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EP2898137A1 - Procédés de teinte et de traitement d'un fil bcf simple - Google Patents

Procédés de teinte et de traitement d'un fil bcf simple

Info

Publication number
EP2898137A1
EP2898137A1 EP13839715.3A EP13839715A EP2898137A1 EP 2898137 A1 EP2898137 A1 EP 2898137A1 EP 13839715 A EP13839715 A EP 13839715A EP 2898137 A1 EP2898137 A1 EP 2898137A1
Authority
EP
European Patent Office
Prior art keywords
yarn
bcf yarn
dye
performance enhancing
bcf
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13839715.3A
Other languages
German (de)
English (en)
Inventor
Wae-Hai Tung
Ronnie Rittenhouse
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Invista Technologies SARL Switzerland
Original Assignee
Invista Technologies SARL Switzerland
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Invista Technologies SARL Switzerland filed Critical Invista Technologies SARL Switzerland
Publication of EP2898137A1 publication Critical patent/EP2898137A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/02—Material containing basic nitrogen
    • D06P3/04—Material containing basic nitrogen containing amide groups
    • D06P3/24—Polyamides; Polyurethanes
    • D06P3/241—Polyamides; Polyurethanes using acid dyes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0065—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/16—Synthetic fibres, other than mineral fibres
    • D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M2101/32—Polyesters
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/16—Synthetic fibres, other than mineral fibres
    • D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M2101/34—Polyamides
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
    • D06M2200/01—Stain or soil resistance
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/34—Material containing ester groups
    • D06P3/52—Polyesters
    • D06P3/54—Polyesters using dispersed dyestuffs
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
    • D06P3/82—Textiles which contain different kinds of fibres
    • D06P3/8204—Textiles which contain different kinds of fibres fibres of different chemical nature
    • D06P3/8214—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of fibres containing ester and amide groups
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23993—Composition of pile or adhesive

Definitions

  • the invention relates to treatment processes for bulk continuous filament (BCF) carpet and related textile fabrics, and specifically, to processes for applying dyes and performance enhancing compositions on BCF yarns during the rewind process prior to twisting, 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.
  • 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.
  • the first process involves converting colorless white yarns into carpet, and dyeing the carpet in a dye bath. This process is referred to as the "acid dye process.”
  • the acid dye process can be either a batch or a continuous dyeing operation. Each dyeing operation requires a large volume of water, steam to set the dyes, and heat to dry the carpet. In addition, collection and disposal of excess dye and acidified performance enhancing solutions add manufacturing cost and place additional burden on waste management and water treatment facilities.
  • the second process adds color pigments into the polymer during the melt spinning process.
  • solution dye process This process is referred to as the "solution dye process.”
  • the solution dye process is a low cost operation, but in comparison to the acid dye process it imposes undesirable inventory allocation measures on the fiber producer and the carpet mill. In order to meet consumer demand, then, the fiber producer and carpet mill may need to keep a costly inventory of colored yarns produced by the solution dye process. Variable production demands and large inventory costs can affect inventory flexibility with the result being the color availability of solution dyed carpets is undesirably limited.
  • Topical chemistries are used to treat carpets and other fabrics for improved stain resistance and/or soil resistance.
  • stain blocker e.g. acid dye blocker
  • anti-soil with fluorochemicals are traditionally used.
  • polyester carpets, such as 2GT and 3GT carpets, and polypropylene carpets anti-soil chemistry may be applied topically to the tufted carpet as part of the carpet finishing process.
  • Polyester and polypropylene carpets typically do not require a stain blocker treatment because of inherent stain resistance to acid dyes and stains owing to their lack of amine end groups that function as acid dye sites.
  • Topical application at the carpet mill can be in the form of exhaust application and spray application.
  • Exhaust application i.e. flex-nip process at high (300 - 400 wt.%) wet pickup
  • Exhaust applications typically use greater amounts of water and energy to dry and cure the carpet than do spray applications.
  • Spray-on fluorochemical products are designed to use less water and energy than exhaust applications, but do not impart satisfactory anti-soil properties.
  • the carpet is also steamed and dyed first, steamed again, rinsed and extracted; and then a blend of SB and FC is applied together at high wet pick up, after which the carpet and chemicals are exposed once again to steam to fix the treatment, followed by drying.
  • a blend of SB and FC is applied together at high wet pick up, after which the carpet and chemicals are exposed once again to steam to fix the treatment, followed by drying.
  • low pH solutions, excess water, and energy are required for the SB and FC to penetrate the carpet and achieve uniform coverage.
  • the typical prior art process is as follows: BCF yarn ⁇ Twist ⁇ heat set ⁇ tufting ⁇ carpet ⁇ dye ⁇ stain block / anti-soil.
  • Carpets have also long been constructed of dyed or pigmented yarns, which constructions are treated in numerous possible ways, including the options of further dyeing, and the application of stain and/or soil resistant compositions with the concomitant use of steam and rinse water, as in the processes described above.
  • the invention disclosed herein provides a process to make textile fabrics, especially tufted articles, without the requirements for dyeing and subsequent stain and soil resistant chemistry application, thus avoiding the costs associated with maintaining large inventories as well as waste generated by steam fixation and rinsing attendant with such large-scale fabric applications.
  • the process involves application of dyes and topical chemistries to undyed single yarns during a yarn rewind process. The chemistries are then optionally heat-set onto the single yarn. The single, treated yarn can then be twisted, weaved and tufted, or weaved and tufted, into a finished fabric or carpet.
  • Novel systems that enable the efficient application of dye solutions and topical chemistries to yarn subsequent to twisting and prior to winding and heat-setting are also disclosed.
  • the disclosed process uses a dye solution and/or performance enhancing composition applicator positioned within a mechanical rewind process.
  • the disclosed process moves the back end, large scale and wasteful stain blocker application step to a single yarn rewind process.
  • the carpet manufacturing process now becomes: BCF yarn ⁇ dye ⁇ optional SB/FC ⁇ optional heat set ⁇ optional twist ⁇ heat set (optionally dry heat set) ⁇ tufting ⁇ carpet.
  • the disclosed process is as effective, or even more effective, than processes of the prior art in terms of fabric soil resistance.
  • neutral pH dye solutions (4-9 pH) can be used instead of the prior art low pH dye solutions (1-3 pH). This reduces the environmental impact of prior art processes.
  • the process of the disclosed invention is counterintuitive since treating the carpet yarn prior to heat setting and tufting is known to affect the quality of the finished carpet, particularly during dyeing. Further, the inventive process is also counter intuitive because soil resistant compositions tend to be very difficult to apply uniformly to twisted yarn bundles at the usual line speed without substantial waste [30 to 80 yards-per-minute (ypm)]. Moreover, the disclosed process is counter intuitive because the prior art yarn rewind apparatuses have not previously accepted topical chemistry applications to single yarn prior to rewinding. However, as shown below, nylon and polyester carpets manufactured with the treated BCF yarn show one or more of the following desirable characteristics:
  • a process for treating single BCF yarn with a dye composition comprises: (a) providing single BCF yarn; (b) winding said BCF yarn on a rewind package; and (c) contacting said BCF yarn with said dye composition while said BCF yarn is in motion and prior to said BCF yarn contacting and winding up on said rewind package.
  • the dye composition can be comprised of an acid dye composition or a disperse dye composition.
  • a process for treating single BCF yarn with a dye composition comprises: (a) providing single BCF yarn; (b) winding said BCF yarn on a rewind package; (c) contacting said BCF yarn with said dye composition while said BCF yarn is in motion and prior to said BCF yarn contacting and winding up on said rewind package; and (d) heat setting said BCF yarn after contacting with said dye composition and prior to winding up on said rewind package.
  • the dye composition can be comprised of an acid dye composition or a disperse dye composition.
  • a process for treating single BCF yam with a dye composition and at least one performance enhancing compositions comprises: (a) providing single BCF yarn; (b) winding said BCF yarn on a rewind package; (c) contacting said BCF yarn with said dye composition; (d) optionally contacting said BCF yarn with a first performance enhancing composition; and (e) contacting said BCF yarn with a second performance enhancing composition prior to said BCF yarn contacting and winding up on said rewind package, wherein said BCF yarn is in motion while contacted with said dye, said optional first performance enhancing composition, and said second performance enhancing composition.
  • the dye composition can be comprised of an acid dye composition or a disperse dye composition.
  • the optional first performance enhancing composition can be stain blocking compositions that are comprised of species having acidic moieties that associate with polymer amine end groups and protect them from staining by acidic dye stains.
  • the general category of chemicals suitable to the process of the instant invention can comprise any chemical that blocks positively charged dye sites.
  • the second performance enhancing composition can be anti-soil compositions that comprise high specific surface energy chemicals or other materials, for example a fluorochemical that imparts high specific surface energy properties such as high contact angles for water and oil, or even a non-fluorochemical particulate material having similar properties.
  • the anti-soil composition can further comprise an anti-stain component.
  • a process for treating single BCF yarn with a dye composition and performance enhancing compositions comprises: (a) providing single BCF yarn; (b) winding said BCF yarn on a rewind package; (c) contacting said BCF yarn with said dye composition; (d) optionally contacting said BCF yarn with a first performance enhancing composition; (e) contacting said BCF yarn with a second performance enhancing composition, wherein said BCF yam is in motion while contacted with said dye, said first performance enhancing composition, and said second performance enhancing composition; and (f) heat setting said BCF yarn after contacting said BCF yarn with said dye composition, said first performance enhancing composition, and said second performance enhancing composition and prior to winding on said rewind package.
  • an untufted, single BCF yarn comprising a dye component
  • said dye component is present on said single BCF yarn prior to tufting the BCF yarn.
  • the dye component is selected from acid and disperse dye ingredients.
  • the yarn can comprise polyamide fiber and/or have polymer components selected from polyester. The yarn can be tufted and manufactured into carpet or fabrics.
  • an untufted, single BCF yarn comprising a dye component, an anti-soil component, and an optional anti-stain component
  • said dyeing component, anti-soil component and optional anti-stain component are present on said single BCF yarn prior to tufting the BCF yarn.
  • the dye component is selected from acid and disperse dye ingredients.
  • the anti-soil component and optional anti-stain component can be selected from the compositions disclosed above.
  • the stain blocking component is optionally present at an amount on weight of fiber of about 0.5 to about 40 ppm elemental sulfur content.
  • the anti- soil component is present at an amount on weight of fiber from about 100 ppm to about 1000 ppm elemental fluorine content.
  • the yarn can comprise polyamide fiber and/or have polymer components selected from polyester. The yarn can be tufted and manufactured into carpet or fabrics.
  • a process for manufacturing carpet comprising providing an untufted, single BCF yarn comprising a dye component, an optional stain blocker component, and an anti-soil component, tufting said BCF yarn, and weaving into said carpet. Because of the dye and performance enhancing components present on the BCF yam prior to tufting and weaving, there is no need to process the finished carpet by dyeing or treating with an acidified stain blocker composition and an anti-soil composition under the current state of the art processes.
  • a system for applying a dye composition to single BCF yarn comprises: (a) a yarn package that transmits a single yarn member; (b) a dye composition applicator disposed downstream of said yarn package that applies said dye composition to said single yarn member; and (c) a rewind package that receives a dyed single yarn member.
  • the dyeing composition can be comprised of acid dye or disperse dye ingredients.
  • a system for applying a dye composition and at least one performance enhancing composition to single BCF yarn comprises: (a) a yarn package that transmits a single yarn member; (b) a dye composition applicator disposed downstream of said yarn package that applies said dye composition to said single yarn member; (c) an optional first performance enhancing composition applicator disposed downstream of said dye composition applicator that applies said first performance enhancing composition to said single yarn member; (d) second performance enhancing composition applicator disposed downstream of said dye composition applicator that applies said second performance enhancing composition to said single yarn member; and (e) a rewind package disposed downstream of said performance enhancing composition applicator that receives a dyed single yarn member.
  • the dyeing composition can be comprised of acid dye or disperse dye ingredients.
  • the optional first performance enhancing composition can comprise anti-stain compositions having species having acidic moieties that associate with polymer amine end groups and protect them from staining by acidic dye stains.
  • the second performance enhancing composition can comprise anti-soil compositions of a high specific surface energy chemical or other material, for example a fluorochemical that imparts high specific surface energy properties such as high contact angles for water and oil, or even a non-fluorochemical particulate material having similar properties.
  • the anti-soil composition can further comprise an anti-stain component.
  • OWF On weight of fiber: The amount of chemistry that was applied as a % of weight of fiber.
  • WPU Weight pick-up
  • a process for treating single BCF yarn comprising contacting the BCF yarn with a dye composition while said yarn is in motion and prior to contacting and rewinding the yarn into a yarn package or cake.
  • the process can also include contacting the BCF yarn with one or more performance enhancing compositions comprising stain blockers and anti-soil compositions.
  • the dye composition comprises a dye component and is adapted to be continuously applied onto twisted BCF yarn at around 200 to 400 ypm, preferably, around 300 ypm.
  • the stain blocker composition comprises an anti-stain component and is adapted to be continuously applied onto single BCF yarn at a wet pick-up of 10 to 50%, preferably 15 to 30%.
  • the anti-soil composition comprises an anti-soil component and is adapted to be continuously applied onto single BCF yarn at a wet pick-up of between about 5 wt.% and about 50 wt.%., including between about 10 wt.% and about 30 wt%, about 20 wt.% to about 30 wt.%, and about 10 wt.% to about 20 wt.%.
  • the single BCF yarn can be optionally heat set after contacting the yarn with the dye composition and the one or more performance enhancing compositions.
  • Heat setting temperatures can range from about 125°C to about 200°C, including from about 160°C to about 195°C.
  • Heat setting dwell times can range from about 0.5 to about 4 minutes, including from about 0.5 to about 3 minute and from about 0.5 to about 1 minute.
  • Dye components for use in the disclosed dye compositions are acid dyes or disperse dyes.
  • Acid dye components are well known to those skilled in the art and are water-soluble ionic species containing one or more organic chromophore moieties.
  • Acid dyes are typically provided in powder form and different acid dyes can be used in combinations to arrive at a precisely defined color choice depending on process conditions such as the use rate of each selected dye component, the use rate of the one or more acid auxiliaries employed, and the residence time of the substrate in the dyeing zone.
  • suitable acid dye compositions are Orange 3G, Red 2B and Blue 4R.
  • Disperse dye components are likewise well known to those skilled in the art and are water-insoluble nonionic species containing one or more organic chromophore moieties. Disperse dyes are either provided in paste form in combination with a dispersing agent or in powder form. Different disperse dyes can be used in combinations to arrive at a precisely defined color choice depending on process conditions such as the use rate of each selected disperse dye component, the specific dispersing agent or agents employed, and the residence time of the substrate in the dyeing zone. Examples of suitable disperse dye compositions are Disperse Red 60, Disperse Yellow 86 and Disperse Violet 33.
  • Anti-stain components for use in the disclosed stain blocker compositions have a component bearing an acidic moiety which associates with polymer amine end groups and protects them from staining by acidic dye stains.
  • the general category of chemicals suitable to the process of the instant invention can comprise any chemical that blocks positively charged dye sites.
  • Stain blockers are available in various forms such as syntans, sulfonated novolacs, sulfonated aromatic aldehyde condensation products (SACs) and/or reaction products of formaldehyde, phenolics, substituted phenolics, thiophenolics, sulfones, substituted sulfones, polymers or copolymers of olefins, branched olefins, cyclic olefins, sulfonated olefins, acrylates, methacrylates, maleic anyhydride, and organosulfonic acids.
  • SACs sulfonated aromatic aldehyde condensation products
  • stain blocker is typically water soluble and generally penetrates the fiber while the anti-soil, usually a fluorochemical, is a non-water soluble dispersion that coats the surface of fiber. More than one stain blocker can be used in the anti- stain compositions.
  • stain blockers include, but are not limited to: phenol formaldehyde polymers or copolymers such as CEASESTAIN and STAINAWAY (from American Emulsions Company, Inc., Dalton, Ga.), MESITOL (from Bayer Corporation, Rock Hill, N.C.), ERIONAL (from Ciba Corporation, Greensboro, N.C.), INTRATEX (from Crompton & Knowles Colors, Inc., Charlotte, N.C.), STAINKLEER (from Dyetech, Inc., Dalton, Ga.), LANOSTAIN (from Lenmar Chemical Corporation, Dalton, Ga.), and SR-300, SR-400, and SR-500 (from E. I.
  • polymers of methacrylic acid such as the SCOTCHGARD FX series carpet protectors (from 3M Company, St. Paul Minn.); sulfonated fatty acids from Rockland React-Rite, Inc., Rockmart, Ga); and stain resist chemistries from ArrowStar LLC, Dalton and Tri-Tex, Canada.
  • Anti-soil components for use in the disclosed anti-soil compositions impart high specific surface energy properties such as high contact angles for water and oil (e.g. water and oil "beads up” on surfaces treated by it).
  • the anti-soil component can comprise a fluorochemical dispersion, which dispersion may be predominantly either cationic or anionic, including those selected from the group consisting of fluorochemical allophanates, fluorochemical polyacrylates, fluorochemical urethanes, fluorochemical carbodiimides, fluorochemical guanidines, non- telomeric fluorochemicals, and fluorochemicals incorporating C2 to C8 chemistries.
  • the fluorochemical can have less than or equal to eight fluorinated carbons, including less than or equal to six fluorinated carbons.
  • Example fluorochemical anti-soil components include: DuPont TLF 10816 and 10894; Daikin TG 2511 , and DuPont Capstone® RCP.
  • Non-fluorinated anti-soil components can include: silicones, silsesquioxanes and silane- modified particulates, organosilane-modified particulates and alkylated particulates, anionic non- fluorinated surfactants and anionic hydrotrope non-fluorinated surfactants, including sulfonates, sulfates, phosphates and carboxylates.
  • the dye composition is adapted to contact the single BCF yarn while it is in motion and prior to contacting the take-up reel or winder. Further, the dye composition can be at a neutral pH (e.g. 4 to 9, including 5.5 to 7.5) because the yarn can be optionally heat set after application of the composition. The process foregoes the need for harsh low pH chemicals; deionized water is suitable for use in the disclosed process.
  • the stain blocker composition is adapted to contact the single BCF yarn while it is in motion and prior to contacting the take-up reel or winder. Further, the stain blocker composition can be at a neutral pH (e.g. 6 to 8) because the yarn can be optionally heat set after application of the composition. The process foregoes the need for harsh low pH chemicals.
  • a neutral pH e.g. 6 to 8
  • the anti-soil composition is adapted to contact the twisted BCF yarn while it is in motion and prior to contacting the take-up reel or winder. Further, the anti-soil composition can be at a neutral pH (e.g. 6 to 8) because the yarn can be optionally heat set after application of the composition. The process foregoes the need for harsh low pH chemicals.
  • the contacting can be performed by any suitable device that applies wet ingredients to a dry substrate, including, but not limited to: applicator pad, nip rollers, wet-wick, dip-tank, sprayer, and mister.
  • cotton wicks can be stacked together to form the desired thickness (e.g. 1 ⁇ 2" - 3") and submersed in the dye bath for transporting dye solution to the moving yarn at a constant flow-rate.
  • the wick thickness selection was based on the optimum wick and yarn contacting time needed to achieve the desired color depth and color consistency.
  • a further option is to use multiple sets of wicking applicator stations. The first wicking applicator station applies the primary color onto the yarn and the second wicking applicator station applies a second color or performance enhancing chemical onto the yarn.
  • Each wicking applicator station can be made up of one or more wicks.
  • Another option is to transport dye solution to the yarn using two rotating rolls covered with wicks.
  • the yarn passes between the two rotating rolls.
  • multiple rolls can be used in series.
  • one roll can apply a first color onto one side of the moving yarn and another roll to apply a second color onto the other side of the yarn to create a unique two color yarn.
  • two sets of nip rolls can be used. The first set can apply the primary color and the second set can apply a second color or performance enhancing chemical onto the yarn. Any combination of the above options can be used to make yarn with multiple colors, color depth and with various performance chemicals.
  • the wet pick-up of the anti-soil composition is between about 5 wt.% and about 50 wt.%., including between about 10 wt.% and about 30 wt%, about 20 wt.% to about 30 wt.%, and about 10 wt.% to about 20 wt.%.
  • the resulting twisted BCF yarn if a fluorine based anti- soil component is used, can have an on weight of fiber from about 100 ppm to about 1000 ppm elemental fluorine, including from about 100 to about 500 ppm elemental fluorine, from about 200 to about 400 ppm, and from about 100 ppm to about 300 ppm elemental fluorine.
  • the wet pick-up of the stain blocker composition is present on weight of fiber from about 500 ppm to about 4%, including from about 1000 ppm to about 3%, from about 0.5% to about 2%, and from about 0.5% to about 1%.
  • Common stain blockers use sulfonated moieties as part of the chemistry, which results in the presence of sulfur on the treated fiber.
  • the sulfur content can range from about 50 ppm with 5% stain blocker to about 1 ppm with 0.1%o stain blocker on weight of fiber.
  • the sulfur content on weight of fiber will range from about 0.5 ppm to about 40 ppm elemental sulfur, including from about 1 ppm to about 30 ppm elemental sulfur, from about 5 ppm to about 20 ppm elemental sulfur, and from about 5 ppm to about 10 ppm elemental sulfur.
  • Sulfur content can be determined by x-ray diffraction or other methods.
  • the performance enhancing compositions can further comprise one or more components selected from the group consisting of: odor control agents, anti-microbial agents, anti-fungal agents, fragrance agents, bleach resist agents, softeners, and UV stabilizers.
  • the single BCF yarn can be made from polyamide fibers, such as those made from nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof. Further, the single BCF yarn can also have additional polymer components, such as polyester. The additional polymer components can be incorporated with the polyamide (by melt-blend or co-polymerization) prior to making a polyamide fiber (e.g. a polyamide/polyester fiber), or can be stand-alone fibers that are twisted with the polyamide fibers to make the twisted BCF yarn.
  • polyamide fibers such as those made from nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof.
  • additional polymer components such as polyester.
  • the additional polymer components can be incorporated with the polyamide (by melt-blend or co-polymerization) prior to making a polyamide fiber (e.g. a polyamide/polyester fiber), or can be stand-alone
  • the BCF yarn can be manufactured with polyamide and / or polyester polymer components.
  • An unexpected benefit of the disclosed process has been discovered in that, whereas a small amount of anti-soil composition is applied compared to known exhaust processes, a high anti-soil component content, such as fluorine, is achieved on the surface of the yarn.
  • the anti-soil composition applied in the process of the disclosed invention can be either fluorochemical or non-fluorochemical based, or a mixture of fluorochemical or fluoropolymer material with non-fluorinated soil resistant materials.
  • the yarns can be made by acid dyed as well as disperse dyed fibers.
  • Yarns suitable for use in the process may further comprise inherent stain resistance, whether by base composition as in the case of polyester, or by the inclusion of strong acid functionality in the polymer composition of the yarn, as in the case of nylon.
  • Use of a dye applicator with the disclosed process eliminates the need for subsequent dyeing and enables the creation of colored carpets that improve inventory flexibility, improve color options, are stain resistant, and are soil resistant without the need for dyeing and performance enhancing chemical applications as practiced under the current state of the art.
  • the single BCF yarn made with the various aspects of the disclosed process, by itself or blended with non-treated fibers and yarns, can be tufted and manufactured into carpets or fabrics.
  • the disclosed process can also be advantageously applied in certain processes where a styling advantage might be derived from differential dyeing and finishing after carpet formation.
  • a soil resistant or stain resistant single yarn of the disclosed invention could optionally be tufted into a carpet among untreated yarns prior to dyeing, thus creating an aesthetic alternative.
  • a system for applying a dye composition and one or more performance enhancing compositions to the single BCF yarn includes: (a) a yarn package that transmits a single yarn member; (b) a dye composition applicator disposed downstream of said yarn package; (c) an optional first performance enhancing composition applicator disposed downstream of said dye composition applicator that applies said first performance enhancing composition to said single yarn member; (d) second performance enhancing composition applicator disposed downstream of said dye composition applicator that applies said second performance enhancing composition to said single yarn member; and (e) a rewind package disposed downstream of said performance enhancing composition applicator that receives a dyed single yarn member.
  • the single yarn members can be single filaments or fibers, or yarns made from a plurality of filaments or fibers.
  • Each applicator can be any suitable device that applies wet ingredients to a dry substrate, including, but not limited to: applicator pad, nip rollers, wet-wick, dip-tank, sprayer, and mister.
  • a supply package yarn is fed at a line speed of about 300 ypm, passing through a dye applicator, disposed downstream of the yarn package, which applies a dye component to the single yarn. From here, the single and dyed yarn is rewound into a package, another aspect of the disclosed process contains both a dye applicator and a steam heat treatment.
  • a supply package yarn which is fed at a line speed of about 300 ypm, passes through a dye applicator, disposed downstream of the yarn package, which applies a dye component to the single yarn. From here, the single and dyed yarn pass through a heat treatment chamber and is rewound into a package.
  • Acid dye stain resistance is evaluated using a procedure modified from the American Association of Textile Chemists and Colorists (AATCC) Method 175-2003, "Stain Resistance: Pile Floor Coverings.”
  • 9 wt % of aqueous staining solution is prepared, according to the manufacturer's directions, by mixing cherry-flavored KOOL-AID ® powder (Kraft Foods, Northfield, IL, a powdered drink mix containing, inter alia, FD&C Red No. 40).
  • a carpet sample (4x6-inch) is placed on a flat non-absorbent surface.
  • a hollow plastic 2-inch (5.1 cm) diameter cup is placed tightly over the carpet sample.
  • KOOL-AID® staining solution Twenty milliliters of the KOOL-AID® staining solution is poured into the cup and the solution is allowed to absorb completely into the carpet sample. The cup is removed and the stained carpet sample is allowed to sit undisturbed for 24 hours. Following incubation, the stained sample is rinsed thoroughly under cold tap water, excess water is removed by centrifugation, and the sample is dried in air. The carpet sample was visually inspected and rated for staining according to the FD&C Red No. 40 Stain Scale described in AATCC Method 175-2003. Stain resistance is measured using a 1-10 scale. An undetectable test staining is accorded a value of 10.
  • a 1320 denier, 64 filament nylon BCF yarn made from deep acid dyeable polymer (Type 417A) was processed on a rewinding machine. Two wicking stations with 1 ⁇ 2" wide, 1" thick were inserted between the creel and rewinder. Acid dyes (Telon Yellow 4R, 137.2 g/l; Red 2BN, 21.0 g/l; Blue BRL, 34.1 g/l) were used to dye the BCF yarn to dark brown color. The winding speed was about 300 yards per minute.
  • a 997 denier, 115 filament white BCF single yarn made from Nylon 66 cationic dyeable polymer was processed using a Suessen heatset machine. Three color wicking stations arranged in series were inserted between the yarn creel and the Suessen heatset machine. A 1 ⁇ 2" wide, 1.5" thick cotton wick was used in each station to apply gold color premet dyes at pH 5.0 (Isolan Yellow NW, 23.0 gram/liter; Isolan Red S-RL, 6 gram/liter; Isolan Black 2S-CP, all by Dystar, L ., Charlotte, NC) onto the moving BCF yarn at 350 ypm. The colored yarn was subsequently treated with hot air (200° C) in a Suessen heatset channel.
  • the dwell time in the channel was about 60 seconds.
  • a different dye formulation Isolan Yellow NW, 9.6 gram/liter; Isolan Red S-RL, 2.8 gram/liter; Isolan Black 2S-CP 7.7 gram/liter
  • different dye formulation Isolan Yellow NW, 2.5 gram/liter; Isolan Red S-RL, 1.7 gram/liter; Irglan Blue 3GL, 27.6 gram/liter
  • Yarns produced in examples 3, 4 and 5 were processed on a Volkmann twisting machine to form three ply yarn having 4.5 twists per inch.
  • the cable twisted yarn was converted into loop pile carpet (1/10 ga. 1/8 inch pile height, 14 stitches per inch, 20 oz per square yard).
  • the finished carpet had an attractive multicolor look, good color fastness and great stain resistance to acid dyes.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Carpets (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Abstract

L'invention concerne des procédés d'application de teintes, de compositions facultatives antitache et antisalissure sur des fils BCF simples pendant un réenroulement, avant torsion, tissage, tricotage ou touffetage. Les procédés s'affranchissent de la nécessité de teindre ou par ailleurs de traiter des tapis ou autres textiles fabriqués à partir du fil BCF utilisant les procédés actuels. Sont également divulgués des systèmes, des fils BCF et des tapis fabriqués à partir du fil BCF traité dans le procédé divulgué.
EP13839715.3A 2012-09-19 2013-09-18 Procédés de teinte et de traitement d'un fil bcf simple Withdrawn EP2898137A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261702853P 2012-09-19 2012-09-19
PCT/US2013/060353 WO2014047143A1 (fr) 2012-09-19 2013-09-18 Procédés de teinte et de traitement d'un fil bcf simple

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EP2898137A1 true EP2898137A1 (fr) 2015-07-29

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EP (1) EP2898137A1 (fr)
JP (1) JP2015531436A (fr)
CN (1) CN104838061A (fr)
AU (1) AU2013318158A1 (fr)
CA (1) CA2882810A1 (fr)
WO (1) WO2014047143A1 (fr)

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Publication number Priority date Publication date Assignee Title
NL125709C (fr) * 1959-12-21
US5414987A (en) * 1991-07-17 1995-05-16 E. I. Du Pont De Nemours And Company Pre-stuffer box conditioning of ply-twisted carpet yarn
US5908663A (en) * 1996-02-01 1999-06-01 Minnesota Mining And Manufacturing Company Topical carpet treatment
US6312783B1 (en) * 2000-11-13 2001-11-06 Oriental Weavers Of America Polypropylene-based carpet yarn
EP1597424A1 (fr) * 2003-02-06 2005-11-23 INVISTA Technologies S.à.r.l. Fil de polyamide effectivement imprimable, procede de fabrication et textile ainsi obtenu
US20060248656A1 (en) * 2005-05-06 2006-11-09 Invista North America S.A.R.L. New process of making permanent acid stain resistance for a lightly dyed polyamide carpet
US20140065346A1 (en) * 2011-03-16 2014-03-06 Wae-Hai Tung Processes to make water and oil repellent bcf yarn

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Title
See references of WO2014047143A1 *

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CN104838061A (zh) 2015-08-12
US20150247284A1 (en) 2015-09-03
JP2015531436A (ja) 2015-11-02
AU2013318158A1 (en) 2015-02-19
WO2014047143A1 (fr) 2014-03-27
CA2882810A1 (fr) 2014-03-27

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