EP1038059B1 - Yarn with heat-activated binder material and process of making - Google Patents
Yarn with heat-activated binder material and process of making Download PDFInfo
- Publication number
- EP1038059B1 EP1038059B1 EP98948411A EP98948411A EP1038059B1 EP 1038059 B1 EP1038059 B1 EP 1038059B1 EP 98948411 A EP98948411 A EP 98948411A EP 98948411 A EP98948411 A EP 98948411A EP 1038059 B1 EP1038059 B1 EP 1038059B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- yarn
- fiber
- binder material
- binder
- bundle
- 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.)
- Expired - Lifetime
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
- D02G3/22—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
-
- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05C—EMBROIDERING; TUFTING
- D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
- D05C17/02—Tufted products
- D05C17/026—Tufted products characterised by the tufted pile surface
Definitions
- the invention relates to yarn suitable for tufting, especially to form carpet face fiber, and other applications.
- the yarn comprises a blend of fibers including a first, preferably synthetic, base fiber, ring spun or wrap spun with a second fiber that at least partially comprises a heat-activated adhesive material having a melting point substantially below that of the base fiber.
- U.S. Patent 3,494,819 to McAlister 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 has been activated to bond contacting fibers.
- Cut-pile carpet is customarily produced from staple yarns or bulked continuous filament yarns.
- staple fiber is conventionally carded, pinned, and spun or wrap spun into a singles yarn, which typically is twisted and plied 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 such as the Suessen or Superba processes.
- the yarn is passed through a heated chamber, while in a relaxed condition.
- 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 190-200°C with a residence time of about 60 seconds for the Suessen process and about 125-140°C with a residence time of about 60 seconds for the Superba process.
- the Superba process utilizes saturated steam and thus the yarn is subjected to a much higher level of humidity than in the Suessen process.
- bulked continuous filament yarn is produced according to various conventional methods. Twisting, entangling, or direct cabling may be utilized in various processes. For example, a 2-ply twisted yarn combining 2 ends of 1185 denier 70 filament nylon-6 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 40 to 60 minutes.
- 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.
- WO-A-94/09196 discloses a synthetic yarn made from a blend of base fibers selected from polyester, nylon 6 and nylon 6,6 and 1 to 12 weight % of a heat-activated binder fiber having a melting point within the range of 165°C to 190°C.
- the blended fiber may be processed in conventional ways, including spinning.
- WO-A-94/20657 discloses ply-twisted yarns comprising blends of 70 to 90 weight % base fiber which is preferably nylon 6,6 or nylon 6, and 10 to 30 weight % of a non-melt compatible polyolefin fiber having a melting point of 130°C to 170°C.
- yarn preferably synthetic, comprises at least one bundle of fiber, the fiber bundle being ring spun or wrap spun with a second fiber (either an insert fiber in the case of ring spun or a wrapping fiber in the case of wrap spun) comprising a heat-activated binder material, preferably a fiber, having a melting point range of about 105 to 190°C, preferably 165 to 190°C, under ambient humidity conditions, such that the yarn comprises a total of 0.1 to 12, preferably 0.25 to 10, more preferably 0.5 to 8, weight percent binder material.
- the preferred fiber bundle comprise staple fibers, preferably in the form of a sliver. Alternatively the bundle of fibers may be continuous filaments.
- the preferred second, binder fiber is a copolyamide, more preferably a copolyamide of the nylon 6/nylon 6,6 type.
- the preferred bundle of fiber is nylon 6.
- the present invention is also an article, preferably tufted, more preferably a carpet, made from this yarn.
- the present invention is also a process of producing a yarn suitable for tufting, the process comprising the steps of:
- the insert fiber is inserted before the front delivery roll into a continuous bundle of base fibers, preferably staple fibers in a sliver.
- This invention also relates to yarn made in accordance with the aforesaid process,
- the yarn When the yarn is twisted, plied and twist set by conventional processes, for example 190-200°C Suessen twistsetting with a residence time of about 60 seconds, and the treated yarn tufted into cut-pile carpet, the resulting carpet displays enhanced carpet tuft appearance, improved resilience, and reduced change of appearance with use.
- conventional processes for example 190-200°C Suessen twistsetting with a residence time of about 60 seconds
- the base fiber is selected from known synthetic fibers suitable for carpet use; such as, polyamides, nylon-6 and nylon-6,6, polyesters, and polyolefins, as well as material fibers, such as cotton and wool.
- 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 105-190°C, preferably 165-190°C, under ambient humidity conditions. This range ensures that the binder fiber will melt during the conventional twist setting process yet will provide adequate adhesive properties during any subsequent dyeing steps and final use. A saturated steam environment, such as in an autoclave, reduces the fiber melting point of polyamide binder fibers dramatically.
- 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.
- 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 110-117°C) copolyamides of the 6/66 Type as in U.S. Patent 5,478,624 to Lofquist.
- thermally activated binder fiber within the weight percent 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 to increase hand, lustre and apparent value.
- Denier per filament, 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 190-205°C 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 1.4 kg/m 2 (40 ounces per square yard) of face yarn including the binder, with an attached backing.
- Carpet construction would be typically 0.06cm (5/32") gauge, 1.9cm (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.
- Carpets also may be produced by introducing a binder yarn as the wrapper yarn that is placed uniformly around a continuous bundle of base staple fibers at wrap (hollow spindle) spinning to produce a wrap spun yarn.
- the binder yarn can consist of 100% heat-activated adhesive fibers or consist of a blend of heat activated adhesive fibers and non-adhesive fibers. Binder yarns as such can be either continuous filament yarn or spun staple yarn produced by conventional manufacturing methods.
- the carpet When the resulting wrap spun yarn is twisted into a plied yarn, twist set by conventional process, and the treated yarn tufted into cut-pile carpet, the carpet displays enhanced carpet tuft appearance, more resilience, and better wear resistance than similar carpets not containing the binder yarn.
- These carpet improvements can be further enhanced by the continuous bundle of base staple fibers being a blend with a low weight percent of heat activated adhesive fibers and a high weight percent of non-adhesive fibers that is wrapped with a binder yarn as described above.
- the continuous bundle (sliver) of base staple fibers is 100% 1.9 tex (17 denier) per filament AlliedSignal T317 nylon-6 staple fibers that is wrapped with a 3.3 tex (30 denier) 12 filament yarn at wrap spinning to produce a 5.4/1 mm/kg (3.35/1) cotton count yarn containing 2"Z" wraps per cm (5.2 "Z" wraps per inch).
- This singles yarn is then plied with another singles end of the same yarn to produce 5.4/2 mm/kg (3.35/2 cotton count) 2 Z wraps per cm x 2.1 s twists cm (5.2 Z wraps per inch x 5.4 S twists per inch) final yarn.
- This final yarn contains a binder yarn, which is the 3.3 tex (30 denier) 12 filament yarn wrapped around each end of the 2 plies.
- This 3.3 tex (30 denier) yarn is a copolyamide nylon having a melt point range of 105-180°C.
- the remainder of the 5.4/2 mm/kg (3.35/2 cotton count) yarn is AlliedSignal T317 nylon-6 staple fibers having a melt point range of 215-225°C, which results in a blend of about 2.0 percent binder.
- This ratio can be increased by using a larger denier binder yarn, or by a low weight percent of heat-activated adhesive fibers and a high weight percent of non-adhesive AlliedSignal T317 nylon-6 staple fibers blend being in the continuous bundle (sliver) of base staple fibers, before wrap spinning, that is wrapped with the 3.3 tex (30 denier) 12 filament binder yarn.
- This final 5.4/2 mm/kg (3.35/2 cotton count) yarn was twist set by a conventional stuffer box Suessen twist setting process.
- the yarn was passed through a heated chamber at 190°C, while in a relaxed condition, with a residence time of 60 seconds. Multiple ends of this yarn were tufted into cut-pile carpet and conventionally finished to obtain the improved product.
- the resulting carpet was compared to a control carpet prepared in the same manner from 100 percent non-adhesive AlliedSignal T317 nylon-6 base staple fibers.
- the carpet containing the 2.0 percent wrapper yarn binder displayed tighter and more defined individual pile tufts, a more resilient, stiffer hand, enhanced carpet surface appearance with significantly less hairiness, and better wear resistance.
- Carpets also may be produced by introducing a binder yarn at ring spinning before the front delivery roll into a continuous bundle of base staple fibers being drafted to produce a ring spun yarn.
- the binder yarn can consist of 100% heat-activated adhesive fibers or consist of a blend of heat-activated adhesive fibers and non-adhesive fibers.
- Binder yarns as such can be either continuous filament yarn or spun staple yarn produced by conventional manufacturing methods. This ring spun yarn has greater strength due to the added strength of the inserted yarn in the total spun yarn structure, which results in improved operating performance at spinning by reducing single end breakouts.
- the resulting ring spun yarn when later twisted into a plied yarn and twist set by conventional processes results in a treated yarn with altered, unique performance properties.
- the unique properties are produced by the heat activated adhesive fibers in the inserted binder yarn being intermingled within the continuous bundle (sliver) of non-adhesive base staple fibers during the ring spinning process, melting during conventional twist setting processes, and then solidifying when emerging from the elevated temperature forming a durable crossbonding with the non-adhesive base staple fibers within the individual ends of the plied yarn and between the individual ends of the plied yarn.
- the treated plied twist set yarn has a more resilient, stiffer hand, significantly improved ply twist retention, and a less hairy surface.
- the hand of the pile is significantly firmer, the individual tufts are tighter and more defined, and the pile surface is cleaner with less hairiness.
- These carpet improvements can be further enhanced by the continuous bundle of base staple fibers being a blend with a low weight percent of heat-activated adhesive fibers and a high weight percent of non-adhesive fibers in which the binder yarn is inserted as described above.
- a 3.3 tex (30 denier) 12 filament yarn is inserted before the front delivery roll into the continuous bundle of base staple fibers (sliver) being drafted at ring spinning.
- the sliver is 100% 1.9 tex (17 denier) per filament AlliedSignal T317 nylon-6 staple fibers, which is spun into a (3.0/1 cotton count) yarn containing 1.9 "z" twists per cm (4.8 "Z” twists per inch).
- This singles yarn is then plied with another singles end of the same yarn to produce 5.2/2 mm/kg (3.0/2 cotton count )1.9 Z twists per cm x 1.6 twists per cm (4.8 Z twists per inch x 4.1 S twists per inch) final yarn.
- This final yarn contains a binder yarn, which is the 3.3 tex (30 denier) 12 filament yarn inserted in each end of the 2 plies.
- This 3.3 tex (30 denier yarn) is a copolyamide nylon having a melt point range of 105-180°C.
- the remainder of the 5.2/2 mm/kg (3.0/2 cotton count) yarn is AlliedSignal T317 nylon-6 staple fibers having a melt point range of 215-225°C, which results in a blend of about 1.7 percent binder.
- This ratio can be increased by inserting a larger denier binder yarn at the front delivery roll, or by a low weight percent of heat activated adhesive fibers and a high weight percent of non-adhesive AlliedSignal T317 nylon-6 staple fibers blend being in the continuous bundle (sliver) of base staple fibers, before ring spinning, in which the 3.3 tex (30 denier) 12 filament binder yarn is inserted at the front delivery roll of ring spinning.
- This final 5.2/2 mm/kg (3.0/2 cotton count) yarn was twist set by a conventional Suessen twist setting process.
- the yarn was passed through a heated chamber at 190°C, while in a relaxed condition, with a residence time of 60 seconds. Multiple ends of this yarn were tufted into cut-pile carpet and conventionally finished to obtain the improved product.
- the resulting carpet was compared to a control carpet prepared in the same manner from 100 percent non-adhesive AlliedSignal T317 nylon-6 base staple fibers.
- the carpet containing the 1.7 percent inserted binder yarn displayed more defined individual pile tufts, a more resilient, stiffer hand, and a cleaner, enhanced carpet surface appearance which is more like a BCF cut pile carpet.
Description
Claims (8)
- A yarn comprisinga. at least one bundle of fiber, andb. a second fiber comprising a heat-activated binder material having a melting point range of about 105°C to 190°C under ambient humidity conditions, said yarn comprising a total of 0.1 to 12 weight percent binder material, characterised in that said bundle is ring spun or wrap spun with said second fiber.
- The yarn of claim 1 comprising 0.25 to 10 weight percent binder material and more preferably, 0.5 to 8 weight percent binder material.
- The yarn of claim 1 or claim 2 wherein the bundle of fiber is selected from the group consisting of staple fibers; a sliver; and continuous filaments.
- The yarn of any preceding claim wherein the second fiber comprising a heat-activated binder fiber.
- The yarn of claim 4 wherein said binder fiber is selected from the group consisting of nylon 6 and a copolyamide of the nylon 6/nylon 6,6 type.
- The yarn of claim 1 wherein the bundle of fiber comprises staple fibers wrap spun with a wrapping fiber, and the wrapping fiber forms substantially all of the heat-activated binder material.
- A process for producing a yarn suitable for tufting, said process comprising the steps of:a. forming a bundle of fiber;b. ring spinning or wrap spinning the bundle of fiber with a second fiber comprising a heat-activated binder material having a melting point range of about 105°C to 190°C under ambient humidity conditions to form a yarn comprising 0.1 to 12 weight percent of the binder material;c. heating the yarn sufficiently to melt the binder material; followed byd. cooling the yarn to solidify the binder material.
- The process of claim 7, wherein the bundle of fiber is formed by spinning staple fiber.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US933822 | 1997-09-18 | ||
US08/933,822 US6682618B1 (en) | 1986-11-24 | 1997-09-19 | Yarn with heat-activated binder material and process of making |
PCT/US1998/019745 WO1999014408A1 (en) | 1997-09-18 | 1998-09-18 | Yarn with heat-activated binder material and process of making |
Publications (3)
Publication Number | Publication Date |
---|---|
EP1038059A1 EP1038059A1 (en) | 2000-09-27 |
EP1038059B1 true EP1038059B1 (en) | 2003-07-30 |
EP1038059B2 EP1038059B2 (en) | 2008-01-02 |
Family
ID=25464560
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP98948411A Expired - Lifetime EP1038059B2 (en) | 1997-09-19 | 1998-09-18 | Yarn with heat-activated binder material and process of making |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP1038059B2 (en) |
AU (1) | AU741990B2 (en) |
DE (1) | DE69816860T3 (en) |
WO (1) | WO1999014408A1 (en) |
ZA (1) | ZA988628B (en) |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6682618B1 (en) | 1986-11-24 | 2004-01-27 | Alliedsignal Inc. | Yarn with heat-activated binder material and process of making |
US6969437B1 (en) | 1997-01-30 | 2005-11-29 | Alliedsignal Inc. | Yarn with heat-activated binder material and process of making |
WO2000012796A1 (en) * | 1998-08-31 | 2000-03-09 | Alliedsignal Inc. | Yarn with heat-activated binder material and process of making |
US6658835B1 (en) * | 2000-11-28 | 2003-12-09 | Honeywell International Inc. | Untwisted wrapped singles yarns and carpets manufactured therefrom |
US6755366B2 (en) | 2002-09-30 | 2004-06-29 | Solutia Inc. | Device for direct insertion of yarn in automatic winder |
US20040175534A1 (en) * | 2002-12-23 | 2004-09-09 | Bridges James C. | Enhanced surface coverings, yarns and methods |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2252999A (en) * | 1937-05-24 | 1941-08-19 | Sylvania Ind Corp | Article and process for the manufacture thereof |
CH220994A (en) * | 1937-05-24 | 1942-05-15 | Sylvania Ind Corp | A method of manufacturing a textile product. |
GB568675A (en) * | 1943-03-12 | 1945-04-16 | George Frederick Rayner | Process of making composite yarns, and the composite yarns so produced |
DD240918A1 (en) * | 1985-09-16 | 1986-11-19 | Ver Baumwollspinnereien Und Zw | METHOD AND DEVICE FOR FASTENING FIBER BEARING |
US4644741A (en) * | 1984-06-11 | 1987-02-24 | Golden Star, Inc. | Mop yarns made by fiber bonding process |
US4668552A (en) * | 1986-07-28 | 1987-05-26 | Collins & Aikman Corporation | Wrap yarns having low-melt binder strands and pile fabrics formed therefrom and attendant processes |
WO1988003969A1 (en) * | 1986-11-24 | 1988-06-02 | Allied Corporation | Synthetic yarn with heat-activated binder fiber |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
NZ220444A (en) * | 1987-05-26 | 1991-06-25 | Wool Res Organisation | Yarn pile fabrics with fusible fibre bonding agent |
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 |
FR2664621B1 (en) * | 1990-07-13 | 1994-08-26 | Schappe Sa | HYBRID WIRE FOR COMPOSITE MATERIALS WITH THERMOPLASTIC MATRIX AND PROCESS FOR OBTAINING SAME. |
WO1994009196A1 (en) * | 1992-10-14 | 1994-04-28 | Allied-Signal 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 |
WO1995030040A1 (en) * | 1994-04-29 | 1995-11-09 | Kleen-Tex Industries, Inc. | Improved track control mat and method of making the same |
JPH09119034A (en) * | 1995-10-26 | 1997-05-06 | Unitika Ltd | Spun yarn containing binder fiber |
-
1998
- 1998-09-18 DE DE69816860T patent/DE69816860T3/en not_active Expired - Lifetime
- 1998-09-18 EP EP98948411A patent/EP1038059B2/en not_active Expired - Lifetime
- 1998-09-18 WO PCT/US1998/019745 patent/WO1999014408A1/en active IP Right Grant
- 1998-09-18 AU AU94988/98A patent/AU741990B2/en not_active Ceased
- 1998-09-21 ZA ZA9808628A patent/ZA988628B/en unknown
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2252999A (en) * | 1937-05-24 | 1941-08-19 | Sylvania Ind Corp | Article and process for the manufacture thereof |
CH220994A (en) * | 1937-05-24 | 1942-05-15 | Sylvania Ind Corp | A method of manufacturing a textile product. |
GB568675A (en) * | 1943-03-12 | 1945-04-16 | George Frederick Rayner | Process of making composite yarns, and the composite yarns so produced |
US4644741A (en) * | 1984-06-11 | 1987-02-24 | Golden Star, Inc. | Mop yarns made by fiber bonding process |
DD240918A1 (en) * | 1985-09-16 | 1986-11-19 | Ver Baumwollspinnereien Und Zw | METHOD AND DEVICE FOR FASTENING FIBER BEARING |
US4668552A (en) * | 1986-07-28 | 1987-05-26 | Collins & Aikman Corporation | Wrap yarns having low-melt binder strands and pile fabrics formed therefrom and attendant processes |
WO1988003969A1 (en) * | 1986-11-24 | 1988-06-02 | Allied Corporation | Synthetic yarn with heat-activated binder fiber |
Non-Patent Citations (1)
Title |
---|
Encyclopedia of polymer science and technology Vol. 13, p.692-699 (John Wiley & Sons, Inc. 1970) * |
Also Published As
Publication number | Publication date |
---|---|
EP1038059B2 (en) | 2008-01-02 |
ZA988628B (en) | 1999-06-29 |
DE69816860T2 (en) | 2004-06-03 |
AU741990B2 (en) | 2001-12-13 |
AU9498898A (en) | 1999-04-05 |
DE69816860D1 (en) | 2003-09-04 |
EP1038059A1 (en) | 2000-09-27 |
WO1999014408A1 (en) | 1999-03-25 |
DE69816860T3 (en) | 2008-06-26 |
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