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Processes to dye and treat bcf yarn

Inactive Publication Date: 2014-09-11
INVISTA NORTH AMERICA R L
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent text describes a process for making textile fabrics without the need for dyeing and stain blocking chemicals. This is done by applying dyes and chemistries to yarns after they are twisted and heat-set. The process reduces the amount of water and chemicals used and the costs associated with large inventories and waste. The dye solutions can have a neutral pH, reducing the environmental impact of the process. The invention results in fabrics with effective soil resistance.

Problems solved by technology

First, because the appearance of carpet has historically depended on the ability to dye wool or nylon or even polyester tufted carpets to the desired shade, it would not be permissible to treat the carpet with compositions such as anti-stain or anti-soil chemistries beforehand that might interfere with the process of uniform dyeing.
Further, the dyeing process would tend to remove the topical treatment chemistries, rendering them ineffective.

Method used

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  • Processes to dye and treat bcf yarn
  • Processes to dye and treat bcf yarn
  • Processes to dye and treat bcf yarn

Examples

Experimental program
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Effect test

example 1

Comparative

[0059]Two 920 denier, 8 dpf, colorless nylon 6,6 BCF yarns were processed on a Volkman twisting machine as described in FIG. 1 to form a 5.75 tpi (twist per inch) 2-ply cable twisted yarn. The twisting speed was about 7000 rpm (turns per minute) and winding speed was about 50 meter per minute. The cable twisted yarn had no color. The cable twisted yarn was heatset on Superba, and converted into cut pile carpet on a ⅛ ga tufting machine to 22 / 32 inch pile height, 35 oz / sq yard carpet and dyed on a continuous dye line to get medium pie crust color. This example was made using the state of art carpet making process with continuous dyer to add color to carpet.

example 2

Inventive

[0060]Two 920 denier, 8 dpf, colorless nylon 6,6 BCF yarns were processed on a Volkman twisting machine as described in FIG. 2 to form a 5.75 tpi (twist per inch) 2-ply cable twisted yarn. A wicking dye applicator was inserted between take up roll and winder. A % inch wide, 1 inch thick cotton wick (Wet Wick by Perperell MA) was used to apply a mixture of acid dyes (Blue 4R @ 5.0 g / l & Orange 3G @ 2.0 g / l in deionized water, pH 9.47) onto the cable twisted yarn. The twisting speed was about 7000 rpm (turns per minute) and winding speed was about 50 meter per minute. The cable twisted yarn was heatset on Superba at 265° F., and tufted into cut pile carpet on a ⅛ ga tufting machine to 22 / 32 inch pile height, 35 oz / sq yard carpet. The tufted carpet had medium shade green color (L 51.26, a −9.71, b+1.45 by Minolta).

example 3

Inventive

[0061]Two 920 denier, 8 dpf, colorless nylon 6,6 BCF yarns were processed on a Volkman twisting machine as described in FIG. 2 to form a 5.75 tpi (twist per inch) 2-ply cable twisted yarn. A wicking dye applicator was inserted between take up roll and winder. A ½ inch wide, 1 inch thick cotton wick (Wet Wick by Perperell MA) was used to apply a mixture of acid dyes (Orange 3G @ 5.712 g / l, Red 2B @ 2.52 g / l, Blue 4R @ 2.268 g / l in deionized water, pH 6) onto the cable twisted yarn. The twisting speed was about 7000 rpm (turns per minute) and winding speed was about 50 meter per minute. The cable twisted yarn was heatset on Superba at 265° F., and tufted into cut pile carpet on a ⅛ ga tufting machine to 22 / 32 inch pile height, 35 oz / sq yard carpet. The tufted carpet had light shade brown color (L 39.17, a 10.48, b 18.14 by Minolta). There were numerous dark, medium and light spots randomly distributed over the carpet that created an interesting salt and pepper toner mixture e...

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Abstract

Disclosed are processes for applying dyes, stain blocker and anti-soil compositions on BCF yarns during cable or air twisting processes, or heat setting processes, prior to weaving, knitting or tufting. Further discloses are process for applying dyes, stain blocker and anti-soil compositions on BCF yarns prior to heat setting. The processes forego the need to dye and otherwise treat carpets and other textiles made from the BCF yarn using current methods. Also disclosed are systems, BCF yarns, and carpets made from the BCF yarn treated by the disclosed process.

Description

FIELD OF THE INVENTION[0001]The invention relates to treatment processes for bulk continuous filament (BCF) carpet and related textile fabrics, and specifically, to processes for applying dyes and topical treatment compositions on BCF yarns during twisting processes (cable or air) or heatseting process prior to weaving, knitting or tufting. The process foregoes the need to dye and otherwise treat carpets and other textiles made from the BCF yarn using current methods. Thus, low inventory overhead is achieved and costly and environmentally unfavorable dyeing and low pH chemical treatment processes are eliminated. Also disclosed herein are systems used to apply the dye and performance enhancement formulations to the BCF yarn, and stain / soil repellent yarns, and carpets with improved anti-stain and anti-soil properties made from the BCF yarn of the disclosed process.BACKGROUND OF THE TECHNOLOGY[0002]Carpets and other fabrics made from synthetic yarns are currently colored using two wel...

Claims

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Application Information

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IPC IPC(8): D02G3/44D06P3/52D03D1/00D05C17/02D02G3/36D06B3/04
CPCD02G3/445D02G3/36D06P3/52D03D1/0017D05C17/023D06B3/04D02G3/285D10B2331/02D10B2331/04Y10T428/23979
Inventor TUNG, WAE-HAIRITTENHOUSE, RONNIEREYNOLDS, DANIEL R.
Owner INVISTA NORTH AMERICA R L
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