Filaments having a low denier per filament are soft but are more prone to breaking. Filaments having a higher denier per filament are more durable, but they are not as soft as filaments having a lower denier per filament. Thus, there is a need in the art for a yarn that provides durability with softness.
According to a first aspect, a method of forming a bulked continuous filament (BCF) yarn comprises: (1) providing N molten streams of polymer, wherein N is an integer and is greater than or equal to 1; (2) providing M spinnerets, wherein M is an integer and is greater than or equal to one; (3) spinning the N molten streams of polymer through the M spinnerets, wherein at least a first group of filaments and a second group of filaments are spun through the M spinnerets, the first group of filaments each having a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different; (4) combining the filaments from the M spinnerets together; and (5) texturizing the spun filaments.
In some implementations, the method further includes winding the BCF yarn after the spun filaments are texturized.
In some implementations, spinning the N molten streams of polymer through M spinnerets consists of spinning a first group of the plurality of filaments having a first average denier per filament and a second group of the plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different.
In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 10% along the lengths of the filaments.
In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments.
In some implementations, each filament in the first group of filaments and the second group of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments.
In some implementations, the first average denier per filament is greater than the second average denier per filament.
In some implementations, the average denier per filament of the first group of filaments is at least 1.5 times larger than the average denier per filament of the second group of filaments.
In some implementations, the first group of filaments are between 2% and 33% of a total number of filaments of the BCF yarn.
In some implementations, a total number of filaments of the BCF yarn is between 50 and 400.
In some implementations, the N molten streams of polymer are extruded from one extruder.
In some implementations, a radial cross-sectional shape of each of the filaments in the first group is the same as a radial cross-sectional shape of each of the filaments in the second group.
In some implementations, a radial cross-sectional shape of each of the filaments in the first group is different from a radial cross-sectional shape of each of the filaments in the second group.
In some implementations, the N molten streams of polymer includes a single polymer.
In some implementations, M equals one, and the spinneret defines a first set of openings having a first diameter and a second set of openings having a second diameter, wherein the first diameter and the second diameter are different.
In some implementations, M is greater than one, and wherein a first spinneret defines a set of openings have a first diameter, and a second spinneret defines a set of openings having a second diameter, wherein the first diameter and the second diameter are different.
In some implementations, the spun filaments are randomly texturized.
According to a second aspect, a bulked continuous filament (BCF) yarn comprises a plurality of filaments, each filament having an average denier along its length, the plurality of filaments comprising a first group of a plurality of filaments having a first average denier per filament, and a second group of a plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different.
In some implementations, the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament.
In some implementations, the first average denier per filament and the second average denier per filament vary less than 10% along the lengths of the filaments.
In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments.
In some implementations, the plurality of filaments comprising the first group of the plurality of filaments and the plurality of filaments comprising the second group of the plurality of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments.
In some implementations, the first average denier per filament is greater than the second average denier per filament.
In some implementations, the first average denier per filament is at least 1.5 times larger than the second average denier per filament.
In some implementations, the first group of filaments are between 2% and 33% of a total number of filaments of the BCF yarn.
In some implementations, a total number of filaments of the BCF yarn is between 50 and 400.
In some implementations, the filaments have the same radial cross-sectional shape.
In some implementations, the first group of the plurality of filaments has a first radial cross-sectional shape, and the second group of the plurality of filaments has a second radial cross-sectional shape, wherein the first and the second radial cross-sectional shapes are different.
In some implementations, all of the filaments are spun from one molten polymer stream.
In a third aspect, a carpet has a pile formed from a BCF yarn, and the BCF yarn comprises a plurality of filaments, wherein each filament has an average denier along its length, the plurality of filaments comprising a first group of a plurality of filaments having a first average denier per filament, and a second group of a plurality of filaments having a second average denier per filament, the first average denier per filament and the second average denier per filament being different.
In some implementations, the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament.
In some implementations, the first average denier per filament and the second average denier per filament vary less than 10% along the lengths of the filaments.
In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary 5% or less along the lengths of the filaments.
In some implementations, the plurality of filaments comprising the first group of the plurality of filaments and the plurality of filaments comprising the second group of the plurality of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments.
In some implementations, the first average denier per filament is greater than the second average denier per filament.
In some implementations, the first average denier per filament is at least 1.5 times larger than the second average denier per filament.
In some implementations, the first group of filaments are between 2% and 33% of a total number of filaments of the BCF yarn.
In some implementations, a total number of filaments of the BCF yarn is between 50 and 400.
In some implementations, the filaments have the same radial cross-sectional shape.
In some implementations, the first group of the plurality of filaments has a first radial cross-sectional shape, and the second group of the plurality of filaments has a second radial cross-sectional shape, wherein the first and the second radial cross-sectional shapes are different.
In some implementations, all of the filaments are spun from one molten polymer stream.
Example features and implementations are disclosed in the accompanying drawings. However, the present disclosure is not limited to the precise arrangements and instrumentalities shown. Similar elements in different implementations are designated using the same reference numerals.
According to a first aspect, a method of forming a bulked continuous filament (BCF) yarn comprises: (1) providing N molten streams of polymer, wherein N is an integer and is greater than or equal to 1; (2) providing M spinnerets, wherein M is an integer and is greater than or equal to one; (3) spinning the N molten streams of polymer through the M spinnerets, wherein at least a first group of filaments and a second group of filaments are spun through the M spinnerets, the first group of filaments each having a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different; (4) combining the filaments from the M spinnerets together; and (5) texturizing the spun filaments. In some implementations, the filaments are texturized randomly.
According to a second aspect, a BCF yarn including a plurality of filaments is provided. Each filament has an average denier along its length. The plurality of filaments includes a first group of a plurality of filaments having a first average denier per filament and a second group of a plurality of filaments having a second average denier per filament. The first average denier per filament and the second average denier per filament are different. Clearly such BCF yarn may be obtained, but is not necessarily obtained, through the method of forming a BCF yarn of the first aspect. Nevertheless, the BCF yarn of the second aspect may show various preferred features similar or equal to the features obtained through the method of the first aspect.
According to a third aspect, a carpet, rug, or carpet tile (collectively referred to herein as “carpet”) comprising the yarn obtained through the first aspect and/or in accordance with the second aspect is provided. Herein this may relate to a flooring product with a tufted or woven pile.
The molten stream of polymer 190 can include any thermoplastic polymer material, for example, polyamide (PA) such as PA6, PA6.6, PA6.10, polyether sulfone (PES) such as PTT, polybutylene terephthalate (PBT), polyethylene terephthalate (PET) or recycled PET, polyolefin (PO) such as polyethylene (PE), or polypropylene (PP).
The spinneret 152 shown in
The first set of openings 162 defined by the spinneret 152 are shaped such that the first group of filaments 172 exiting the first set of openings 162 have a first radial cross-sectional shape, and the second set of openings 164 defined by the spinneret 152 are shaped such that the second group of filaments 174 exiting the second set of openings 164 have a second radial cross-sectional shape. The first group of filaments 172 and second group of filaments 174 produced by the first set of openings 162 and second set of openings 164, respectively, produce the same cross-sectional shape, as shown in
The spun filaments 172, 174 are then combined to form a BCF yarn 199 and are texturized by the texturizer 180 to texturize the BCF yarn 199. Texturizing may result in the length of the filament shrinking by 3-25%, for example. Other aspects measuring the extent to which the filaments are texturized include crimping, total recovery, bulking, and shrinkage. The texturizer 180, which is shown in
The molten stream of polymer 390 can include any thermoplastic polymer material, for example, polyamide (PA) such as PA6, PA6.6, PA6.10, polyether sulfone (PES) such as PTT, polybutylene terephthalate (PBT), polyethylene terephthalate (PET) or recycled PET, polyolefin (PO) such as polyethylene (PE), or polypropylene (PP).
The spin pack 340 shown in
The first set of openings 362 defined by the first spinneret 352 are shaped such that the first group of filaments 372 exiting the first set of openings 362 have a first radial cross-sectional shape, the second set of openings 364 defined by the second spinneret 354 are shaped such that the second group of filaments 374 exiting the second set of openings 364 have a second radial cross-sectional shape, and the third set of openings 366 defined by the third spinneret 356 are shaped such that the third group of filaments 376 exiting the third set of openings 366 have a third radial cross-sectional shape. The first group of filaments 372, second group of filaments 374, and third group of filaments 376 spun through the first set of openings 362, second set of openings 364, and third set of openings 366, respectively, produce the same cross-sectional shape. However, in other implementations, the first group of filaments, second group of filaments, and third group of filaments have different cross-sectional shapes.
The filaments 372, 374, 376 spun by each of the spinnerets 352, 354, 356 are then combined to form a BCF yarn 399 and are texturized by the texturizer 180 shown in
The molten stream of polymer 490a, 490b, 490c can include any thermoplastic polymer material, for example, polyamide (PA) such as PA6, PA6.6, PA6.10, polyether sulfone (PES) such as PTT, polybutylene terephthalate (PBT), polyethylene terephthalate (PET) or recycled PET, polyolefin (PO) such as polyethylene (PE), or polypropylene (PP).
The spin pack 440 shown in
The first set of openings 462 defined by the first spinneret 452 are shaped such that the first group of filaments 472 exiting the first set of openings 462 have a first radial cross-sectional shape, the second set of openings 464 defined by the second spinneret 454 are shaped such that the second group of filaments 474 exiting the second set of openings 464 have a second radial cross-sectional shape, and the third set of openings 466 defined by the third spinneret 456 are shaped such that the third group of filaments 476 exiting the third set of openings 466 have a third radial cross-sectional shape. The first group of filaments 472, second group of filaments 474, and third group of filaments 476 produced by the first set of openings 462, second set of openings 464, and third set of openings 466, respectively, produce the same cross-sectional shape. However, in other implementations, the first group of filaments, second group of filaments, and third group of filaments produced by the first set of openings, second set of openings, and third set of openings, respectively, produce different cross-sectional shapes.
The filaments 472, 474, 476 spun by each of the spinnerets 452, 454, 456 are then combined to form a BCF yarn 499 and are texturized by the texturizer 180 shown in
The implementations of systems shown in
In some implementations, M equals one. The one spinneret defines a first set of openings having a first diameter and a second set of openings having a second diameter that is different than the first diameter. In some implementations, M is greater than one. A first spinneret defines a set of openings that have a first diameter, a second spinneret defines a set of openings that have a second diameter that is different than the first diameter.
The M spinnerets spin at least a first group of filaments and a second group of filaments. The first group of filaments each have a first average denier per filament along a length of the filaments, and the second group of filaments each have a second average denier per filament along a length of the filaments. The first and second average denier per filament are different. In some implementations, the first average denier per filament is greater than the second average denier per filament. The radial cross-sectional shape of each of the filaments in the first group can be the same as or different than a radial cross-sectional shape of each of the filaments in the second group.
Clearly, the BCF yarn obtained through the method of the first aspect described in the figures also shows the features of the second and third aspects.
In some implementations of the first, second, and/or third aspects, the total number of filaments of the BCF yarn is between 50 and 400, and the first group of filaments, which have a larger denier per filament than one or more other groups of filaments, are between 2% and 33% of a total number of filaments of the BCF yarn. In some implementations, the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament. In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 10% along the lengths of the filaments. In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 5% along the lengths of the filaments.
It is not excluded that the first and/or the second group would include less than 2% of the filaments of the yarn, or even as few as only 1 filament. For example, in some implementations, the BCF yarn obtained through the first, second, and/or third aspect contains a plurality of, e.g., up to 50 or 100, groups of filaments of all different denier per filament.
In some implementations, the difference in DPF between the respective groups of filaments is such that the filaments of the first group along their length always have a denier value that is smaller, or larger as the case may be, than the denier the filaments of the second group have along their length. In other words, the filaments of the first group, at any radial cross-section, are thicker/thinner, than any segment along the length of the filaments of the second group. As aforestated, in some implementations, the DPF of each filament is constant along its length and/or varies less than 10% or less than 5% along its length.
In some implementations of the first, second, and/or the third aspect, each filament in the first group of filaments and/or the second group of filaments have a wavelike axial cross-sectional shape along the lengths of the filaments. Wavelike refers to a change in the DPF of the filament in different segments along the length of the filament. For example, one segment along the length of the filament may have a DPF that is larger than the DPF of another segment along the length of the filament. The change in DPF for each filament may vary between 10% and 40%, for example. As shown in
In some implementations of the first, second, and/or the third aspect, the average denier per filament of the first group of filaments is at least 1.5 times larger than the average denier per filament of the second group of filaments.
The BCF yarn is texturized such that the overall length of the yarn is reduced by between 3% and 25%, depending on the processing speeds, conditions, and desired output of the yarn. For example, a higher percentage of reduction in length yields a bulkier yarn. The amount of texturizing is measured by using ASTM D4031-01, which includes heating the BCF yarn and measuring an increase in tension or an increase in linear density of the BCF yarn in response to the heating. The heating of the BCF yarn can be performed with an oven or with a designated measurement tool, such as a textured yarn tester (TYT).
In some implementations of the first, second, and/or the third aspect, the distribution of the filaments of the first and second group in the cross-section of the yarn is such that they are equally, or at least more or less equally, distributed, for example such that the inner 50% area of the yarn contains not more than 1.25 times (100/G) % filaments of a group, where G is the number of groups of filaments having different denier. Thus, filaments of the first and second group are present at the outer surface of the yarn, as well as in the center of the yarn. The more or less equal distribution leads to a softer feeling of the yarn and the carpet containing the yarn.
In some implementations of the first, second, and/or the third aspect, the total number of filaments of the BCF yarn is between 50 and 400, and the first group of filaments, which have a larger denier per filament than one or more other groups of filaments, are between 2% and 33% of a total number of filaments of the BCF yarn. In some implementations, the average deniers of the filaments in the BCF yarn vary between 2 denier per filament and 25 denier per filament. In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 10% along the lengths of the filaments. In some implementations, the average denier per filament of the first group of filaments and the average denier per filament of the second group of filaments vary less than 5% along the lengths of the filaments. In some implementations, such as described above in relation to
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claims. Accordingly, other implementations are within the scope of the following claims.
Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present claims. In the drawings, the same reference numbers are employed for designating the same elements throughout the several figures. A number of examples are provided, nevertheless, it will be understood that various modifications can be made without departing from the spirit and scope of the disclosure herein. As used in the specification, and in the appended claims, the singular forms “a,” “an,” “the” include plural referents unless the context clearly dictates otherwise. The term “comprising” and variations thereof as used herein is used synonymously with the term “including” and variations thereof and are open, non-limiting terms. Although the terms “comprising” and “including” have been used herein to describe various implementations, the terms “consisting essentially of” and “consisting of” can be used in place of “comprising” and “including” to provide for more specific implementations and are also disclosed. As used herein, when a value is given as “between” a first and second number, the range includes the first and second numbers.
Filing Document | Filing Date | Country | Kind |
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PCT/US2021/037675 | 6/16/2021 | WO |
Number | Date | Country | |
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63039635 | Jun 2020 | US | |
63042316 | Jun 2020 | US |