WOOL-LIKE SYNTHETIC MULTIFILAMENT YARNS

Abstract

Wool-like, synthetic multifilament yarns may be produced with a plurality of primary yarns and at least one secondary yarn. Generally, the primary yarn and secondary yarn may be produced from polyamides. The wool-like multifilament yarns may be produced by: (1) melt-spinning the primary yarns and the secondary yarn; (2) drawing and texturizing the primary yarns and the secondary yarns; (3) entangling the texturized primary yarns and the texturized secondary yarn to form the inventive yarn; (4) optionally subjecting the inventive yarn to heat-setting or heat annealing; and (5) winding the yarn onto a package for distribution. The multifilament yarns may be used to produce floorcoverings.

Claims

1. A wool-like multifilament yarn comprising: (a) a plurality of texturized primary yarns formed from a first fiber-forming synthetic polymer, wherein said texturized primary yarns exhibit a residual elongation to break in the range of 50 to 700 percent as measured according to ISO 2062; and (b) at least one texturized secondary yarn formed from a second fiber-forming synthetic polymer, wherein said texturized secondary yarn exhibits a residual elongation to break in the range of 50 to 700 percent as measured according to ISO 2062, wherein the denier of said texturized primary yarns is greater than the denier said texturized secondary yarn.

2. The multifilament yarn according to claim 1, wherein said first fiber-forming synthetic polymer and/or said second fiber-forming synthetic polymer comprises a polyamide.

3. The multifilament yarn according to claim 2, wherein said polyamide comprises at least one polyamide selected from the group consisting of Nylon 6, Nylon 11, Nylon 12, Nylon 5,6, Nylon 6,6, Nylon 6,10, and Nylon 6,12.

4. The multifilament yarn according to claim 2, wherein said first fiber-forming synthetic polymer and/or said second fiber-forming synthetic polymer comprise the same polyamide.

5. The multifilament yarn according to claim 1, wherein said texturized primary yarns and said secondary yarn comprise filaments having a cross-sectional shape selected from the group consisting of round, oval, triangular, multilobal, irregular, and hollow.

6. The multifilament yarn according to claim 1, wherein said texturized primary yarns comprise a first set of filaments and said secondary yarn comprise a second set of filaments, wherein said first set of filaments and said second set of filaments have different cross-sectional shapes.

7. The multifilament yarn according to claim 1, wherein said texturized primary yarns have a denier in the range of 100 to 2,000.

8. The multifilament yarn according to claim 7, wherein said texturized primary yarns have a denier per filament in the range of 2 to 20.

9. The multifilament yarn according to claim 7, wherein said texturized secondary yarns have a denier in the range of 50 to 750.

10. The multifilament yarn according to claim 9, wherein said texturized secondary yarns have a denier per filament in the range of 2 to 25.

11. The multifilament yarn according to claim 1, wherein said multifilament yarns comprise 2 to 10 of said texturized primary yarns.

12. The multifilament yarn according to claim 11, wherein said multifilament yarn comprises only one of said texturized secondary yarn.

13. A floorcovering face yarn comprising said multifilament yarn according to claim 1.

14. A textile comprising said multifilament yarn according to claim 1.

15. A process for the manufacture of a multifilament yarn, said process comprising: (a) texturizing a plurality of primary yarns formed from a first fiber-forming synthetic polymer and at least one secondary yarn formed from a second fiber-forming synthetic polymer to thereby form texturized primary yarns and a texturized secondary yarn, wherein said primary yarns exhibit a residual elongation to break in the range of 50 to 700 percent as measured according to ISO 2062, wherein said primary yarns comprise less than 100 tack points per meter of yarn; (b) entangling said texturized primary yarns and said texturized secondary yarn within an entangling device to thereby form said multifilament yarn; (c) optionally, heat setting said multifilament yarn; and (d) winding said multifilament yarn to form a package.

16. The process according to claim 15, wherein said texturizing of step (a) comprises false-twist texturing, mechanical crimping, and/or stuffer box crimping.

17. The process according to claim 15, wherein said texturizing of step (a) comprises stuffer box crimping.

18. The process according to claim 15, wherein said entangling device comprises a cable twisting device or an air twisting device.

19. The process according to claim 15, further comprising melt-spinning said first fiber-forming synthetic polymer to form said primary yarns and melt-spinning said second fiber-forming synthetic polymer to form said secondary yarn, wherein said melt-spinning occurs at a rate in the range of 100 to 1,500 meters per minute.

20. The process according to claim 19, wherein said melt-spinning does not involve a drawing step.

Description

DETAILED DESCRIPTION

[0014] The present invention generally relates to the manufacture of floorcovering face yarns formed from melt-spun synthetic fibers, such as melt-spun polyamide fibers. The inventive yarns closely resemble wool-based yarns in terms of aesthetics and hand. As discussed below in greater detail, the wool-like yarns of the present invention may be produced by combining a plurality of melt-spun, multifilament yarns, i.e., the primary yarns, with a second single yarn, i.e., the secondary yarn. As discussed below, the primary yarns and secondary yarns differ from each other in various ways, such as fiber bundle size. In various embodiments, the primary yarns and the secondary yarns are continuous multifilament yarns that may be melt-spun from various fiber-forming synthetic polymers, such as polyamides. The inventive, wool-like multifilament yarns of the present invention may be used in various applications, such as floorcoverings, due to the yarn's improved aesthetics and hand.

[0015] As discussed below in greater detail, the wool-like multifilament yarns of the present invention may be produced by: (1) melt-spinning the primary yarns and the secondary yarn; (2) drawing and texturizing the primary yarns and the secondary yarns; (3) entangling the texturized primary yarns and the texturized secondary yarn to form the inventive yarn; (4) optionally subjecting the inventive yarn to heat-setting or heat annealing; and (5) winding the yarn onto a package for distribution.

The Primary Yarns and Secondary Yarns

[0016] The starting materials for use in the inventive process include continuous filament singles yarns divided into two typesa plurality of primary yarns and at least one secondary yarn. In one or more embodiments, the inventive yarns can comprise, consist essentially of, or consist of a plurality of the primary yarns and at least one secondary yarn.

[0017] The inventive yarns may be formed from one or more primary yarns. In various embodiments, the inventive yarns can comprise at least 2, 3, 4, or 5 and/or less than 20, 15, 10, 8, or 6 primary yarns.

[0018] The primary yarns may be oriented to such a degree so as to possess a residual elongation to break of at least 50, 100, 150, 200, 250, 300, 350, or 400 percent and/or less than 700, 650, 600, 550, or 500 percent as measured according to ISO 2062.

[0019] In various embodiments, the primary yarns may comprise or consist of filaments that are not substantially interlaced. For example, the primary yarns may comprise less than 200, 150, 100, 75, 50, or 35 tack points per meter of yarn.

[0020] The starting secondary yarn may be oriented to such a degree so as to possess a residual elongation to break of at least 50, 100, 150, 200, 250, 300, 350, or 400 percent and/or less than 700, 650, 600, 550, or 500 percent as measured according to ISO 2062.

[0021] In various embodiments, the denier of the primary yarns is greater than that of the secondary yarn. In one or more embodiments, the primary yarns may have a denier of at least 100, 200, 300, 400, or 500 and/or less than 2,000, 1,500, 1,000, or 750. Additionally or alternatively, the primary yarns may have a denier per filament of at least 2, 3, 4, 5, 6, or 7 and/or less than 50, 40, 30, 25, 20, or 15.

[0022] In various embodiments, the secondary yarn has a denier of at least 50, 100, 150, 200, or 225 and/or less than 1,000, 750, 500, 400, 350, or 300. Additionally or alternatively, the secondary yarn may have a denier per filament of at least 2, 4, 5, 6, 7, 8, 9, or 10 and/or less than 50, 40, 30, 25, 20, or 15.

[0023] In various embodiments, the primary yarns and/or the secondary yarn may comprise or consist of filaments with the same or different cross-sectional shapes. Exemplary cross-sectional shapes include, but are not limited to, round, oval, triangular, square, multilobal, irregular, and/or hollow. In one or more embodiments, the primary yarns and the secondary yarns comprise or consist of filaments having different cross-sectional shapes. In certain embodiments, the primary yarns comprise or consist of filaments with a round cross-sectional shape and the secondary yarn comprises or consists of fibers with a multilobal cross-sectional shape, such as a trilobal shape.

[0024] In various embodiments, the primary yarns and/or the secondary yarn may be low-oriented yarns (LOY). More specifically, in various embodiments, the primary yarns and/or the secondary yarn may be subjected to little or no drawing when created during the melt-spinning steps. In such embodiments, the primary yarns and/or the secondary yarn may be immediately transferred to the texturizing (i.e., crimping) device from the melt-spinning device without being subjected to any orientation (i.e., drawing).

[0025] Both the primary yarns and the secondary yarn can be continuous filament, melt-spun yarns, which may be melt-spun utilizing standard melt-spinning equipment and methods known to those skilled in the art.

[0026] The primary yarns and secondary yarn may be melt-spun from any suitable fiber-forming synthetic polymer known in the art including, for example, polyamides, polyesters, or polyolefins. In various embodiments, the primary yarns and secondary yarn may be melt-spun from a polyamide, with the primary yarns and the secondary yarns being formed from the same or different polyamides. Exemplary fiber-forming polyamides include, but are not limited to, Nylon 6, Nylon 11, Nylon 12, Nylon 5,6, Nylon 6,6, Nylon 6,10, Nylon 6,12, copolymers thereof, and blends thereof. In certain embodiments, both the primary yarns and the secondary yarn are melt-spun from Nylon 6,6. In other embodiments, both the primary yarns and the secondary yarn are melt-spun from a Nylon 6,6 copolymer containing one or more sulfonated co-monomers.

[0027] The primary yarns and/or the secondary yarn may contain colorant species, preferably pigments incorporated at the melt-spinning stage. The primary yarns and the secondary yarn may contain the same or different colorants.

[0028] The primary yarns and/or the secondary yarn may contain one or more active additives incorporated into the polyamide at the melt-spinning stage. Such additives include, but are not limited to, antioxidants, UV stabilizers, metal deactivators, processing aids, nucleating agents, antimicrobials, flame retardants, and antistatic agents.

[0029] In various embodiments, the primary yarns and/or the secondary yarn may have been exhibited to little or no shrinkage during the melt-spinning process.

[0030] As discussed below, the melt-spinning and drawing processes may be carried out utilizing separate melt-spinning and drawing sequences. Alternatively, in certain embodiments, the melt-spinning and drawing processes may be a combined spin-draw process. In one or more embodiments, the primary yarns and the secondary yarn may be melt-spun and drawn using the same or different methods.

The Method of Producing the Inventive Yarns

[0031] The wool-like multifilament yarns of the present invention may be produced by: (1) melt-spinning the primary yarns and the secondary yarn; (2) drawing and texturizing the primary yarns and the secondary yarns; (3) entangling the texturized primary yarns and the texturized secondary yarn to form the inventive yarn; (4) optionally subjecting the inventive yarn to heat-setting or heat annealing; and (5) winding the yarn onto a package for distribution.

[0032] As noted above, the primary yarns and the secondary yarns may be produced using any melt-spinning technique known in the art. In various embodiments, the melt-spinning process may occur at a rate of at least 100, 200, 300, 400, or 500 and/or less than 2,500, 1,500, 1,000, 750, or 600 meters per minute (MPM). Furthermore, in various embodiments, the melt-spinning may occur at a temperature in the range of 250 to 350 F.

[0033] The primary yarns may be texturized using any suitable method known in the art. Likewise, the secondary yarn may also be texturized using the same method as the primary yarns or, alternatively, may be texturized using a different method.

[0034] In various embodiments, the primary yarns are simultaneously and separately texturized, with the texturizing being carried out using any suitable method including, but not limited to, false-twist texturing, mechanical crimping, friction texturing, and stuffer box crimping. In a preferred embodiment, the texturizing process is carried out using stuffer box crimping. In certain embodiments, the texturizing process does not involve false-twist texturizing or friction texturizing. In one or more embodiments, the secondary yarn may also be subjected to a texturizing process, using the same or different process as applied to the primary yarns. In a preferred embodiment, the secondary yarn is texturized.

[0035] During the texturizing step, the secondary yarn may be intermingled with the primary yarns, thereby giving the yarn a speckled appearance.

[0036] As noted above, the primary yarns and/or the secondary yarn can be low orientation yarns when introduced into the texturizing step. The separation of the melt-spinning and texturizing steps allows the combination of yarns having low deniers and/or the combination of yarns having different deniers. Another benefit of using low orientation yarns during the texturizing step is that it allows the melt-spinning step to occur at a higher machine output, which reduces the costs of the preceding melt-spinning step. The denier of the resulting melt-spun yarn can be modified as necessary during the texturizing/drawing step.

[0037] Additionally, in various embodiments, the primary yarns and/or the secondary yarn may also be subjected to drawing during the texturizing steps. In certain embodiments, this drawing occurs at elevated temperatures above room temperature. Alternatively, the drawing may be carried out at room temperature.

[0038] In various embodiments, the texturizing/drawing step mitigates any formation of interlacing within the primary yarns. This can be accomplished by not using an air tack jet during the texturizing step. Consequently, in various embodiments, the texturized primary yarns after the texturizing/drawing step may comprise or consist of filaments that are not substantially interlaced. For example, the texturized primary yarns may comprise less than 200, 150, 100, 75, 50, or 35 tack points per meter of yarn.

[0039] The texturized primary yarns may be produced in such a manner as to possess a residual elongation to break of at least 50, 100, 150, 200, 250, 300, 350, or 400 percent and/or less than 700, 650, 600, 550, or 500 percent as measured according to ISO 2062.

[0040] The texturized secondary yarn may be produced in such a manner as to possess a residual elongation to break of at least 50, 100, 150, 200, 250, 300, 350, or 400 percent and/or less than 700, 650, 600, 550, or 500 percent as measured according to ISO 2062.

[0041] In one or more embodiments, the texturized primary yarns may have a denier of at least 100, 200, 300, 400, or 500 and/or less than 2,000. Additionally or alternatively, the texturized primary yarns may have a denier per filament of at least 2, 3, 4, 5, 6, or 7 and/or less than 50, 40, 30, 25, 20, or 15.

[0042] In various embodiments, the texturized secondary yarn has a denier of at least 50, 100, 150, 200, or 225 and/or less than 1,000, 750, 500, 400, 350, or 300. Additionally or alternatively, the texturized secondary yarn may have a denier per filament of at least 2, 4, 5, 6, 7, 8, 9, or 10 and/or less than 50, 40, 30, 25, 20, or 15.

[0043] In certain embodiments, the texturizing step does not involve any air bulking steps.

[0044] Next, in various embodiments, the texturized primary yarns and the secondary yarn may be combined together in an entangling device and entangled together to form the face yarn. The entangling device may be any such device known to those skilled in the art including, but not limited to, a cable twisting device or a fluid jet entangling device. In a preferred embodiment, the entangling process is carried out using a Gilbos air twist device. While in the entanglement device, the primary yarns and the secondary yarn may be entangled to form a face yarn, which may be wound up into a suitable package.

[0045] In various embodiments, the texturized primary yarns and the single secondary yarn may be wound together onto a suitable package after being introduced into an entanglement device.

[0046] In an optional step, the resulting face yarn may be heat-set or annealed by any suitable method prior to being re-wound into a package. In such embodiments, the face yarn may be annealed or heat-set using any suitable device and method known to those skilled in the art. In one or more embodiments, the yarn may be heat-set using a Superba or Suessen heat setting method.

[0047] Lastly, the resulting yarn may be wound onto a package for subsequent distribution.

[0048] The inventive yarns of the present invention can exhibit aesthetic features that are very similar to wool-based yarns. For example, the inventive yarns may look like wool and have a soft hand.

[0049] The inventive yarns of the present invention may be used to produce various articles including floorcovering (e.g., rugs and carpets), textiles, and clothing. In certain embodiments, the inventive yarns are used to manufacture floorcoverings.

DEFINITIONS

[0050] It should be understood that the following is not intended to be an exclusive list of defined terms. Other definitions may be provided in the foregoing description, such as, for example, when accompanying the use of a defined term in context.

[0051] As used herein, the terms a, an, and the mean one or more.

[0052] As used herein, the term and/or, when used in a list of two or more items, means that any one of the listed items can be employed by itself or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination, B and C in combination; or A, B, and C in combination.

[0053] As used herein, the terms comprising, comprises, and comprise are open-ended transition terms used to transition from a subject recited before the term to one or more elements recited after the term, where the element or elements listed after the transition term are not necessarily the only elements that make up the subject.

[0054] As used herein, the terms having, has, and have have the same open-ended meaning as comprising, comprises, and comprise provided above.

[0055] As used herein, the terms including, include, and included have the same open-ended meaning as comprising, comprises, and comprise provided above.

NUMERICAL RANGES

[0056] The present description uses numerical ranges to quantify certain parameters relating to the invention. It should be understood that when numerical ranges are provided, such ranges are to be construed as providing literal support for claim limitations that only recite the lower value of the range as well as claim limitations that only recite the upper value of the range. For example, a disclosed numerical range of 10 to 100 provides literal support for a claim reciting greater than 10 (with no upper bounds) and a claim reciting less than 100 (with no lower bounds).

CLAIMS NOT LIMITED TO DISCLOSED EMBODIMENTS

[0057] The preferred forms of the invention described above are to be used as illustration only, and should not be used in a limiting sense to interpret the scope of the present invention. Modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.

[0058] The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as it pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.