include winding of the yarn prior to performing the cabling and/or twisting.
The cabled and/or
twisted BCF yarn may then again he wound to a bobbin or reel prior to being
heat set.
[0012]
It should be also appreciated that twisting in the context of the
present
invention may refer to twisting alone or steps of twisting and cabling.
Twisting may thus include
twisting a single yarn comprising a plurality of filaments, or twisting a
plurality of yarns around
each other. The term 'cabling' means twisting at least one yarn comprising at
least one filament
around at least one other yarn comprising at least one filament. Cabling
usually requires
filaments or yarns wound on at least two bobbins to be combined together.
Further, one bobbin
can comprise a plurality of individual filaments or yams bundled together. In
the following, a
bobbin, reel, roll, tube and the like are all referred to as bobbin.
[0013]
In another aspect of the present disclosure, a method for forming a
twisted and heat-set Bulked Continuous side-by-side bi-component Filament
(BCF) yam is
provided. The method may include: extruding the first polymer component and
the second
polymer component e.g. at a gradual temperature having a range of 240 C to 300
C through a
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plurality of temperature zones, and at a pressure range of e.g. 60 bars to 130
bars to obtain a
plurality of side-by-side hi-component filaments grouped together to obtain a
continuous side-
by-side bi-component filament yarn. Each side-by-side bi-component filament of
the plurality
of side-by-side bi-component filaments may include a first polymer component
and a second
polymer component. The first polymer component may form a first side of the
side-by-side hi-
component filaments, wherein the first polymer component comprises
polybutylene
terephthalate (PBT) in at least 25 and up to 75 volume percent of the filament
in the BCF yarn.
Further, the second polymer component may form a second side of the side-by-
side hi-
component filaments, wherein the second polymer component comprises one of
polyethylene
terephthalate (PET) or polylactic acid (PLA) in at most 75 and down to 25
volume percent of
the filament in the BCF yarn. The method may further include: cabling the
continuous side-by-
side hi-component filament yarn in a range of 40 TPM (Twist Per meter) to 350
TPM, with at
least one other ply to obtain the continuous side-by-side bi-component
filament yarn having
twists. This is also referred to as twisted BCF yarn. Subsequently, the
twisted BCF yarn is heat
set, preferably in a range of 100 C to 200 C to obtain a twisted and heat set
BCF yarn Such
twisted and heat-set BCF yarns have been shown to exhibit an elongation to
break in a range of
40% to 65%, and floor coverings manufactured therefrom exhibit a Hexapod
rating after 12000
cycles of more than 2.
[0014]
In another aspect of the present disclosure, a floor covering material
is
provided. The floor covering material may include a base backing and a
plurality of twisted and
heat-set Bulked Continuous side-by-side hi-component Filament (BCF) yarns
configured on
the base backing. The twisted and heat-set BCF yarns may include a plurality
of side-by-side
bi-component filaments. Each side-by-side bi-component filament of the
plurality of side-by-
side hi-component filaments may include a first polymer component and a second
polymer
component. The first polymer component may form a first side of the side-by-
side hi-
component filaments, wherein the first polymer component comprises
polybutylene
terephthalate (PBT) in at 1east25 and up to 75 volume percent of the filament
in the BCF yarn.
Further, the second polymer component may form a second side of the side-by-
side hi-
component filaments, wherein the second polymer component comprises one of
polyethylene
terephthalate (PET) or polylactic acid (PLA) in at most 75 and down to 25
volume percent of
the filament in the BCF yarn. The BCF yam may be obtained by a single-step
continuous
process, and subsequently, after the single-step continuous process, is
followed by steps of
cabling and heat-setting at predetermined parameters. The floor covering as
obtained may
exhibit a Hexapod rating after 12000 cycles of more than 2.
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[0015]
This together with the other aspects of the present disclosure, along
with
the various features of novelty that characterize the present disclosure, is
pointed out with
particularity in the claims annexed hereto and forms a part of the present
disclosure. For a better
understanding of the present disclosure, its operating advantages, and the
specified object
5
attained by its uses, reference should be made to the accompanying drawings
and descriptive
matter in which there are illustrated exemplary embodiments of the present
disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016]
The advantages and features of the present disclosure will become better
understood with reference to the following detailed description taken in
conjunction with the
accompanying drawings, in which:
[0017]
FIG. 1 illustrates a cross-sectional perspective view of a twisted and
heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yarn, in
accordance
with an exemplary embodiment of the present disclosure;
[0018] FIGS. 2A
to 2L illustrate various cross-sectional views of side-by-side
bi-component filaments, in accordance with exemplary embodiments of the
present disclosure;
[0019]
FIG. 3 illustrates a block diagram of a method for forming a Bulked
Continuous side-by-side bi-component Filament (BCF) yarn, in accordance with
an exemplary
embodiment of the present disclosure; and
[0020] FIG. 4
illustrate an article, such as a floor covering material made from
Bulked Continuous side-by-side bi-component Filament (BCF) yarns, in
accordance with an
exemplary embodiment of the present disclosure.
[0021]
Like reference numerals refer to like parts throughout the description
of
several views of the drawing.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0022]
The exemplary embodiments described here in detail for illustrative
purposes are subject to many variations in implementation. The present
disclosure provides a
bulked continuous side-by-side bi-component filament (BCF) yarn, a method for
making such
BCF yarn, and a floor covering material made from such BCF yarn. It should be
emphasized,
however, that the present disclosure is not limited to floor covering
materials and methods for
preparing the same. It is understood that various omissions and substitutions
of equivalents are
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contemplated as circumstances may suggest or render expedient, but these are
intended to cover
the application or implementation without departing from the spirit or scope
of the present
disclosure.
[0023]
The terms "a" and "an" herein do not denote a limitation of quantity,
but
rather denote the presence of at least one of the referenced items.
[0024]
The terms "having", "comprising", "including", and variations thereof
signify the presence of a component.
[0025]
The present disclosure provides a twisted and heat-set Bulked
Continuous side-by-side bi-component Filament (BCF) yarn. The BCF yarn may
include a
plurality of side-by-side bi-component filaments. Each side-by-side bi-
component filament of
the plurality of side-by-side bi-component filaments may include a first
polymer component
and a second polymer component. The first polymer component may form a first
side of the
side-by-side bi-component filaments, wherein the first polymer component
comprises
polybutylene terephthalate (PBT) in at least 25 and up to 75 volume percent of
the filament in
the BCF yarn. Further, the second polymer component may form a second side of
the side-by-
side bi-component filaments, wherein the second polymer component comprises
one of
polyethylene tcrephthalate (PET) or polylactic acid (PLA) in at most 75 and
down to 25 volume
percent of the filament in the BCF yarn. The BCF yam may be obtained by a
single-step
continuous process which is subsequently followed by steps of cabling and heat-
setting at
predetermined parameters. The twisted and heat-set BCF yarn as obtained may
exhibit an
elongation to break in a range of 40% to 65%. Floor covering produced from the
yarn may
exhibit a Hexapod rating after 12000 cycles of more than 2.
[0026]
A twisted and heat-set Bulked Continuous side-by-side bi-component
Filament (BCF) yarn will now be explained in conjunction with FIGS. 1 to 4 as
below, in
accordance with various exemplary embodiments of the present disclosure.
Without departing
from the scope of the present disclosure, the drawings as shown herein are
only for better
understanding of the disclosure and may not be in anyway considered to be
limiting only to the
diagrams as disclosed herein. There may be various other forms that may be
covered by the
claims of the present disclosure.
[0027]
Referring now to FIG. 1, a cross-sectional perspective view of a twisted
and heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yarn
100 is
illustrated in accordance with an exemplary embodiment of the present
disclosure. The yarn
100 may include a plurality of side-by-side bi-component filaments 110. Each
side-by-side bi-
component filament 110, as shown in FIG. 2A, of such plurality of side-by-side
hi-component
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filaments may include a first polymer component 112 and a second polymer
component 114.
The first polymer component 112 may form a first side 110a of the side-by-side
hi-component
filaments 110. Further, the second polymer component 114 may form a second
side 110b of the
side-by-side bi-component filaments 110. In one preferred embodiment of the
present
disclosure, the first polymer component 110 may include polybutylene
terephthal ate (PBT) in
at least 25 and up to 75 volume percent of the filament 110 in the BCF yarn
100. Further, in
one preferred embodiment of the present disclosure, the second polymer
component 114 may
include one of polyethylene terephthalate (PET) or polylactic acid (PLA) or
recycled PET in at
most 75 and down to 25 volume percent of the filament 110 in the BCF yarn 100.
However,
without departing from the scope of the present disclosure, the first and
second polymer
components 112, 114 may be any suitable polyesters, in any desired volume
percent of the
filament 110 in the BCF yarn 100 depending upon the requirement.
[00281 The twisted and heat-set BCF yarn 100 may include
various shapes of
the side-by-side bi-component filament 110, such as shown in FIGS. 2A to 2L.
As shown in
FIGS. 2A and 2B, the side-by-side bi-component filament 110, respectively,
include a side-
by-side full semi-circular cross-sectional shape, a side-by-side hollow semi-
circular cross-
sectional shape. Further, as shown in FIGS. 2C and 2D, the side-by-side bi-
component
filament 110 includes a side-by-side full tri-lobal cross-sectional shape and
a side-by-side
hollow tri-lobal cross-sectional shape, respectively. Further, as shown in
FIGS. 2E and 2F, the
side-by-side hi-component filament 110 includes a side-by-side full delta
cross-sectional
shape and a side-by-side hollow delta cross-sectional shape, respectively.
Further, as shown in
FIGS. 2G and 2H, the side-by-side hi-component filament 110 includes a side-by-
side full
concave cross-sectional shape and a side-by-side hollow concave cross-
sectional shape,
respectively. Further, as shown in FIGS. 21 and 2J, the side-by-side hi-
component filament
110 includes a side-by-side full octa-lobal cross-sectional shape and a side-
by-side hollow
octa-lobal cross-sectional shape, respectively. Further, as shown in FIGS. 2K
and 2L, the
side-by-side hi-component filament 110 includes a side-by-side full elliptical
cross-sectional
shape and a side-by-side hollow elliptical cross-sectional shape,
respectively. However,
without departing from the scope of the present disclosure, the side-by-side
bi-component
filament 110 may include various other shapes, such as, a side-by-side full
multi-lobal cross-
sectional shape, a side-by-side hollow multi-lobal cross-sectional shape, or
any other shape as
required. Further, without departing from the scopes of the present
disclosure, the first and the
second side together as a whole comprise a side-by-side full circle cross
sectional shape, a
side-by-side hollow circular cross-sectional shape. It is furthermore not
excluded that the
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filament 110 may include a third or fourth component, also in a side-by-side
relation and the
term hi-component may be understood to include at least two components
intimately bonded
together.
[0029] The twisted and heat-set BCF yarn 100, as
described, may be obtained
by a single-step continuous process. The skilled person will understand that
such processes
may generally include steps of extruding, spinning, quenching, spin finish
application,
drawing, texturizing, cooling, intermingling and winding at the predetermined
parameters.
These steps, sub-steps or process elements are all generally performed without
intermediate
winding to a bobbin. It will be understood that the yarn or filament may be
buffered or taken-
up temporarily but that the process is otherwise continuous. For the sake of
the present
discussion, the output of the single-step continuous process will be referred
to as BCF yarn,
for the purpose of distinguishing it from the twisted and heat set product of
the subsequent
process steps. The BCF yarn is at least bulked by the further described
texturizing process.
[0030] Subsequently, after the single-step continuous
process, steps of cabling
and heat-setting at predetermined parameters are followed. The BCF yarns
according to the
invention are preferably one, two, three, or four ply where two, three, or
four ply yams are
twisted or cabled. The term 'single-step process' means that all such steps
are performed on a
single machine having various machine sections, and may also be referred to as
single
machine process. Referring now to FIG. 3, to describe a method 200 of making
the BCF yarn
100 via the single-step continuous process 300, and subsequently followed by
steps of cabling
or twisting 210 and heat-setting 220.
[0031] The method 200 as shown in FIG. 3 will be described
in conjunction
with FIGS. 1 and 2A. As shown, the method 200 includes the single-step
continuous process
300, which starts at 310 by extruding the first polymer component 112 via a
first extruder El
and the second polymer component 114 via a second extruder E2. The first
polymer
component 112 and the second polymer component 114 are extruded under
predetermined
conditions, such as gradual temperature and pressure to obtain a plurality of
side-by-side hi-
component filaments 110. These may be grouped together to obtain a continuous
side-by-side
hi-component filament yam. The skilled person will be aware that the point at
which the
individual filaments become a yarn may be indeterminate although the filaments
designated to
form each final yarn will already be defined. In one embodiment of the present
disclosure, the
first polymer component 112 and the second polymer component 114 may be
extruded by
conventional means at a gradual temperature having a range of 240 C to 305 C
through a
plurality of temperature zones (tl ...tn), and at the pressure range of 60
bars to 130 bars.
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Further, at 320 spinning of the continuous side-by-side bi-component filament
is performed.
Further, at 330, the continuous side-by-side bi-component filament is
gradually quenched, at
the predetermined parameters, via, an air flow. In one embodiment the
predetermined
parameters of the quenching air flow may include: a quenching air flow
temperature in a
range of 10 C to 25 C, quenching air flow rate in a range of 0.1mps to 0.8mps,
and quenching
air flow pressure in a range of 1 mhars to 4 mbars. After quenching, spin
finish application is
performed at 340 on the continuous side-by-side bi-component filament yarn.
The spin finish
application may also be otherwise conventional. Furthermore, at 350, after the
spin finish
application, the spin finish application yarn is sequentially drawn under
predetermined
conditions, such as drawing speed and drawing temperature. In one embodiment
of the
present disclosure, the drawing speed may be in a range of 760mpm to 3500mpm
and even up
to 4000mpm or 5000mpm, and the drawing temperature range may be in a range of
75 C to
200 C. Thereafter, at 360, the drawn yarn is texturized at a texturizing
temperature range of
130 C to 200 C and a texturizing vacuum pressure range of -50 mbars to -150
mbars. Various
conventional texturizing processes may be employed. Moreover. at 370, the
continuous side-
by-side bi-continuous filament yarn is cooled at a cooling drum speed having a
range of 10
mpm to 60 mpm and a cooling drum vacuum having a range of -20mbars to -
80mbars. The
cooled continuous side-by-side bi-continuous filament may further be
optionally intermingled
at 380 and wound at 390. At this point, subsequent to the texturizing process,
the yarn may be
referred to as BCF yarn.
[0032] In one embodiment of the present disclosure, at
least one of the first
and second polymer components 112, 114 is provided with a dye, either before
or after being
extruded. The first and/or second polymer components 112, 114 may be solution-
dyed, either
using pigments or solvent dyes or a combination thereof. Further, in one
embodiment of the
present disclosure, the at least one of the first and second polymer
components is hank-dyed,
space-dyed or yarn-dyed. One way to dye the at least one of the first and
second polymer
components 112, 114 is to dip them in a vat of dye after they are extruded.
[0033] Subsequently to the single-step process, the BCF
yarn is cabled and/or
twisted at step 210. This is understood to be a separate step i.e. it does not
take place in line
and at the same speed as the single-step process and is performed from one or
more bobbins
of the BCF yarn. In this context it is further understood that individual
filaments may be
twisted or plied together or that groups of filaments or bundles of yarns may
be cabled by a
combination of individual twists and collective rotations. Reference to
twisting is thus
intended to encompass all alternatives of such twisting, plying and cabling
operations.
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[0034] In the twisting or cabling step at 210, the BCF yarn is imparted
with
permanent and distinctive texture in the form of twists. In addition, cabling
or twisting
improves tip definition and integrity. The tip is that end of the yarn which
is extending
vertically from the carpet backing and visually and physically apparent to the
consumer.
5 Twists are generally expressed as twists per meter or TPM. Such cabling
and/or twisting of
the continuous side-by-side hi-component filament yarn may he done in a range
of 40 TPM to
350 TPM; preferably 100 TPM-300 TPM; more preferably 200 TPM-250 TPM, for
example
about 230 TPM, to obtain the continuous side-by-side bi-component filament
yarn having
such twists. Cabling or twisting parameters with respect the combination of
types of the first
10 and second polymer components 112, 114 are shown in Table 1.
Polymer PET-50% & PBT-50% PET-13% & PBT-67% PET-
67% & PB T-33%
TPM 230 230 230
Twist Direction
Spinti le Ppm 5000 5000 5000
Table 1
[0035] As defined above in Table 1: 'Twist direction' "S" refers to a yarn
spun
in clockwise direction and is normally used to create left-handed twill.
Further, 'spindle rpm'
refers to the speed of the spindle where the twisting takes place. Subsequent
to cabling and/or
twisting, the yarn may again be wound to a bobbin or the like for subsequent
processing in the
next step of the process.
[0036] As described above, cabling or twisting imparts twists to the yarn,
however, increases the tendency of undesirable torqueing in the yarn.
Therefore, after twisting
and cabling, at step 220, the twisted BCF yarn is heat set. Heat treating of
the fibers, filaments
or yarn of the present invention is carried out by a fluid, such as air,
steam, or any other
compressible liquid or vapor capable of transferring heat to the twisted yarn
as it continuously
travels through a heat setting device. It should be noted that the heat set is
performed while
the filaments or yarn are in relaxed state. The temperature of such fluid must
be such that the
yarn does not melt. This step of heat setting utilizes such fluid stream
capable of transferring
heat to the twisted BCF yarn as it continuously travels through the heat
setting device, at a
temperature of 85 C to 200 C; preferably 100 C to 190 C; more preferably 130 C
to 180 C,
for example about 130 C or 140 C. This process is affected by the length of
time during
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which the twisted BCF yam is exposed to the heating medium (time/temperature
effect).
Generally, useful exposure times are from 30 seconds to 3 minutes; preferably
from 45
seconds to 11/2 minutes; for example, about 1 minute.
[0037] Preferably, the twisted BCF yam is heated to a
temperature sufficiently
above the glass transition temperature of the respective materials for heat
setting to occur.
Without being bound by theory. It is believed that heat setting above the
glass transition
temperature relieves the stress in the filaments resulting from the drawing
and twisting. Bonds
created as linkages and entanglements between the molecular chains that have
been frozen-in
during processing can be overcome by the supply of heat, giving rise to
greater freedom for
the bonds to revert to states of lower energy. Subsequent cooling, will result
in a state of
lower stress and the yarn will be heat-set in its new configuration and will
not draw back or
untwist once released.
[0038] Table 2 illustrates cabling or heat setting
parameters used on the
Power-Heat-Set type machine (operating with superheated steam at atmospheric
pressure)
with respect to the combination of types of the first and second polymer
components 112,
114.
Polymer PET-56% & PAT-611% PET-33% & PAT-67% PET-
67% & PET-33%
Twist Direction
Over feed speed 285 285
2E5
De very speed 250 250
250
Dwell time 80 Sec 60 Sec 60
Sec
Stuffing pressure 1 32% 32%
32%
MK temp Igt2 170C 170C 170C
Dew point set Al 30`C 9irC
Cooling fan on/off ON ON ON
Accumulator bask speed 215 215
215
Accumulator jump speed 225 225
225
no. of ends per tunnel 10 10 10
Table 2
[0039] As defined above in the table:
[0040] -Twist direction- as "S- represents a yarn is
twisted in clockwise and is
normally used to create left-handed twill. However, without departing from the
scope of the
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present disclosure, the twist direction may also be "Z", which represents that
a yarn is twisted
in counter-clockwise and is normally used to create right-handed twill.
[0041] "Over feed Speed" represents the speed in m/min at
which the over-
feed rollers in the heat set machine run. This is normally 10-30% more than
the delivery
speed, to keep the yarn slack before entering the actual heat set process,
ensuring that heat
setting takes place in the relaxed condition of the yarn.
[0042] "Delivery Speed" represents the feed speed in m/min
of the yarn at the
heat set machine.
[0043] "Dwell time" represents the total time yarn stays
inside the actual heat
setting process.
[0044] "Stuffing pressure 1- represents the level of
additional crimp (known as
frieze) given in the yarn during the heat setting process.
[0045] "GKK temp 1&2" represents the actual temperature
yarn is exposed for
heat setting.
[0046] -Dew point set 1&2" represents the moisture level inside the
actual
heat setting tunnel.
[0047] "Accumulator basic speed" represents the normal
speed in m/min of the
yarn outlet from the heat setting tunnel.
[0048] -Accumulator jump speed" represents the higher
optional speed of the
yarn outlet from the heat setting tunnel.
[0049] "No of ends per tunnel" represents total number of
yarns which are heat
set together in each heat setting tunnel.
[0050] Heat setting for the twisted BCF yarns stabilizes
the twist and causes
the BCF yarn 100 to lock in the twists and gain volume in the BCF yarn 100.
This volume
growth may be described as "bulk development". Heat setting also retains the
twist during use
and there is not such a loss of resilience and of overall appearance due to
matting. The unique
yarn and carpet made therefrom based on the side-by-side bi-component
filaments disclosed
herein, results in an ability to thermally lock in the twist structure and
enables to gain volume
in the BCF yarn 100. In the present invention, the twisted and heat-set BCF
yarn is produced
having the number of the side-by-side bi-component filaments in the range of
25 filaments to
1000 filaments. Further, the twisted and heat-set BCF yarn 100 exhibits a
denier per filament
(DPF) ratio in the range of 0.5 DPF to 50 DPF, and a linear density in a range
of 600 denier to
6000 denier. The denier value is obtained for the BCE yarn after the one-step
process and
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before the heat set. The skilled person understands that this value may change
upon heat
setting the BCF yarn 100.
[0051] According to an important aspect of the invention,
the yarn may also be
subjected to a frieze process prior to heat setting. In one configuration,
this involves
introducing the twisted BCF yam into a stuffing box subsequent to it being
removed from the
bobbin and prior to introduction into the heat setting machine. This bunching
up of the yarn
creates crinkles in the yarn, which is then set in place during the heat set
process. Heat setting
is thus a necessary step to produce such frieze yarn.
[0052] Moreover, in the present invention, the twisted and
heat-set BCF yam
100 that is produced using the above process has an elongation to break in a
range of 40% to
65%. In the present specification, elongation to break is determined according
to ASTM D
2256 (2015) using a gauge length of 500 mm. a test speed of 500 mmfmin, a
pretension of 0.5
cl\l/tex and break identified by a 90% drop in peak force.
[0053] More importantly, carpet produced with twisted and
heat-set BCF yarn
100 comprising the compositions of the first and second polymers 112, 114
arranged in side-
by-side arrangements of the invention were tested for performance in a Hexapod
Tumble Test
typically used in the art to evaluate commercial carpet performance and found
to have a
Hexapod rating after 12000 cycles of more than 2.
[0054] Such Hexapod rating of more than 2 after 12000
cycles is obtained due
to the unique combination of the first polymer component 112 forming the first
side 110a in at
least 25 and up to 75 volume percent, and the second polymer component 114
forming the
second side 110a in at most 75 and down to 25 volume percent of the filament
in the BCF
yarn, along with the heat setting of such yarn.
[0055] Table 3, presented below, illustrates various
combinations of the first
and second polymer components 112, 114 and resulting properties including
"elongation to
break" and "Hexapod rating" as obtained in the BCF heat set yarns 100 and
carpets made
from such yarns, in comparison to other conventionally available yarns. The
parameters of the
carpets are chosen to be as close as possible to each other in order to
provide a fair
comparison between different yarns. For all cases, the filaments are circular
cross-section.
The table clearly shows that the items made from twisted and heat-set BCF
yarns exhibit
higher Hexapod rating compared to the items that were made from mono-component
heat-set
yarns or bi-component BCF yarns that were not heat set.
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OD
to
Ltj
Bi-Component Percentage
Hexapod rating (tumbler wt 3.81 Kg)
r=.)
Filament of polymenrs
Heat setting
Denier/Fil
Hexapod 00
parameter Final Product Elongation Stitch
Carpet Final
Polymer ament
Pile height Carpet Backing Rating @
Polymer B A % B % (degree C) to break Guage rate /10
cut/loop yarn carpet
A
(mm) backing GSM 12000
cm
GSM GSM
cycles
PBT PET 50 50 140 1200/120 2 ply
230 Ipm heat set 54,56 1/8 t h 48 12 CUT Hot melt
1300 1120 2420 2,5
PBT Recycled PET 50 50 140 1200/120 2 ply
230 tpm heat set 55,2 1/8 t h 48 12 CUT Hot melt
1300 1120 2420 3
PBT PLA 50 50 130 1200/120 2 ply
230 tpm heat set 58,4 1/8 t h 48 12 CUT Hot melt
1300 1120 2420 2
Mono component filament
100% PET 140 1200/120 2 ply 230 tpm heat set
39,58 1/8 t h 48 12 CUT Hot melt 1300 1126 2426
1
100% PBT 140 1200/120 2 ply 230 Ipm heat set
40,2 1/8 t h 48 12 CUT Hot melt 1300 1135 2435
1,5
Without heat
PBT PET 50 50 1200/120 1 ply BOP 33,55 1/8 th
48 x 2 12 CUT Hot melt 1300 1060 2360 1,5
setting
Without heat
PBT Recycled PET 50 50 1200/120 1 ply BCF 35,5 1/8 th
48 x 2 12 CUT Hot melt 1300 1060 2360 1,5
setting
Without heat 2 ply 230 tpm cold drawn
PBT PET 50 50 1200/120 1/8 t h
48 12 CUT Hot melt 1300 1100 2400 1,5
setting and relaxed at 80 0, 10 s
Mono component filament
Without heat
100% PET 1200/120 1 ply BCF 28,54 1/8 th 48 x 2 12 CUT
Hot melt 1300 1050 2350 1
setting
Without heat
100% PBT 1200/120 1 ply BCF 29,3 1/8 th 48 x 2 12 CUT
Hot melt 1300 1050 2350 1
setting
Table 3
lEdd
oe
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[0056] The Hexapod rating as referenced throughout the
present specification
is obtained using the D 5252 ¨ 98a (2003) standard for the operation of the
Hexapod tumble
drum tester of 3.8 Kg weight. The test was performed using a standard, upright
type vacuum
cleaner as supplied with the Hexapod drum tester. As can be seen from the
results, the
5 Hexapod rating for carpets made with the hi-component filament yarns of
the invention is
considerably higher than that for either 100 % PET or 100% PBT. Furthermore,
the Hexapod
rating for carpets made with the bi-component filament yarns without heat set
is also far
lower than that of the invention. Also, in the case of cold drawing the cabled
yarn and
subsequent relaxation in warm water at 80 C, no improvement is apparent in the
Hexapod
10 rating.
[0057] Referring now to FIG. 4, a floor covering material
400 is shown in
accordance with an exemplary embodiment of the present disclosure. The floor
covering
material 400 may include a base backing 410, and a plurality of twisted and
heat-set Bulked
Continuous side-by-side bi-component Filament (BCF) yarns 100 configured on
the base
15 backing 410, as described above and excluded from the description herein
for the sake of
brevity of the disclosure and to avoid repetition of the subject matter. The
floor covering
material 400 may include, but is not limited to, carpets, rugs, mats and so
forth. In one
embodiment of the present disclosure, the twisted and heat-set BCF yarns 100
are tufted on
the base backing 410 to form the floor covering material 400. In one
embodiment of the
present disclosure, the twisted and heat-set BCF yarns 100 are knitted on the
base backing
410 to form the floor covering material 400. In one embodiment of the present
disclosure, the
twisted and heat-set BCF yarns 100 are woven on the base backing 410 to form
the floor
covering material 400. In one embodiment of the present disclosure, the
twisted and heat-set
BCF yarns 100 are knotted on the base backing 410 to form the floor covering
material 400.
[0058] As presented, the present disclosure is advantageous in providing
such
bulk continuous side-by-side hi-component filament yarns or carpets that may
be able to
withstand high level of wear and tear and avoid delamination of bi-components
from each other
over the maximum period of time.
[0059] The foregoing descriptions of specific embodiments
of the present
disclosure have been presented for purposes of illustration and description.
They are not
intended to be exhaustive or to limit the present disclosure to the precise
forms disclosed, and
obviously many modifications and variations are possible in light of the above
teaching. The
embodiments were chosen and described in order to best explain the principles
of the present
disclosure and its practical application, and to thereby enable others skilled
in the art to best
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utilize the present disclosure and various embodiments with various
modifications as are suited
to the particular use contemplated. It is understood that various omissions
and substitutions of
equivalents are contemplated as circumstances may suggest or render expedient,
but such
omissions and substitutions are intended to cover the application or
implementation without
departing from the spirit or scope of the present disclosure.
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