Note: Descriptions are shown in the official language in which they were submitted.
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DIFFERENTIALLY VAT DYED YARNS AND METHOD OF MAKING THE SAME
RELATED APPLICATION DATA
The present application claims priority pursuant to Article 8 of the Patent
Cooperation
Treaty to United States Provisional Patent Application Serial Number
63/152,118 filed February
22, 2021 and United States Provisional Patent Application Serial Number
63/283,716 filed
November 29, 2021, each of which is incorporated herein by reference in its
entirety.
FIELD
The present application relates to vat dyed yarns and, in particular, to vat
dyed yarns
comprising plies yielding a tweed or heathered appearance.
BACKGROUND
Current processes for producing colored nylon floor coverings, such as
carpets, have
several disadvantages. Acid dyes, for example, are commonly employed for
coloration of
nylon fibers used in carpet yarns due to the ease with which cationic nylon
polymer accepts the
dye. This ease of dyeing, however, also facilitates staining if the nylon
fibers are exposed to
contaminants having dye-like properties during use. Moreover, acid dyes are
commonly
applied to nylon fibers in batch or continuous processes. Under this approach,
a risk exists of
ozone fading if the material is installed in a tropical environment.
Treatments have been
developed to improve resistance of acid dyed nylon to ozone fading. These
treatments include
novolak resins, acrylic polymers, tannic acid or various combinations thereof.
Such treatments,
nevertheless, can alter shades of the dyed fiber and/or induce a reduction in
lightfastness of the
dyed fibers.
Moreover, these disadvantages further complicate producing nylon floor
coverings
having a tweed or heathered appearance. In many cases, acid dyed nylon plies
of differing color
are individually produced and subsequently twisted or entangled. Lack of tight
color control in
the acid dyed batches can produce color anomalies degrading the tweed or
heathered effect.
SUMMARY
In view of the foregoing, yarns are described herein which comprise plies dyed
with at
least one vat dyestuff yielding a tweed or heathered appearance. In one
aspect, a yarn comprises
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a first ply and a second ply each dyed with at least one vat dyestuff, wherein
a denier ratio
between the first ply and the second ply is greater than 1. In another aspect,
a yarn comprises a
first single strand and a second single strand each dyed with at least one vat
dyestuff, wherein a
difference in color depth (DL*) between the dyed first single strand and the
dyed second single
strand has an absolute value of at least 2 when the vat dyestuff is in an
oxidized state. In some
embodiments, an absolute value of DL* ranges from 2-50 or from 3-30. An
absolute value of
DL* can also range from 5-20 or 10-30, in some embodiments. As set forth
herein the
terminology of "first ply and second ply" can be interchangeable with "first
single strand and
second single strand". As described further herein, the first ply and the
second ply can be dyed
in the same dyebath in a single dyeing process. In another aspect, a yarn
comprises a first ply
and a second ply each dyed with at least one vat dyestuff, wherein a
reflectance ratio between the
second ply and the first ply ranges from 0.05 to 0.95. In some embodiments,
the reflectance ratio
ranges from 0.4 to 0.6. The first ply and second ply of yarns described herein
can be formed of
any desired composition. In some embodiments, the first ply and second ply are
synthetic fibers.
The first ply and second ply, for example, can be formed of polyamides.
Additionally, yarns
described herein can be used to fabricate various textile articles including
floor coverings, such
as carpet
In another aspect, a yarn comprises a first ply and a second ply each dyed
with at least
one vat dyestuff, wherein the first ply and second ply are formed of differing
polyamides. In
some embodiments, the polyamide of the first ply has lower crystallinity than
the polyamide of
the second ply. The first ply, for example, can be formed of nylon 6, and the
second ply is
formed of nylon 6,6. Moreover, the polyamide of the second ply can exhibit
anionic character,
in some embodiments. The polyamide of the second ply may comprise a sulfur
content. The
polyamide yarn can exhibit any of the denier and/or reflectance ratios
described herein.
In another aspect, methods of dyeing yarns are described herein. A method, in
some
embodiments, comprises providing a yarn comprising a first ply and a second
ply, and contacting
the yarn with a dyeing composition comprising at least one vat dyestuff in
reduced form. Once
applied to the first and second plies, the vat dyestuff is oxidized, wherein
the dyed first ply
exhibits a darker or deeper color than the dyed second ply. The darker or
deeper color of the first
ply can originate from more of the vat dyestuff being received or exhausted
onto the first ply
relative to the second ply. In some embodiments, a difference in color depth
(DL*) between the
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dyed first ply or single strand and the dyed second ply or single strand has
an absolute value of at
least 2 when the vat dyestuff is in an oxidized state. In some embodiments,
DL* ranges from 2-
50 or from 3-30. Moreover, in some embodiments, a denier difference between
the first ply and
second ply can yield a reflectance difference, wherein the lower denier ply
reflects less light
leading to a lighter coloring.
These and other embodiments are further described in the detailed description
which
follows.
DETAILED DESCRIPTION
Embodiments described herein can be understood more readily by reference to
the
following detailed description, examples, and drawings. Elements, apparatus,
and methods
described herein, however, are not limited to the specific embodiments
presented in the
detailed description, examples, and drawings. It should be recognized that
these embodiments
are merely illustrative of the principles of the present invention. Numerous
modifications and
adaptations will be readily apparent to those of skill in the art without
departing from the spirit
and scope of the invention.
In one aspect, a yarn comprises a first ply and a second ply each dyed with at
least one
vat dyestuff, wherein a denier ratio between the first ply and the second ply
is greater than 1. In
some embodiments, the denier ratio is greater than 1.5 or greater than 2. The
denier ratio
between the first ply and the second ply, for example can range from 1.2 to
10, in some
embodiments. The denier ratio can be chosen according to several consideration
including, but
not limited to, the composition of the first and second plies, the chemical
identify of the vat
dyestuff, and exhaustion levels of the vat dyestuff on the first ply and the
second ply. In some
embodiments, the first ply has a denier of 12 or higher, and the second ply
has a denier less than
12. The denier ratio or disparity between the first ply and the second ply can
be employed to
modulate individual reflectance values of the first and second plies. The
higher denier first ply,
for example, can exhibit higher reflectance while the lower denier second ply
exhibits lower
reflectance. This gradient in reflectance can render the second ply lighter in
color to the
observer, yielding the desired tweed or heathered effect.
In another aspect, a yarn comprises a first ply and a second ply each dyed
with at least
one vat dyestuff, wherein a reflectance ratio between the second ply and the
first ply ranges from
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0.05 to 0.95. In some embodiments, the reflectance ration ranges from 0.3 to
0.7 or from 0.4 to
0.6.
The first ply and second ply of yams described herein can be formed of any
desired
composition The first ply and the second ply can be formed of the same
composition or
differing compositions. The first ply and the second ply can comprise
synthetic compositions,
natural compositions, or various combinations of synthetic and natural
compositions. Specific
compositions of the first ply and the second ply are chosen according to the
technical objectives
described herein of providing a yam with a tweed or heathered appearance. In
some
embodiments, for example, the first ply and second ply can be selected or
chemically engineered
to receive differing amounts of the vat dyestuff. The first and second plies,
for example, can
exhibit differing levels of crystallinity. The first ply can exhibit lower
crystallinity than the
second ply, thereby providing an inter-chain structure for receiving higher
amounts of the vat
dyestuff relative to the higher crystallinity second ply. Moreover, in some
embodiments, the first
ply can exhibit a chemical structure more receptive to the vat dyestuff
relative to the second ply.
The first ply can comprise a higher number of cationic moieties or moieties
having positive
dipole moments for interaction with the anionic character of the vat dyestuff
relative to the
second ply. Additionally, the second ply can comprise a higher number of
anionic moieties or
moieties having negative dipole moments for repelling or otherwise interfering
with the anionic
character of the vat dyestuffs during the dyeing process. Such chemical
tailoring can result in
more vat dyestuff being exhausted onto the first ply than the second ply,
thereby yielding the
desired color differential between the plies to provide a tweed or heathered
appearance.
The foregoing technical principles are illustrated by forming the first ply
and the second
ply of differing polyamides. The first ply, for example, can be nylon 6, and
the second ply is
nylon 6,6. The nylon 6 exhibits lower crystallinity relative the nylon 6,6.
The lower crystallinity
can provide a more open structure for receiving greater amounts of the vat
dyestuff.
Additionally, the nylon 6 may include greater number of cationic amine groups
for interaction
with the vat dyestuff In contrast, the nylon 6,6 fiber can comprise a sulfur
content for
generating anionic moieties or functionalities for repelling or otherwise
interfering with anionic
character of the vat dyestuff in the dyeing process. In some embodiments, the
nylon 6,6 can
comprise a sulfur content of at least 2,000 ppm. The nylon 6,6, for example
can have a sulfur
content of 2,000 to 3,300 ppm.
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Yarns having construction and properties described herein can be used to
provide a
variety of textile products. In some embodiments, the yams are employed in
floor coverings,
such as carpets. The yams, for example, can be tufted and coated to produce a
finished tweed or
heathered carpet. Alternatively, the yarn comprising the first ply and the
second ply can be
tufted into a greige carpet construction, and subsequently dyed in batch mode
or continuous
mode using a vat dyeing system. The vat dyes greige is subsequently coated to
provide a
finished tweed or heathered carpet.
In addition to exhibiting the color differentiation between the first and
second plies
described herein, the dyed yams can also display enhanced lightfastness, wet
fastness, color
fastness to ozone and/or resistance to household bleach. Dyed yarn, for
example, can be
resistant to undiluted household bleach or diluted bleach of 0.3% sodium
hypochlorite solution.
In some embodiments, the nylon fibers dyed with one or more vat dyestuffs can
meet one or
more criteria set forth in Table I.
Table I - Properties of Dyed Nylon Fibers
Property Test Grayscale (GS)
Rating
Lightfastncss AATCC Test Method 16, Option 3-5
Color Fastness to Ozone AATCC 129 4-5
Wet Fastness Transfer to undyed control 4-5
Household Bleach Resistance Application of household 4-5
bleach (24hrs)
Any vat dyestuff not inconsistent with the objectives of the present invention
can
be applied to nylon fibers having construction and/or properties described.
Suitable vat
dyestuffs can contain two or more ketone groups separated by a system of
conjugated
bonds. In some embodiments, vat dyestuffs include indigo and derivatives
thereof. Vat
dyestuffs may also include various derivatives of anthroquinones. Table II
provides a
non-limiting list of vat dyes for use with nylon fibers according to some
embodiments
described herein.
Table II - Vat Dyestuffs for Nylon Fiber Dyeing
Vat Yellow 33
Vat Green 13
Vat Brown 1
Vat Brown 3
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Vat Brown 57
Vat Blue 6
Vat Black 22
Vat Black 25
Vat Black 27
Vat Yellow 4
Vat Green 1
In another aspect, methods of dyeing yarns are described herein. A method, in
some
embodiments, comprises providing a yarn comprising a first ply and a second
ply, and contacting
the yarn with a dyeing composition comprising at least one vat dyestuff in
reduced form. Once
applied to the first and second plies, the vat dyestuff is oxidized, wherein
the dyed first ply
exhibits a darker or deeper color than the dyed second ply. The darker or
deeper color of the first
ply can originate from more of the vat dyestuff being received or exhausted
onto the first ply
relative to the second ply, as described herein. Moreover, in some
embodiments, a denier
difference between the first ply and second ply can yield a reflectance
difference, wherein the
lower denier ply reflects less light leading to a lighter coloring. Notably,
the first ply and the
second ply are combined to form the yarn prior to dyeing in the same or common
vat dyebath.
Therefore, the differential color effects between the dyed first ply and
second ply are achieved in
a single dyebath or single vat dyeing process. The ability to achieve the
differential color effects
in a single or common process realizes process efficiencies over individual
dyeing of the first ply
and second ply followed by combining the individually dyed plies into the yarn
construction.
The dyeing composition can include one or more vat dyestuffs in any amount not
inconsistent with the obj ectives ofthe present invention. In some
embodiments, vat dyestuff is
present in the dyeing composition at an add-on level of at least 0.1% on
weight fiber. Vat
dyestuff can al so be present in the dyeing composition at add-on levels
according to Table ITI.
Table III ¨ Amount of Dyestuff(s) on weight fiber (owf)
> 0.25
> 0.5
>1
0.1-1
0.25-1
The dyeing composition including one or more vat dyestuffs can be prepared
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according to several techniques. In some embodiments, an aqueous dispersion of
one or more
vat dyestuffs is initially provided. Purified water free or substantially free
of hardening
species such as calcium and magnesium can be used as the dispersion continuous
phase.
Alternatively, one or more water softening agents can be added to the
dispersion to sequester
hardening species. Such purified or treated water is generally referred to as
soft water herein.
Vat dyestuff(s) are added to the continuous aqueous phase in amounts
consistent with the add-
on levels provided in Table III. The continuous aqueous phase may be heated to
a temperature
of 30-35 C and mixing may be employed to assist in dispersion of the vat
dyestuff(s).
A reducing system is prepared for combination with the aqueous dispersion of
the vat
dyestuff(s). In some embodiments, a reducing system comprises one or more
chemical
species for reducing the vat dyestuff(s), thereby placing the dyestuff(s) in
the water soluble
form. Reduction of the vat dyestuff(s) may convert the dyestuff(s) to leuco
form, in some
embodiments. Any suitable reductant species not inconsistent with the
objectives of the
present invention can be employed. Sodium dithionite and/or sodium
hydrosulfite, for
example, can be a reductant for one or more vat dyestuffs. In some
embodiments, ferrous
sulfate can be used in conjunction with sodium dithionite for dyestuff
reduction. The
reducing agent can be added to soft water to provide the reducing system. In
some
embodiments, the water is heated to a temperature of 30-35 C, and the one or
more reductants
are added with mixing or other mechanical agitation. Amounts of reducing agent
added to the
soft water can be sufficient to reduce all or substantially all of the vat
dyestuffs employed in
the dyeing process. Once dispersion and wetting of the reducing system has
been achieved, it
can be added to the exhaust dyeing equipment containing the dispersed form of
the vat dyes
and an initial water charge. In some embodiments, a reducing system is not
necessary as the
vat dyestuffs are provided in reduced form from the manufacturer. For example,
a solution of
reduced vat dyestuff can be commercially available and used in accordance with
methods
described herein.
One or more alkaline species for adjusting the pH of the dyeing composition is
dispersed
in soft water. Caustic soda (NaOH) or aqua ammonia, for example, can be
employed as an
alkaline pH adjusting agent Other pH adjusting agents are well-known in the
art and may also
be used. Once produced, the pH adjusting composition is added to the exhaust
dye equipment.
In a further step of the dyeing composition, dispersing agent(s) and/or
leveling agent(s) are
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added. Polyvinylpyrrolidone, for example, can serve as a dispersing agent for
the vat dyestuffs
as well as a providing some retarding and leveling action. Moreover, if
carrier is found to be
useful for a given formulation, benzyl alcohol can be used. Additionally, many
options exist
for dispersing agents, leveling agents, carriers and/or swelling agents that
may be useful for
nylon fiber dyeing compositions. Table IV provides amounts of reducing and pH
adjustment
agents for dyeing compositions having various dyestuff concentrations (owl)
for application by
exhaust dyeing systems.
Table IV - Reducing and pH Adjustment Agents
Dyestuff Concentration (owf) Sodium Dithionite (g/L) Caustic Soda 50%
(g/L)
0.1% 2-3 2.5-3.5
0.11-1.0% 2-3 4-5
>1.0% 3-4 5-7
Table V provides amounts of reducing and pH adjustment agents for dyeing
compositions having various dyestuff concentrations (owf) for application by a
continuous
dyeing system at 450% wet pick up.
Table V - Reducing and pH Adjustment Agents
Dyestuff Concentration (owf) Sodium Dithionite (g/L) Caustic Soda 50%
(g/L)
0.1% 4-5 9-10
0.11-1.0% 5-7 14-16
> 1.0% 6-8 .. 17-20
Table VI provides amounts of reducing and pH adjustment agents for dyeing
compositions having various dyestuff concentrations (owf) for application by
continuous
space dyeing at 100% wet pick up.
Table VI ¨ Reducing and pH Adjustment Agents
Dyestuff Concentration (owl) Sodium Dithionite (g/L) Caustic Soda 50%
(g/L)
0.1% 18-22 28-32
0.11-1.0% 23-27 33-37
> 1.0% 28-32 38-42
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Additionally, Table VII provides various liquor ratios (LR) for exhaust
dyeing, continuous dyeing and continuous space dyeing processes according to
some embodiments.
Table VII -Liquor Ratios
Dyeing Process Liquor Ratio
Exhaust 25:1
Continuous 4.5:1
Continuous Space 1:1
With reference to application by exhaust dyeing equipment, initial mixing and
wetting out of the nylon fiber, yarn or greige by the dyeing composition can
be allowed to
occur over a time period of at least 15 minutes at a temperature of 30-35 C. A
temperature
ramp is subsequently administered. In some embodiments, temperature is ramped
at
1.5 C/min to an 80 C hold for 45 minutes. Once the dyeing cycle is complete,
the bath can
be overflowed for initial cooling followed by draining off the spent dyebath
from the
exhaust dyeing apparatus. A rinse bath of ambient water is then provided, and
the dyed
nylon fibers are circulated through the bath for a minimum of 15 minutes to
remove any
unfixed material from the fiber surfaces. Depending on dyeing composition, it
may be
helpful to add an organic acid component, such as acetic acid, to assist in
unfixed material
removal and to lower pH of the nylon fibers. In some embodiments, 30-80
percent dyestuff
exhaustion is achieved.
After rinsing, the dyed nylon fibers are removed from the exhaust dyeing
apparatus
and extracted to mechanically remove as much water as possible, without fiber
damage.
The extracted fibers are then subjected to air drying. Air drying can occur at
ambient
temperature or elevated temperatures. In some embodiments, for example, air
drying occurs at
temperatures of 200-300 F, such as 240-260 F. Drying is continued until a
moisture content of
5% or less is achieved. The drying process also serves as an oxidation step
for the vat dyestuffs
on the nylon fibers. This drying and oxidation fixes the vat dyestuffs on the
nylon fibers,
greatly improving their fastness properties listed in Table I herein. Dyestuff
oxidation and
fixing during the heating process fundamentally differs from prior processes
where one or more
oxidizing agents are employed for vat dyestuff oxidation. For example, prior
processes can use
peroxide and/or other oxidants for dyestuff oxidation. The present method
surprisingly
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oxidizes and fixes the vat dyestuffs in the absence of such oxidizing species,
thereby
simplifying the dyeing process.
For continuous dyeing processes, the main difference with exhaustion processes
is the
separation of the vat dyestuff dispersion from the reducing system until just
prior to application
of the dyeing composition to the nylon fibers. For example, a bath containing
the pre-dispersed
vat dyestuff(s) can be held in Tank A while Tank B contains the reducing
system, pH
adjustment agent(s) and other auxiliary materials such as wetting agents,
leveling agents,
carriers and the like. The contents of Tanks A and B are metered and mixed
together in
appropriate ratio to provide the dyeing composition. The dyeing composition is
then applied to
the nylon yam or carpet greige being processed continuously through either a
space dye line (in
the case of yam) or a continuous broad loom dye range (in the case of nylon
carpet greige).
After the two baths are combined and applied, the fiber can be exposed to heat
to promote
exhaustion of the vat dyestuff(s) on the fibers. Generally, saturated steam
can be used as the
heat source. After the heating cycle, the dyed fibers can be rinsed, extracted
and dried as
described above. The drying process oxidizes the vat dyestuff(s).
In some embodiments, a pretreatment process is applied to one or more of the
plied,
including the cationic ply and/or the anionic ply. The pretreatment process
can be incorporated
into example methods to increase the hydrophobic character of the cationic
poly and/or the
anionic ply. For instance, the pretreatment can include contacting a ply with
a wax (e.g., in the
form of a wax emulsion) to produce a wax-finished ply.
Certain embodiments of the disclosure can include a yarn made from at least
two plies
(e.g., a first ply and a second ply), where one of the at least two plies is a
wax-finished ply. In
these embodiments, the yarn can have a construction defining the spatial
relationship between
the wax-finished ply and one or more other plies of the at least two plies,
along the length of the
yarn. As an example for illustration, one type of construction can include a
"barberpole"
construction, where the wax-finished ply and one of the other plies are
twisted or otherwise
wrapped around each other to create a diagonal stripping effect. With such a
striping effect, a
point moving from one position on the yarn to a second position along the
length of the yarn
would cross from the wax-finished ply to the other ply wrapped around it and
then cross the
wax-finished ply again repeating the pattern.
Aspects of barber pole constructions can include a regular or irregular
striping effect. In a
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regular stripping effect, the positions of the wax-finished ply and the other
ply wrapped around it
are regularly spaced so that along a length of the yarn, the position of the
wax-finished ply
repeats at least every 2 mm (e.g., between 0.2 cm and 2 cm, between 0.5 cm and
1.5 cm, between
0.5 and 1 cm, or between 0.6 and 0.8 cm). This effect can be adjusted in
several manners. For
instance, the thickness of the wax-finished ply and/or the other ply wrapped
around it may be
adjusted. Alternatively or additionally, the number and/or density of twists
in the yarn may be
adjusted. For constructions having an irregular stripping effect, the position
of the wax-finished
ply is not regularly spaced and so does not have a specific repeating value.
More particularly, some constructions can be produced by arranging the first
ply and the
second ply to produce the construction. Aspects of arranging the first ply and
the second ply can
include introducing twists into the yarn at a density of 1 twists per inch to
10 twists per inch,
such as 2 to 8, 1 to 5, or 8 to 10 twists per inch. In these constructions,
the twists can be regularly
spaced to produce a regular stripping effect or irregularly spaced to produce
an irregular striping
effect. In certain constructions the density of twists may vary along the
length of the yarn or may
be constant.
Embodiments of the disclosure can also include methods for producing a dyed
yarn.
Example methods for producing a dyed yarn can include obtaining a first ply
and a second ply,
optionally, applying a pretreatment process to at least one of the first ply,
the second ply, or both
arranging the first ply and the second ply to form a yarn having a
construction, for example, a
barberpole construction, exposing the yarn to a dyebath including at least one
vat dyestuff in
reduced form (i.e. reduced vat dyestuff), and oxidizing the vat dyestuff
applied to the yarn.
Some advantages of preparing dyed yarns according to methods of the present
disclosure
can include improved color differentiation between the first ply and the
second play. For
instance, it has been discovered that pretreatment of the ply or plies prior
to dyeing the yarn can
produce a greater difference in color values between the first play and the
second ply in
comparison to untreated ply or plies. Additionally, properties such as ionic
character (e.g.,
anionic or cationic) can impact dyestuff uptake. Further, these differences in
dye uptake can be
realized in a more economic manner by exposing the yarn including the plies to
the dyebath
together, rather than separately dying each of the plies. Thus yarns in
accordance with the
present disclosure may demonstrate improve color values for providing a
heathered or tweed
appearance, while also presenting economic advantages in manufacturing.
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In some example embodiments, various fiber properties can be achieved through
differentiation between a first ply and a second ply, for example to achieve a
barberpole and/or
heathered effect with a vat dyestuff application. In some instances, a first
ply or filament can be
darker after dyeing and a second ply or filament can be lighter after dyeing.
Differences between
the plies after dyeing can enable the tuning of various properties of a fiber.
In some
embodiments, total ply denier can be varied where a first ply has a total
denier greater than a
second ply, and a second ply has a total ply less than the first ply. In some
embodiments, denier
per filament can be varied where a first ply has a high denier per filament
relative to a second ply
(i.e. fewer filaments of larger cross section) and the second ply has a lower
denier per filament
relative to the first ply (i.e. higher number of total filaments of smaller
cross section). In some
embodiments, luster level (e.g. TiO2 content) can be varied where a first ply
has a higher luster
value relative to a second ply (i.e. lower TiO2 content) and the second ply
has a lower luster
value relative to the first ply (i.e. higher TiO2 content). In some
embodiments, filament cross
section (e.g. modification ratio) can be varied where a first ply has a higher
modification ratio
(MR) cross section relative to a second ply (i.e. more angular cross section),
and the second ply
has a lower MR cross section relative to the first ply (i.e. more rounded
cross section). In some
embodiments, a nylon chemical property can be varied where a first ply is
cationic or highly
cationic and/or having a high amine group content (e.g. relative to a second
ply), and a second
ply is anionic or highly anionic, having a high sulfur content (e.g. relative
to the first ply). In
some embodiments, nylon physical characteristics can be varied where a first
ply has a low
crystallinity (e.g. nylon 6 type) and a second ply has a higher crystallinity
(e.g. nylon 6.6 type).
In some embodiments, extrusion finish properties can be varied where a first
ply has a high
wetting speed finish (i.e. to promote high dyestuff exhaustion) and a second
ply has a low
wetting speed finish or a repellant finish, for example a wax finish (e.g. to
promote low dyestuff
exhaustion).
Various embodiments of the invention have been described in fulfillment of the
various
objectives of the invention. It should be recognized that these embodiments
are merely
illustrative of the principles of the present invention. Numerous
modifications and adaptations
thereof will be readily apparent to those skilled in the art without departing
from the spirit and
scope of the invention.
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EXAMPLES
The examples herein provide aspects of embodiments of the present disclosure.
These
examples are not meant to limit embodiments solely to such examples, but
rather to illustrate
some possible implementations.
Table 1 was developed by, first, producing 11 different twisted, heatset yarn
packages,
using dyeable commercial yarns for carpet use. Self-plied yarn packages were
produced from
each yarn type, using 5.25 twist per inch settings, and Superba heat setting.
The 1200 Ascend yarn, 2200 parts sulfur, was used to create a series of dyed
yarn skeins,
using a range of strengths, from 0% (no dyestuff present) to 1.5% owf
dyestuff, in increments of
0.25% owf dyestuff. This information was used to create a relationship between
L* value (depth
of color) and the % owf of the dyestuff, for estimating how much dyestuff was
present on the
dyed yarn combinations produced for this study.
The dyestuff used was color index Vat Black 27, sold by Dystar as Indanthrene
Olive R
Liquid. An Ahiba lab dyeing apparatus was used and a Gretag Macbeth Color-eye
7000A was
used for color measurements to determine the tristimulus values of the cut end
of the dyed
skeins. The L* information was used to determine DL* (delta L*) differences
between the two
yarns dyed competitively in each test case, as well as to determine an
estimate of the amount of
Vat Black 27 present on each yarn skein.
Table 1. Example attributes of dyed yarn skeins.
Nylon Total OL R
Vendor Type Denier Info DPF Comments
L* % OL R % of Tot DL*
la Ascend 6.6 1200 2200 pts S 7 semi dull
54.65 0.502 42.91 -4.54
2 Invista 6.6 1425 12 semi dull 50.11 0.6678
57.09
lb Ascend 6.6 1200 2200 pts S 7 semi dull
56.68 0.436 30.03 -13.6
3 Ascend 6.6 1700 KET 26 semi dull 43.1 1.016
69.97
lc Ascend 6.6 1200 2200 pts S 7 semi dull
48.79 0.737 50.46 0.3
4 Ascend 6.6 1352 3300 pts S 21 semi dull 49.09 0.7237
49.54
Id Ascend 6.6 1200 2200 pts S 7 semi dull
58.53 0.3831 29.91 -12.9
5 Ascend 6.6 1360 NET 20 semi dull 45.67 0.8977
70.09
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1 e Ascend 6.6 1200 2200 pts S 7 semi dull
53.14 0.553 44.63 -3.39
6 Ascend 6.6 1352 2200 pts S 21 semi dull 49.75 0.686
55.37
if Ascend 6.6 1200 2200 pts S 7 semi dull
53.31 0.5449 19.22 -22.6
7 Invista 6.6 1245 19 bright 30.67 2.29 80.78
1g Ascend 6.6 1200 2200 pts S 7 semi dull
54.66 0.498 22.17 -20.4
8 Ascend 6.6 1320 KET 20 semi dull 34.25 1.748
77.83
lh Ascend 6.6 1200 2200 pts S 7 semi dull
62.12 0.2922 29.07 -12.9
9 Ascend 6.6 1285 NET 10 semi dull 49.18 0.7128
70.93
li Ascend 6.6 1200 2200 pts S 7 semi dull
58.77 0.382 16.67 -25.9
10 Aquafil 6 1395 19 semi dull 32.88 1.91
83.33
lj Ascend 6.6 1200 2200 pts S 7 semi dull
56.24 0.445 28.15 -15.2
11 Ascend 6.6 1200 CET 7 bright 41.08 1.136 71.85
Table 2 displays dying properties for two twisted yarn packages. In one of the
packages,
a wax pretreatment (NF818 5%) applied prior to dying. The resulting dyed yarn
has a larger DL*
value compared to the yarn without pretreatment.
Table 2. Comparison of dying properties between wax pretreated yarn and
control
Vendor Type Denier Info DPF L*
% OL R % of Tot DL*
Ascend 6.6 1200 2200 S 7 48.32
0.7508 44.39189 4.39
Aquafil 5 min 6 1395 control 19 44.16
0.9405 55.60811
Ascend 6.6 1200 2200 S 7 48.88
0.7122 38.82257 6.06
Aquafil 5 min 6 1395 NF818 5% 19 40.67 1.1223
61.17743
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