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WO2021055405A1 - Fils et tapis d'esthétique de couleur variable aléatoire - Google Patents

Fils et tapis d'esthétique de couleur variable aléatoire Download PDF

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Publication number
WO2021055405A1
WO2021055405A1 PCT/US2020/050970 US2020050970W WO2021055405A1 WO 2021055405 A1 WO2021055405 A1 WO 2021055405A1 US 2020050970 W US2020050970 W US 2020050970W WO 2021055405 A1 WO2021055405 A1 WO 2021055405A1
Authority
WO
WIPO (PCT)
Prior art keywords
fiber
continuous filament
polymer
yarn
denier
Prior art date
Application number
PCT/US2020/050970
Other languages
English (en)
Inventor
John Y. Kim
Katherine SHARP
Original Assignee
INVISTA North America S.à r.l.
Invista Textiles (U.K.) Limited
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 North America S.à r.l., Invista Textiles (U.K.) Limited filed Critical INVISTA North America S.à r.l.
Publication of WO2021055405A1 publication Critical patent/WO2021055405A1/fr

Links

Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
    • 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
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/08—Interlacing constituent filaments without breakage thereof, e.g. by use of turbulent air streams
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/20—Formation of filaments, threads, or the like with varying denier along their length
    • 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
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/16—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using jets or streams of turbulent gases, e.g. air, steam

Definitions

  • the field of the disclosure generally relates to synthetic fiber extrusion, and, more particularly, to yarns and carpets of random variable color aesthetic and methods of manufacture.
  • a yam comprising: i) a first continuous filament fiber produced by a method comprising: (a) extruding molten polymer through an orifice; (b) quenching the extruded molten polymer to form at least one fiber; (c) drawing said fiber; and (d) winding said fiber into a package, whereby the rate of polymer extrusion through the orifice in (a) is increased and decreased to create variation in filament denier along the length of the first continuous filament fiber, and (ii) a second continuous filament fiber different from the first continuous filament fiber.
  • Figure 1 illustrates a carpet made with a plurality of colors and including a plurality of bands made with yams in accordance with aspects of the present disclosure and another band made with conventional yarn.
  • Figure 2 illustrates a cut pile carpet made with a plurality of colors and having one band made with yarn in accordance with aspects of the present disclosure and another band made with conventional yarn.
  • Figure 3 illustrates a loop pile carpet made with a plurality of colors and having one band made with yarn in accordance with aspects of the present disclosure and another band made with conventional yarn.
  • Figure 4 is a graph illustrating denier changes at various extmsion pump settings in accordance with aspects of the present disclosure.
  • Figure 5 is a graph illustrating yam bulk changes at various extrusion pump speed settings in accordance with aspects of the present disclosure.
  • Figure 6 is a graph illustrating filament cross-section changes at various extrusion pump speed settings in accordance with aspects of the present disclosure.
  • Figure 7 is a graph illustrating the relationship between actual pump speed and pump speed setting in accordance with aspects of the present disclosure when the pump is set to cycle between operation at a speed of 3100 rpm and operation at a speed of 7500 rpm at one second intervals.
  • Figure 8 is a graph illustrating settings the relationship between actual pump speed and pump speed setting in accordance with aspects of the present disclosure when the pump is set to cycle between operation at a speed of 3100 rpm and operation at a speed of 7500 rpm at three second intervals.
  • the present disclosure describes yams, and processes for making the same, comprising continuous filaments with variable filament properties useful for creating carpets with novel aesthetics.
  • the present disclosure provides a yam including (i) a first continuous filament fiber and (ii) a second continuous filament fiber different from the first continuous filament fiber (i), wherein the fiber (i) is produced by a method comprising: (a) extruding molten polymer through an orifice; (b) quenching the extruded molten polymer to form at least one fiber; (c) drawing said fiber; and (d) winding said fiber into a package, wherein the rate of polymer extmsion through the orifice in (a) is increased and decreased to create variation in filament denier along the length of the first continuous filament fiber.
  • processes disclosed herein involve varying a rate of polymer extrusion flow with time, thereby causing a denier (thickness) of an extruded fiber to oscillate between small and large along its length, while maintaining a constant polymer flow from the extruder.
  • the fibers produced by the present process provide yams exhibiting a unique aesthetic effect in a carpet by breaking up a carpet uniformity typically associated with cabled yams.
  • the fibers of the present disclosure enable a wide range of color designs never before possible with solution dyed fibers. Furthermore, different combinations of conventional fibers with the fibers of the inventive process can also create a wide variety of carpet aesthetics.
  • variations in an output of a spinning pump impart a primary physical property of the denier oscillating (changing) along the fiber length.
  • secondary fiber properties along the fiber length including changes in a cross-sectional shape of the fiber, a bulk of the fiber, and a color depth of the fiber along a length of the fiber in concert with the denier variation, are also affected by the denier variation.
  • the primary fiber property measured for control using the processes described herein is fiber denier.
  • the standard fiber property measurements also quantify fiber properties along the fiber.
  • Useful effects of oscillating denier along the fiber length include variations of color intensity in the yarn, variations of fiber color prominence in processed yarns, e.g., as seen in a carpet, and variable color patterns or streaks.
  • the fiber with the oscillating denier can combined with other variable fibers of the same type, or mixed with uniform fibers, or mixed with variable fibers having a different shape or period of variation, for different desired aesthetics.
  • aspects of the disclosure provide a novel approach for achieving unique yam and fabric aesthetics which cannot be obtained by conventional techniques. Accordingly, fibers with variations in denier, cross-section, bulk, and color depth allow for a higher level of creativity in fabric design, with a lower cost and improved performance over methods currently utilized.
  • the processes of the present disclosure involve varying a mnning speed of spinning pumps of a continuous filament spinning process at various amplitudes (percentage of standard speed) and frequencies during a spinning process to introduce periodic property variations along the fiber length.
  • the fiber is formed from a melt-spinnable polymer.
  • suitable melt-spinnable polymers include polyamides, polyesters, and olefins, amongst other examples.
  • the melt- spinnable polymer is melted and extruded by at least one spinning pump through a spinneret having at least one orifice. In this way, a positive displacement melt extrusion spinning pump forces the polymer melt through spinnerets to form the filaments.
  • the processes described herein cycle a mnning speed, e.g., revolutions per minute (rpm), of at least one spinning pump used in the extrusion of the polymer melt.
  • a mnning speed e.g., revolutions per minute (rpm)
  • rpm revolutions per minute
  • the disclosed processes involve cycling meter spinning pumps at various amplitudes, i.e., a percentage of standard speed, and frequencies during the spinning process to introduce at least one of a sinusoidal pattern property variation, a cyclic pattern property variation, and a square pattern property variation, and along the fiber length.
  • a sinusoidal pattern property variation i.e., a percentage of standard speed
  • frequencies during the spinning process to introduce at least one of a sinusoidal pattern property variation, a cyclic pattern property variation, and a square pattern property variation, and along the fiber length.
  • an increase and decrease in polymer extrusion rate varies in a regular pattern including at least one of a cyclic; a sinusoidal; and a square.
  • a throughput of one spinning pump position is balanced against a throughput of another spinning pump position to maintain a constant output of the two spinning pumps.
  • the balancing is extended to permit variation at a positional level, with a changing of an extrusion rate at one spinning position in the opposite sense of its neighboring spinning pump, while maintaining constancy of a total flow rate at the melt extruder feeding both positions.
  • constant extruder throughput ensures that extruder pressures, temperatures, pigment additions, viscosities, etc., remain constant to maintain polymer uniformity and relatively good spinning efficiencies.
  • along-end property variations may be affected while maintaining constant throughput from the spinning machine and/or position.
  • the increase and decrease in a period of the polymer flow extrusion rate is irregular. In this way, the period of the polymer flow rate increase and decrease is irregular.
  • the changing of the polymer flow extrusion rate occurs in random and set interval breaks. In even further embodiments, the changing of the polymer flow extrusion rate occurs with respect to complex wave functions.
  • Examples of running speed variations include increasing and decreasing the polymer flow rate by a magnitude greater than ⁇ 15% of an average or an initial polymer extrusion flow rate of the polymer melt. In this way, an increase and decrease in the rate of polymer extrusion is greater than plus 15% and minus 15%, respectively, of an average polymer extrusion flow rate.
  • aspects of the present disclosure achieve a fiber having denier variation along a length of the fiber of at least plus 10% and minus 10% within a fiber length of 2000 meters. In this way, first continuous filament fiber has a denier variation along its length of at least plus 10% and minus 10% within a fiber length of 2000 meters.
  • running speed variations include a change of ⁇ 20% or more in running speed.
  • aspects of the present disclosure achieve a BCF fiber having denier variation along a length of the BCF fiber of at least plus 20% and minus 20% within a fiber length of 4000 meters.
  • a first continuous filament fiber has a denier variation along its length of at least plus 20% and minus 20% within a fiber length of 4000 meters.
  • a running speed variation of ⁇ 25% or more is observable when the fiber is cabled into yarn and converted into a carpet fabric.
  • a running speed variation includes increasing and decreasing the polymer extrusion flow rate by a magnitude greater than ⁇ 30%. In this way, an increase and decrease in the rate of polymer extrusion is greater than plus 30% and minus 30%, respectively, of the average polymer extrusion rate.
  • variations in running speed of about ⁇ 30-40%, or even ⁇ 50% or more, are aesthetically interesting.
  • the rate (frequency) at which the spinning pump rate (rpm amplitude) changes further determines a number and degree of property variations along a given fiber length.
  • the amplitudes of the spinning pumps are varied by ⁇ 30% and ⁇ 50% at 1-3 second cycles (or frequencies of 0.33-1 Hz). In embodiments, an improved cycling effect was obtained with higher amplitude variation and cycling at ⁇ 1 Hz.
  • a change in spinning speed in a range of ⁇ 30-50% and at a cycle of two through three seconds allows for a broad fiber.
  • the color of this broad fiber is a mid-dark color.
  • a change in spinning speed in a range of ⁇ 35-45% at a cycle of two through three seconds also allows for a medium sample.
  • the color of this medium fiber is mid dark color.
  • a change in spinning speed of ⁇ 40% at a cycle of three seconds allows for a preferred fiber.
  • the color of the preferred fiber is a dark variant color.
  • the fibers having the denier variation are of a relatively darker shade of the desired color, while the other fibers without denier variation are relatively of a lighter shade of the color.
  • the CIELAB color shade scale it is preferred there is a difference in the L* values between the fibers having denier variation and the homogeneous fibers of at least 7, preferably 7 to 10.
  • the spinning pumps of the present disclosure are synchronized via programing code so that an overall spinning machine throughput remains constant, thereby preventing interruption in the polymer melt extrusion process.
  • the overall spinning machine throughput remains constant because of the synchronization of spinning pumps via programing code.
  • This maintains consistency in the extrusion process and in a face-plate draw-bulk process for optimal process continuity with maximum variation in secondary yarn properties, i.e., bulk, cross-section, and color depth.
  • face-plate processes of finish application, drawing, heating, bulk texturizing, interlace formation and winding remain essentially constant. Together, these process elements being constant propagates variation in the secondary property effects, i.e., bulk, cross-section, color depth, and minimizes process interruptions.
  • a yarn includes a first continuous filament fiber produced by extruding molten polymer through an orifice, quenching the extruded molten polymer to form at least one fiber, drawing said fiber, and winding said fiber into a package.
  • a rate of polymer extrusion through the orifice is increased and decreased to create variation in filament denier along the length of first continuous filament the fiber.
  • the yam includes a second continuous filament fiber different from the first continuous filament fiber.
  • tonal aesthetics can be achieved where the desired subtle variations can be perceived within a room-sized carpet.
  • Fiber from the inventive processes can be used independently; in phase, out of phase, or randomly paired with another modified fiber; or in conjunction with fiber from standard, uniform production to affect the degree of variation in the final article, e.g., carpet.
  • combining fiber produced in this manner invites creative design based on combinations of dominant and recessive colors allowing multiple design aesthetics.
  • the processes described herein include an additional bulk texturing step after the drawing step and before a winding step. In this way, a first continuous filament fiber is produced by a method which includes a bulk texturing step after the drawing step and before the winding step (d).
  • Figures 1-3 illustrate examples of the color contrast carpet samples showing how various fiber combinations of the disclosed processes appear by cabling with other fibers of the disclosed process, and with homogenous fibers, and then tufted into carpets.
  • a carpet is shown having four bands of yam indicated by the numerals 1-4 in Figure 1.
  • bands 1, 2, and 4 illustrate yams created using the novel fiber with changing (oscillating) denier described herein, while band 3 illustrates a control yarn made from a fiber without an oscillating denier.
  • band 1 illustrates a carpet made with inventive fibers having the denier variation.
  • Band 2 illustrates a carpet made from a standard fiber and the inventive fiber with denier variation.
  • the standard fiber is an alabaster color
  • the denier variation fiber with denier variation is another color.
  • the second continuous filament fiber has a different variation in filament denier along its length as compared with the first continuous filament fiber.
  • Band 3 illustrates a control carpet made from two fibers without denier variation.
  • Band 4 illustrates a carpet made from the inventive fiber with denier variation and a homogeneous fiber without denier variation.
  • the inventive fiber with denier variation is an alabaster color, while the homogeneous fiber is another color.
  • the second continuous filament fiber has a homogenous filament denier along its length.
  • a cut pile carpet having two bands of yarn indicated by the numerals la and 2a.
  • the cut pile carpet is made from fibers having two colors/barber pole, such as a lighter color and a darker color.
  • band la the cut pile carpet is made from inventive fibers with denier variation.
  • the inventive fibers are the soft pewter color.
  • band 2a the cut pile carpet is a control made from two fibers without denier variation.
  • one fiber without denier variation is a lighter color, while the second fiber is a darker color.
  • a loop pile carpet made from two bands of yarn indicated by the numerals lb and 2ab.
  • the loop pile carpet is made from fibers having two colors/barber pole, such as a lighter and a darker color.
  • the cut pile carpet is made from inventive fibers with denier variation.
  • the inventive fibers are the soft pewter color.
  • the loop pile carpet is a control made from two fibers without denier variation.
  • Figure 4 illustrates the effects of spinning pump speed variability with respect to fiber denier along the length of the fiber.
  • the spinning pump speed variability settings are in a range of ⁇ 15-40%, with increasing maxima and decreasing minima as speed variability settings increase.
  • the minimum denier is between 700 to 800, while the maximum denier is between 1100 to 1200.
  • the minimum denier is between 800 to 900, while the maximum denier is between 1200 to 1300.
  • the minimum denier is about 600, while the maximum denier is about 1400.
  • Figure 5 illustrates the effects of spinning pump speed variability with respect to bulk.
  • bulk can be defined by standard ASTM D4031 - 07 (2016) Standard Test Method for Bulk Properties of Textured Yarn.
  • the spinning pump speed variability settings are in a range of ⁇ 15-40%, with bulk changing more gradually.
  • the minimum bulk is between 16 to 17, while the maximum bulk is between 20 to 21.
  • the minimum bulk is between 15 to 16, while the maximum bulk is between 20 to 21.
  • the minimum bulk is between 15 to 16, while the maximum bulk is between 20 to 21.
  • the minimum bulk is between 15 to 16, while the maximum bulk is between 20 to 21.
  • Figure 6 illustrates the effects of spinning pump speed variability with respect to filament cross-sections, as measured by the modification ratio, which is the ratio obtained by dividing an outer diameter of a fiber by an inner diameter of the fiber.
  • the values of the x-axis illustrate the variation in spinning pump speed
  • the y-axis represents values which correlate to the modification ratio.
  • the higher the value in the y-axis the higher the modification ratio.
  • the higher the modification ratio the greater the change in cross-section of the fiber.
  • the lower the value in the y-axis the lower the modification ratio, thereby resulting in a less amount of change in the cross-section of the fiber.
  • Figure 6 shows there is a gradual increase in the variation in modification ratio as the spinning pump speed variability settings are increased from ⁇ 15 to + 40%
  • Figure 7 illustrates the relationship between actual pump speed and pump speed setting when the polymer extrusion pump is set to cycle between operation at a speed of 3100 rpm and operation at a speed of 7500 rpm at 1 second intervals.
  • the square wave curve represents desired settings for changing the polymer extrusion flow rate at the spinneret, while the triangle wave illustrates the actual variation in pump speed.
  • the actual settings are offset from the desired settings. Since the polymer extrusion flow rate change (amplitude) is delayed, the flow rate change is always incomplete as the spinning pump speed change happens before the polymer extrusion flow can equilibrate.
  • the triangle wave illustrates that 1 second occurs between a minimum value of the triangle wave and a subsequent minimum value of the triangle wave. Alternatively, 1 second occurs between a maximum value of the triangle wave and a subsequent maximum value of the triangle wave.
  • Figure 8 illustrates the relationship between actual pump speed and pump speed setting when the polymer extrusion pump is set to cycle between operation at a speed of 3100 rpm and operation at a speed of 7500 rpm at 3 second intervals.
  • the square wave curve represents desired settings for changing the polymer extrusion flow rate at the spinneret, while the triangle wave illustrates the actual variation in pump speed. It will be seen that, with the pump and spinneret combination employed in this embodiment, there is better correlation between pump speed setting and actual pump speed variation when the setting is varied at 3 second intervals.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)

Abstract

La présente invention concerne d'une manière générale l'extrusion de fibres synthétiques et, plus particulièrement, des fils et des tapis d'esthétique de couleur variable aléatoire et des procédés de fabrication correspondants. Selon l'invention, un fil comprend : (i) une première fibre de filament continu obtenue par un procédé comprenant : (a) l'extrusion de polymère fondu à travers un orifice ; (b) le refroidissement brusque du polymère fondu extrudé pour former au moins une fibre ; (c) l'étirage de ladite fibre ; et (d) l'enroulement de ladite fibre en un paquet, ce par quoi la vitesse d'extrusion de polymère à travers l'orifice en (a) est augmentée et diminuée pour créer une variation de denier de filament le long de la longueur de la première fibre de filament continu ; et (ii) une seconde fibre de filament continu différente de la première fibre de filament continu.
PCT/US2020/050970 2019-09-16 2020-09-16 Fils et tapis d'esthétique de couleur variable aléatoire WO2021055405A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201962900677P 2019-09-16 2019-09-16
US62/900,677 2019-09-16
US201962907732P 2019-09-30 2019-09-30
US62/907,732 2019-09-30

Publications (1)

Publication Number Publication Date
WO2021055405A1 true WO2021055405A1 (fr) 2021-03-25

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4103481A (en) * 1974-03-08 1978-08-01 Akzona Incorporated Variable diameter yarn
US4489543A (en) * 1977-08-17 1984-12-25 Celanese Corporation Self-crimping yarn
US4546043A (en) * 1984-01-18 1985-10-08 Teijin Limited Hollow irregular multifilament yarn and process and spinneret for producing the same
US4791026A (en) * 1986-11-27 1988-12-13 Teijin Limited Synthetic polymer multifilament yarn useful for bulky yarn and process for producing the same
US5307616A (en) 1991-08-12 1994-05-03 Milliken Research Corporation Method to manufacture a slub yarn
US5958548A (en) * 1996-08-14 1999-09-28 Nyltec Inc. Carpet tufted with bulked continuous filament carpet face yarns utilizing new sheathed core filaments and related selection techniques to produce cost savings
US20020174644A1 (en) * 2001-03-22 2002-11-28 Kun-Chi Hsieh Fancy yarn spinning device
EP1364084A1 (fr) 2001-01-25 2003-11-26 Milliken & Company Fil teint par sections

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4103481A (en) * 1974-03-08 1978-08-01 Akzona Incorporated Variable diameter yarn
US4489543A (en) * 1977-08-17 1984-12-25 Celanese Corporation Self-crimping yarn
US4546043A (en) * 1984-01-18 1985-10-08 Teijin Limited Hollow irregular multifilament yarn and process and spinneret for producing the same
US4791026A (en) * 1986-11-27 1988-12-13 Teijin Limited Synthetic polymer multifilament yarn useful for bulky yarn and process for producing the same
US5307616A (en) 1991-08-12 1994-05-03 Milliken Research Corporation Method to manufacture a slub yarn
US5958548A (en) * 1996-08-14 1999-09-28 Nyltec Inc. Carpet tufted with bulked continuous filament carpet face yarns utilizing new sheathed core filaments and related selection techniques to produce cost savings
EP1364084A1 (fr) 2001-01-25 2003-11-26 Milliken & Company Fil teint par sections
US20020174644A1 (en) * 2001-03-22 2002-11-28 Kun-Chi Hsieh Fancy yarn spinning device

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