AU606085B2 - Carpets utilising synthetic yarn with heat-activated binder fiber - Google Patents

Description

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PCT WORLD AU-Al -80254/87 WRDINTELLECTUAL PROPERTY ORGANIZATION PCT I~n aI M eau INTERNATIONAL APPLICATIONPUBLISHU) T ~P a TQOPjTION TREATY (PCT) (51) International Patent Classificatirjn 4: 11 International Publication Number: WNO 88/ 03969 D02G 3/40 Al 1(43) International Publication Date: 2 June 1988 (02.06.88) I M (21) International Application Number: PCT/US87/02339 (22) Internatiorial Filing Date: 15 September 1987 (15,09.87) (31) Priority Application Number: 934,389 (32) Priority Date: (33) Priority Country: 24 November 1986 (24.11,86)1 (81) Designated States: AT (European patent), AU, BE (European pate.nt), CH (European patent), DE (European patent), FR (European patent), GB (European patent), IT (European patent), JP, LU (European patent), NL (European patent), SE (European patent), Publkshed Willi international search report.

21 JUL 19R, AUSTRALIAN j J 16 JUN 1988 L PATENT OFFICE (71) Applicant: ALLIED CORPORATiqN (US/US]; Law Department Leather), PO. Box 2245-R, Morristown, NJ 0796G (US).

(72) Inventor: HACKLER, Lewis, Richardson P.O, Box 176, Colonial Heights, VA 23834 (US), (74) Agent: WINTER, Richard, Allied Corporation, Law Department (F.My, Leather), P.O. Box 2245-R, Morristown, NJ 07960 (US), aT Title: SYNTHETIC YARN WITH HEAT-ACTIVATED BINDER FIBER lis douument contains the w~ndments made uiidr ~ction 49 and is correct for (57) Abstract Syrvhetic 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 I-4 weight percent, otr a heat activated binder fiber with a melting point witnin the range of I IQ-170)C, preferably 130,160'C, A preferred binder fiber is a copolyamide, fiber, including ternary copolyamides of the 6/66/12 type, When the yarn Is twisted, plied and twist set by conventional processes and the treated yarn tufted Into carpet, the resutijg carpet displays enhanced wear and appearance properties.

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Insert place and date of signature.

Signature of Declarant(s) (no attestation required).

Note: Initial all alterations.

Declared aiMorris Township this 21st day of April 1989 ADLIED CORPORATION V i i H. assegi sisian ''Secreiary DAVIES COLLISON MELBOURNE and CANBERRA.

11111 1 I II i N milliE III iU ii I I I II I I iIiii~ Ii I- r- WO 88/03969 PCrJUS87/02339 SYNTHETIC YARN WITH HEAT-ACTIVATED BINDER FIBER 1. Field of the Invention The invention relates to synthetic yarn for carpet face fiber and other applications, the yarn comprising 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 base fiber. In a process for production of carpet, exposure of the yarn to usual process conditions for twist setting the 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. Description of Related Art It has been known to blend non-adhesive fibers with potentially adhesive fibers to form a yarn or other textile dtructure, then to activate the potentially adhesive fibers to bond them to contacting fibers, thus modifying end-use properties of the yarn. U.S. Patent 2,252,999 to Wallach, issued August 19, 1941, provides a process wherein a yarn comprising an admixture of non-adhesive and potentially adhesive fiber is tormed, the potentially adhesive fiber is.activated, and the fibers compacted while in an adhesive condition so that they adhere to each other at points of contact. U.S. Patent 3,877,214 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 i 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 substapnially twistless compact yarn ?AL comprising a proportion of potentially adhesive fiber Swhich have been activated to bond to contacting sibers.

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-rr WO 88/03969 PCr[US97/02339 -2- 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. For example, 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. In a typical process 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.

For nylon-6 base fiber, the conditions for this step are typically 195-200' C with a residence time of about seconds for the Suessen process and about 135-140 C with a residence time of about 60 seconds for the Superba process.

Similarly, bulked continuous filament nylon yarn is produced according to various conventional methods.

Twisting, entangling, or direc cabling may be utilized in vart 3u processes. For example, 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.

Mtltiple ends of the twist set yarns are tufted into cut pile carpet and conventionilly finished to obtain the desired carpet product.

SUMMARY OF THE INVENTION r~yhtic yarn omprioo.a a lnd of bae fibe:

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-3 In accordance with the present invention there is provided a process for production of carpet comprising twist setting synthetic yarn for carpet face fiber comprising base fiber selected from nylon-6, nylon-6-6, and polyester and 1-12 weight percent heat-activated binder fiber with a melting point within the range of 110 to 170*C under ambient humidity conditions while simultaneously heating said yarn sufficiently to substantially melt said heat-activated binder fiber; subsequently cooling said yarn to solidify said melt, thereby encapsulating and bonding intersecting points of said base fiber; then incorporating the heat-treated yarn into the carpet construction.

S* The invention further provides carpet produced by the process defined in the immediately preceding paragraph.

Preferably the binder comprises 1-8 weight percent and hav a melting point in the range 130 to 160 0 C. 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 preferred binder fibers.

4 When the yarn is twisted, plyed and twist set by conventional processes, for example 195°C for 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.

DESCRIPTION OF THE PREFERRED EMBODIMENT Applicant has discovered that by incorporation of a minor proportion of heat-activated binder fiber with

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7 \4 substantially lower melting point than the base fiber 90o1o inmdatO63,48025flrm3 3a into the yarn construction, the standard heat conditions for twist setting the yarn will cause the binder fiber to melt, substantially loosing its identity as a fiber. It will flow to intersecting points of base fiber and upon subsequent cooling will encapsulate and bind fibers and yarn together, thereby retaining the twist in cut-pile carpets. Carpets made with the yarn of this invention can be improved in surface, aesthetics, hand, durability and wear performance. By careful selection of the binder fiber desired improvement is "built-in" to the yarn with no additional process steps required by the yarn spinner, the carpet manufacturer, or in dyeing and finishing.

goes The base fiber is selected from known synthetic fiber suitable for carpet use. Preferred base fiber o 0 includes polyamide, partictularly 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 i10-170 0 C, preferably 130-16 0 0C, under ambient humidity conditions. This range ensures that the binder fiber -:000" will melt during the conventional twist setting process yet #**too C0 9 go b N'' 901mdtO63±824AIrMs4 WO 81~/03969 PCr[US87/02339 -4will 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 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. incorporated herein by reference.

A melt bonding copolyamide adhesive fiber is commercially available from EMS as GRILONS type K 140 (melting range 130-140 C) and type K 115 (melting range 110-117 C).

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.

By selection of the 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 *1 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.

With the utilization of this invention, 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. For the Suessen process, under relatively low humidity conditions, the twisted yarn is subjected to a temperature of 190-205°C for a residence time of 50-60 seconds. In the Suessen process 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. As the fiber emerges from the elevated temperature condition, the binder solidifies and encapsulates or bonds two or more base fibers together at intersecting points in a durable bond, Subsequent processing including dyeing, finishing, and backcoating using commercial processing methods does not soften the bond points sufficiently to weaken them, but rather will strengthen them. The resultant carpet can be of many forms, but a typical style would be cut-pile carpet with about 40 ounces per square yard (1.4 kg/m 2 of face yarn including the binder, with an attached backing. Carpet construction would be typically 5/32" (4 mm) gauge, 3/4" (20 mm) 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 pro<Lation of loop-pile carpet.

EXAMPLE 1 A blend of staple fiber was produced with 3 AL,, weight percent GAILOQNO Type K 140 copolyamide fiber having a melt point range of 130-140 0 C and 97 weight percent base SUBSTITQTE SHEET -6staple fiber (Allied Type 521 nylon-6 fiber having a melt point range of 215-225 0

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 (185 tpm), was plyed with a similar yarn to produce a 2-ply 3's/2 cotton count 4.7Zx4.0S yarn (185Z x 160S).

The 2-ply yarn was twist set by a conventional Sussen twist setting process. The yarn was passed through a heated chamber at about 195°C while in a relaxed condition, with a residence time of about 60 seconds.

Multiple ends of this yarn was 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 base staple fiber. The carpet containing the binder staple fiber blend displayed enhanced carpet tuft appearance, more resilience, and better wear resistance.

EXAMPLE 2 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. In the following example the carpet manufacturer simply uses normal processing techniques to obtain the desired effect.

Filament nylon yarn is produced according to various conventional '£iber 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.

In various processes, twisting, entangling, or 7M direct cabling may be utilized. Direct cabling is often R used, as in this example, where a 70 denier (78 dtex) 14 /filament yarn is combined with a 1185 denier (2000 dtex) SUBSTITUTE

SHEET

-7filament in the creel of the direct cabler to produce a yarn with 3.5 twist per inch (140 tpr) in each of the singles and 3.5 twist (140 tpm) in 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 yiArn together, thereby retaining the twist in cut pile carpet.

:n this example a copolyamide 70 denier (78 dtex) nylon yarn having a melt point range of 130-140 0

C

results in the binder fiber for the combination, combined with 2 ends of 1185 denier (2000 dtex), 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.

When the product is subjected to conventional twist setting, the binder is activated producing a final prQduc-. 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 270OF (130 0 in saturated steam, with a residence time of abowt 60 seconds. As the fiber emerges from the elevated temperature condition, 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 coarpet and conventionally finished to obtain the improved product.

UBSTITUTE SHEE 4

Claims (6)

1. A process for production of carpet comprising twist setting synthetic yarn for carpet face fiber comprising base fiber selected from nylon-6, nylon-6-6, and polyester and 1-12 weight percent heat-activated binder fiber with a melting point within the range of 110 to 170°C under ambient humidity conditions while simultaneously heating said yarn sufficiently to substantially melt said heat-activated binder fiber; subsequently cooling said yarn to solidify said j" melt, thereby encapsulating and bonding intersecting spoints of said base fiber; then incorporating the heat-treated yarn into the carpet construction.

2. The process of claim 1 wherein said binder fiber has a melting point within the range of 130 to 160 0 C. s 3. The process of claim 2 wherein said synthetic yarn comprises 1 to 8 weight percent binder fiber.

4. The process of claim 1 wherein said binder fiber is a copolyamide. The process of claim 4 wherein said binder fiber is a ternary copolyamide of the 6/66/12 type. 6, The process of claim 5 wherein said binder fiber has a melting point within the range of 110 to 150*C.

7. The process of claim 6 wherein said synthetic yarn comprises 1 to 8 weight percent binder fiber. \Qq 8. The process of claim 7 wherein said base fiber is Uml I1 1* -9- nylon 6.

9. The process of claim 1 wherein said base fiber is nylon 6. A process according to claim 1 substantially as hereinbefore described with reference to the Examples.

11. A carpet produced by the method of any preceding claim. DATED this 23rd day of October 1990. ALLIED CORPORATION By Its Patent Attorneys DAVIES COLLISON I e f If *I ~OlO3,IftEDdaLO63,a~8O2S4a1Lrci~ /2 1 INTERNATIONAL SEARCH REPORT IntillnatonAl Appication' No PCT/US 87/02339 1. CLASSIFICATION OF SU@JKCT MATTER (it several classirication synmba apply, indicate all) Acceoim4 to Intarnatlonl Patent CiaaeiriCallan (IPC) or to both National Classification and IPC IPC 4: D 02 G 3/40 i1. FIELDS SEARCMED Minimum Documentation Ss.,'hedI Classification Siatemn Classificationi ymboie IC4 D02 G Documnentation Searched other them~ Minimum Documentation to the Extent that such Documents are Included In the Fields SearchedJ I iii, DOCUMENTS CONSIDERED TO SE RELAVANT' Cate*gory Citation ot Document, ii with indi cation, whore appropriate, ot the relevant Passage$ lv R elevant to claim NO, 13 XFR, A, 2124919 P. COATS LTD) 1-3,9 22 September 1972 see page 2, lines 1-13, 16-20; page 3, lines 11-13, 17-23; page 6, ldies 17-19 Y 4-8,11,13, 15t17,19 X US, A, 3494822 (LIH.P. WELDON) 1-3 February 1970 see column 1, line 46 column 2, line 9, lines 47-56 Y GB, A, 1168404 (INVENTA AG) 4-8fli1,j3, 22 October 196915,7 9 see poage 2, lines 4-6 1,71 cited in the application Special categories of Cited dolUment~i; T" later document Published after the International fiing date document deonning the ge6nersi :stte af the art which is not or priority date end not in contlitt with thes application but ctonsidered to be of particulrlst ~~vancv cited to understand the Principie or theory underivinit the Invention "V4 earlier document but published on of attar the Intermational document of Particular relevancei the claimed invention fili ng date cannot be considered novel or cannot be considered to d ocument Which may throw doubts *m priority claim(s) or Involve an Inventive step which is Cited to solilblish the Publication date of another document ot particular relevoncsi' the claim"d Invention Citation or other spe 'pel reason (ats specified) cannot be considered to Involve in Inventive step when the document referring t~o an diel disclosure, use, eshibition or document is combined with one at more other such daOiJ. other means ments. such comolnation doing uuviuj,y In q perioon skilied 1110 document published prior to the International filing date but In the arn. later then the priority date claimed OA" document member of th. same patent family IV, .111RTIPICATION Date ot the Actual Competion of the Iritenalonl Search 16th December 1987 International Searching Authority V.tP.OPFAN PATENT OFFICE form; OCT/ISA/2114 (second sheet) tjanusry tasa) Date Of Mailing Of this Informational Search Rcport 10 FEB 1988 -9 Ii I ANNEX TO THE INTERNATIONAL SEARCH REPORT ON INTERNATIONAL PATENT APPLICATION NO. US 8702339 SA 18888 This annexc lists the patent family nmenmbers relating to the pateni ;t cited in the above-mentioned international 5-mrch report. The members arc as contained in the European P'atent Office E.DP ile on 28101/88 The European P-otcnt Office is in no way liable for these particulars which are merely given for the purpose of information. Put ubliatio Pmet fa ilyPublication FR-A- 2124919 22-09-72 NL-A- 7201188 01-08-72 OE-A,B 2204119 21-09-72 AU-A- 3832672 04-10-73 BE-A- 778609 16-05-72 US--A- 3494822 1C0-02-70 None GB-A- 1168404 22-10-69 FR-A- 1574742 18-07-69 CH-A- 491150 3A'-05-70 BE-A- 712009 11-09-68 OE-A- 1745029 13-04-72 For more details about this ann~ex .1 $ee Official Journal of the European Patent Office, No. 12182