EP0324773A1 - Synthetic yarn with heat-activated binder fiber. - Google Patents
Synthetic yarn with heat-activated binder fiber.Info
- Publication number
- EP0324773A1 EP0324773A1 EP87906522A EP87906522A EP0324773A1 EP 0324773 A1 EP0324773 A1 EP 0324773A1 EP 87906522 A EP87906522 A EP 87906522A EP 87906522 A EP87906522 A EP 87906522A EP 0324773 A1 EP0324773 A1 EP 0324773A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- yarn
- fiber
- carpet
- binder fiber
- melt
- 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.)
- Granted
Links
Classifications
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/44—Yarns or threads characterised by the purpose for which they are designed
- D02G3/445—Yarns or threads for use in floor fabrics
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/40—Yarns in which fibres are united by adhesives; Impregnated yarns or threads
- D02G3/402—Yarns in which fibres are united by adhesives; Impregnated yarns or threads the adhesive being one component of the yarn, i.e. thermoplastic yarn
Definitions
- the invention relates to synthetic yarn for carpet face fiber and other applications, the yarn comprisin a blend of fibers including a first synthetic base fiber and a second heat-activated adhesive fiber with a melting point substantially below that of the first synthetic bas fiber.
- a process for production of carpet exposure o the yarn to usual process conditions for twist setting th yarn causes the heat-activated adhesive fiber to melt substantially completely, losing its identity as a fiber, and to flow to points of intersecting base fibers to create a bond upon subsequent cooling, thus altering properties and performance of the resulting product. 2.
- Patent 3,377,214 to Van der Werf, issued April 15, 1975 discloses a twist-free yarn comprising a polyamide fiber melting under a relatively low temperature as a bonding component.
- U.S. Patent 3,494,819 to McAlister, issued February 10, 1970 discloses a blend of fusible and non-fusible polyethylene terephthalate fibers incorporated into fabric, wherein the finished fabric is heated to fusion temperatures to provide improved pill resistance.
- U.S. Patent 3,978,267 to Selwood, issued August 31, 1976 discloses a substantially twistless compact yarn comprising a proportion of potentially adhesive fiber which have been activated to bond to contacting fibers. The use of thermoplastic binder fibers in combination with structural fibers to form self-bonding nonwoven fabrics is known.
- U.S. Patent 2,880,112 to Drelich, issued March 31, 1959 discloses the use of nylon- 6 to bond viscose rayon and other cellulosic materials to form washable nonwoven fabrics.
- Cut-pile carpet is customarily produced from staple yarns or bulked continuous filament yarn.
- staple fiber is conventionally carded, pinned, and spun or wrap spun into a singles yarn, which typically is twisted and plyed with similar yarn to form a 2-ply or 3-ply yarn construction.
- This yarn is twist set by utilizing one of several commercially available twist setting processes .
- the yarn is passed through a heated chamber, while in a relaxed qondition.
- the temperature of this process step is crucial to the proper twist setting of the base fiber, to obtain desired properties of the final carpet product.
- the conditions for this step are typically 195-200oC with a residence time of about 60 seconds for the Suessen process and about 135-140oC with a residence time of about 60 seconds for the Superba process.
- bulked continuous filament nylon yarn is produced according to various conventional methods.
- Twisting, entangling, or direct cabling may be utilized in various processes.
- a 2-ply twisted yarn combining 2 ends of 1185 denier 70 filament yarn is prepared and subjected to conventional twist setting conditions, such as that for the staple yarn above or in an autoclave at 132°C in saturated steam, with a residence time of about 60 seconds.
- twist set yarns Multiple ends of the twist set yarns are tufted into cut pile carpet and conventionally finished to obtain the desired carpet product.
- Synthetic yarn comprises a blend of base fiber selected from the group consisting of polyester, nylon-6 and nylon 6,6 and 1-12 weight percent, preferably 1-8 weight percent, of a heat activated binder fiber with a melting point within the range of 110-170°C, preferably 130-160oC.
- a preferred binder fiber is a copolyamide fiber within the specified melting point range.
- Ternary copolyamides of the 6/66/12 type are examples of preferre binder fibers.
- the base fiber is selected from known synthetic fiber suitable for carpet use.
- Preferred base fiber includes polyamide, particularly nylon-6 and nylon-6,6, and polyester, particularly polyethylene terephthalate.
- the binder fiber is selected to provide good adhesion to the base fiber. It is important that the melting point of the binder fiber be in the range of
- a preferred class of binder fiber for use with polyamide base fibers are copolyamides within the specified melting point ranges. Suitable copolyamides of the 6/66/12 type and a process for their production are disclosed in U.K. Patent 1,168,404, issued October 22, 1969 to Inventa A. G., incorporated herein by reference.
- a melt bonding copolyamide adhesive fiber is commercially available from EMS as GRILON® type K 140 (melting range 130-140°C) and type K 115 (melting range 110-117oC).
- the binder fiber can be blended with base staple fiber, and the resulting staple fiber blend can then be processed in known ways. It is important to insure a thorough blending to avoid potential clumps in the finished carpet.
- the staple fiber blend should contain 1-12 weight percent binder fiber, preferably 1-8 weight percent. Higher amounts cause undesirable harshness of hand due to the conditions of the twist setting process causing the binder fiber to melt substantially completely.
- Spun yarns prepared from such a staple fiber blend and subjected to thermal activation can provide strength properties approaching that of bulked continuous filament (BCF) yarns. Properties of BCF yarns can-also be enhanced.
- thermally activated binder fiber within the weight ranges and melting point ranges specified it is possible to modify end-use properties of the finished carpet to improve wear resistance, resilience, reduced change of appearance over time and with use, and increased hand, lustre and apparent value.
- Denier per filamant, cut length, fiber cross-section, crimp type and frequency, surface finish, melt viscosity, softening point, melting point, dye affinity, and other properties are crucial to achieving ideal properties in the final product.
- a proper selection of the binder fiber must be made to obtain the desired, or optimum results from the finished carpet product. This will depend on numerous factors including the denier, length, crimp, finish, and other properties of the base fiber product.
- twist setting conditions normally used are sufficient to activate the binder fiber, to create bind points which strengthen the final product, thereby imparting other characteristics which are desirable.
- the twisted yarn is subjected to a temperature of 190-205oC for a residence time of 50-60 seconds.
- motion of the fiber while in the relaxed state caused by vibration or air currents, sufficiently motivates the molten binder fiber to flow to the intersecting "touch points" of the base fiber, as a function of the melt flow properties of the binder fiber and surface characteristics.
- the binder solidifies and encapsulates or bonds two or more base fibers together at intersecting points in a durable bond.
- the resultant carpet can be of many forms, but a typical style would be cut-pile carpet with about 40 ounces per square yard of face yarn including the binder, with an attached backing. Carpet construction would be typically 5/32" gauge, 3/4" pile height, and the carpet would be dyed, dryed, backcoated, and sheared using normal processing techniques.
- the yarn of the invention would also provide important property improvements in the production of loop-pile carpet.
- a blend of staple fiber was produced with 3 weight percent GRILON® Type K 140 copolyamide fiber having a melt point range of 130-140°C and 97 weight percent base staple fiber (Allied Type 521 nylon-6 fiber having a melt point range of 215-225°C).
- the blended fiber was carded, pinned and spun into a singles yarn by conventional processing methods.
- the yarn a 3's cotton count yarn containing 4.7 "Z" twists per inch, was plyed with a similar yarn to produce a 2-ply 3' s/2 cotton count 4.7Zx4.0S yarn.
- the 2- ⁇ ly yarn was twist set by a conventional Sussen twist setting process.
- the yarn was passed through a heated chamber at about 195oC while in a relaxed condition, with a residence time of about 60 seconds.
- Carpets also may be produced from bulked continious filament (BCF) yarns, and carpets thus made can be improved in surface, aesthetics, hand, or in durability and wear by using this invention.
- BCF continious filament
- Filament nylon yarn is produced according to various conventional fiber producer manufacturing methods. These methods are not particularly related to the invention, except that another, smaller, filament yarn will accompany a base yarn throughout subsequent process steps. Often the combination will result in a 2-ply, 3-ply, or other form needed for the carpet style.
- twisting, entangling, or direct cabling may be utilized.
- Direct cabling is often used, as in this example, where a 70 denier 14 filament yarn is combined with a 1185 denier 70 filament in the creel of the direct cabler to produce a yarn with 3.5 "S" twist per inch in each of the singles and 3.5 "Z” twist i the resultant 2-ply twisted yarn (1185 x 2 ply).
- the final yarn contains a third component, a binder yarn, which has a lower melting point and which will lose much of its identity in subsequent process steps, as it is melted and flows to bind fibers and yarn together, thereb retaining the twist in cut pile carpet.
- a copolyamide 70 denier nylon yarn having a melt point range of 130-140°C results in th binder fiber for the combination, combined with 2 ends of 1185 denier, results in a blend of about 2.8 percent binder.
- This ratio can be doubled by using two ends, or varied by providing other denier products to the system.
- the binder is activated producing a final product with the desirable characteristics of enhanced carpet tuft appearance, more resilience, and better wear resistance than similiar carpets not containing the binder.
- the twist setting conditions for this are typically 270°F, in saturated steam, with a residence time of about 60 seconds.
- the binder solidifies and encapsulates or bonds two or more base yarns together in a permanent or durable bond. Multiple ends of these yarns are tufted into cut pile carpet and conventionally finished to obtain the improved product.
Abstract
Le fil synthétique comprend un mélange de fibres de base sélectionnées parmi le groupe constitué de polyester, nylon-6 et nylon 6,6 et 1-12 % en poids de préférence, 1-8 % en poids d'une fibre de liaison thermoactivée ayant un point de fusion de 110 à 170°C, de préférence 130-160°C. Une fibre de liaison préférée est une fibre de copolyamide comprenant des copolyamides ternaires du type 6/66/12. Lorsque le fil est torsadé, retordu par des procédés conventionnels et que le fil traité est touffeté pour faire un tapis, le tapis obtenu se caractérise par un meilleur aspect et une plus grande résistance à l'usure.The synthetic yarn comprises a mixture of base fibers selected from the group consisting of polyester, nylon-6 and nylon 6.6 and 1-12% by weight preferably, 1-8% by weight of a thermo-activated binder fiber having a melting point of 110 to 170 ° C, preferably 130-160 ° C. A preferred binding fiber is a copolyamide fiber comprising ternary copolyamides of the type 6/66/12. When the yarn is twisted, twisted by conventional methods and the treated yarn is tufted to make a carpet, the carpet obtained is characterized by a better appearance and greater resistance to wear.
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US93438986A | 1986-11-24 | 1986-11-24 | |
US934389 | 1986-11-24 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0324773A1 true EP0324773A1 (en) | 1989-07-26 |
EP0324773B1 EP0324773B1 (en) | 1990-11-22 |
Family
ID=25465490
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP87906522A Expired - Lifetime EP0324773B1 (en) | 1986-11-24 | 1987-09-15 | Synthetic yarn with heat-activated binder fiber |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0324773B1 (en) |
JP (1) | JP2719338B2 (en) |
AU (1) | AU606085B2 (en) |
CA (1) | CA1314771C (en) |
WO (1) | WO1988003969A1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5284009A (en) * | 1993-03-09 | 1994-02-08 | E. I. Du Pont De Nemours And Company | Fiber blends for improved carpet texture retention |
WO1994009196A1 (en) * | 1992-10-14 | 1994-04-28 | Allied-Signal Inc. | Synthetic yarn with heat-activated binder fiber |
EP0696654A1 (en) | 1994-08-09 | 1996-02-14 | Hercules Incorporated | Textile structures containing linear low density poly-ethylene binder fibers |
US6030685A (en) * | 1995-06-07 | 2000-02-29 | Alliedsignal Inc. | Carpet and yarns therefor |
US6117546A (en) * | 1996-03-03 | 2000-09-12 | Hercules Incorporated | Yarns containing linear low density polyethylene fibers |
US6658835B1 (en) | 2000-11-28 | 2003-12-09 | Honeywell International Inc. | Untwisted wrapped singles yarns and carpets manufactured therefrom |
Families Citing this family (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6969437B1 (en) | 1997-01-30 | 2005-11-29 | Alliedsignal Inc. | Yarn with heat-activated binder material and process of making |
US6682618B1 (en) * | 1986-11-24 | 2004-01-27 | Alliedsignal Inc. | Yarn with heat-activated binder material and process of making |
NZ220444A (en) * | 1987-05-26 | 1991-06-25 | Wool Res Organisation | Yarn pile fabrics with fusible fibre bonding agent |
DE3717921A1 (en) * | 1987-05-27 | 1988-12-15 | Ackermann Goeggingen Ag | YARN, ESPECIALLY SEWING YARN, AND METHOD AND DEVICE FOR THE PRODUCTION THEREOF |
US5032333A (en) * | 1990-02-27 | 1991-07-16 | E. I. Du Pont De Nemours And Company | One-line interlacing of bulked continuous filament yarns and low-melting binder fibers |
US5175038A (en) * | 1990-09-07 | 1992-12-29 | E. I. Du Pont De Nemours And Company | Carpet yarns and carpets with improved balance of newness retention and bulk |
US5079810A (en) * | 1990-12-28 | 1992-01-14 | E. I. Du Pont De Nemours And Company | Ultrasonic cutting of fabric tufts to provide improved retention of tuft indentity during use |
DE4240335A1 (en) * | 1992-12-01 | 1994-06-09 | Spindor N V | Bonded fibre mixed yarn based on wool and opt. other carpet fibre - with melt bonding fibre and use in woven or knitted textile, esp. wall covering or carpet to increase yarn structure retention |
AU741990B2 (en) * | 1997-09-18 | 2001-12-13 | Shaw Industries Group, Inc. | Yarn with heat-activated binder material and process of making |
AU5701599A (en) * | 1998-08-31 | 2000-03-21 | Allied-Signal Inc. | Yarn with heat-activated binder material and process of making |
US7261849B2 (en) * | 2002-04-30 | 2007-08-28 | Solutia, Inc. | Tacky polymer melt spinning process |
US20040175534A1 (en) * | 2002-12-23 | 2004-09-09 | Bridges James C. | Enhanced surface coverings, yarns and methods |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1085567A (en) * | 1965-06-28 | 1967-10-04 | Ici Ltd | Improvements in or relating to compact filament bundles and their production |
CH491150A (en) * | 1967-03-13 | 1970-05-31 | Inventa Ag | Process for the production of ternary mixed polyamides |
ZA72545B (en) * | 1971-01-29 | 1972-10-25 | Coats Ltd J & P | Process for production of filamentary structures |
JPS6133382Y2 (en) * | 1980-06-23 | 1986-09-30 |
-
1987
- 1987-09-15 JP JP62505896A patent/JP2719338B2/en not_active Expired - Fee Related
- 1987-09-15 EP EP87906522A patent/EP0324773B1/en not_active Expired - Lifetime
- 1987-09-15 AU AU80254/87A patent/AU606085B2/en not_active Expired
- 1987-09-15 WO PCT/US1987/002339 patent/WO1988003969A1/en active IP Right Grant
- 1987-09-22 CA CA000547494A patent/CA1314771C/en not_active Expired - Lifetime
Non-Patent Citations (1)
Title |
---|
See references of WO8803969A1 * |
Cited By (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1994009196A1 (en) * | 1992-10-14 | 1994-04-28 | Allied-Signal Inc. | Synthetic yarn with heat-activated binder fiber |
US5478624A (en) * | 1992-10-14 | 1995-12-26 | Alliedsignal Inc. | Synthetic yarn with heat-activated binder fiber |
US5284009A (en) * | 1993-03-09 | 1994-02-08 | E. I. Du Pont De Nemours And Company | Fiber blends for improved carpet texture retention |
EP0696654A1 (en) | 1994-08-09 | 1996-02-14 | Hercules Incorporated | Textile structures containing linear low density poly-ethylene binder fibers |
US5698480A (en) * | 1994-08-09 | 1997-12-16 | Hercules Incorporated | Textile structures containing linear low density polyethylene binder fibers |
US5712209A (en) * | 1994-08-09 | 1998-01-27 | Hercules Incorporated | Fabrics comprising filling yarns comprising linear low density polyethylene fibers |
US5824613A (en) * | 1994-08-09 | 1998-10-20 | Hercules Incorporated | Laminates comprising textile structures comprising linear low density polyethylene fibers |
US6030685A (en) * | 1995-06-07 | 2000-02-29 | Alliedsignal Inc. | Carpet and yarns therefor |
US6117546A (en) * | 1996-03-03 | 2000-09-12 | Hercules Incorporated | Yarns containing linear low density polyethylene fibers |
US6658835B1 (en) | 2000-11-28 | 2003-12-09 | Honeywell International Inc. | Untwisted wrapped singles yarns and carpets manufactured therefrom |
US7398640B2 (en) | 2000-11-28 | 2008-07-15 | Honeywell International Inc. | Untwisted wrapped singles yarns and carpets manufactured therefrom |
US7402217B2 (en) | 2000-11-28 | 2008-07-22 | Honeywell International Inc. | Untwisted wrapped singles yarns and carpets manufactured therefrom |
Also Published As
Publication number | Publication date |
---|---|
WO1988003969A1 (en) | 1988-06-02 |
JPH02501835A (en) | 1990-06-21 |
AU606085B2 (en) | 1991-01-31 |
AU8025487A (en) | 1988-06-16 |
EP0324773B1 (en) | 1990-11-22 |
CA1314771C (en) | 1993-03-23 |
JP2719338B2 (en) | 1998-02-25 |
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