Patent Application
20250051968
Melt spun filaments, such as melt spun filaments of PET are known in the art. Some types of polymers, hence filaments, strands or bundles, are difficult to dye, or to provide with a color varying along the length of the filament, bundle or strand.
It is known to change the color of filaments in a bundle by changing the dye sourcing. However, this process is time consuming and can be wasteful. In addition, it is also known in US Published Patent Application No. 2010/0297442 to vary the output of spin pumps when spinning a plurality of filament bundles that each have a different color to provide a color variation along the length of a composite thread made with the plurality of filament bundles.
However, a need in the art exists for systems and methods for improving the color variation of a bundle of filaments and/or a yarn.
Various implementations include systems and methods of providing multifilament bundles of melt spun polymer filaments that provide a color variation along the length of the filament, bundle, or strand.
A first aspect includes a system for producing at least one bundle of filaments. The system includes N extruders, wherein N is an integer greater than 1, at least one spin station for receiving molten polymer streams from the N extruders, and a processor. Each extruder includes a polymer having a color, hue, luster, and/or dyeability characteristic, and the colors, hues, lusters, and/or dyeability characteristics of the polymers in the N extruders are different from each other. Each spin station includes at least one spinneret through which a plurality of melt-spun filaments are spun from at least two of the molten polymer streams received by the spin station and a group of N spin pumps upstream of the spinneret. Each spin pump is in fluid communication and is paired with one of the N extruders. The processor is in electrical communication with the N spin pumps and is configured to execute computer readable instructions that cause the processor to adjust the volumetric flow rate of the polymers pumped by each spin pump to achieve a ratio of the polymers to be included in a yarn comprising the filaments spun from the spinneret. In some implementations, the number of extruders N is 3 or 4.
In some implementations, the instructions further cause the processor to determine the volumetric flow rate of each polymer to be pumped by each spin pump and generate the instructions to the spin pumps based on the volumetric flow rate determinations.
In some implementations, the instructions also cause the processor to adjust the timing of the volumetric flow rate changes and hence adjust the corresponding denier and/or color changes in the yarn. The instructions cause the processor to adjust the speeds and volumetric flow rates of some or all of the spin pumps for an amount of time based on a desired color variation in the yarn.
In some implementations, the instructions cause the processor 110 to randomize the amount of time that the speeds and volumetric flow rates through some or all of the spin pumps are varied.
In some implementations, the spin station is a first spin station, and the group of N spin pumps are the first group of N spin pumps. The system further comprises a second spin station and a second group of N spin pumps upstream, wherein each spin pump of this second group of spin pumps is in fluid communication and is paired with one of the N extruders. The ratio is a first ratio for the first spin station, and the instructions further cause the processor to adjust the volumetric flow rate of the polymers pumped from each spin pump of this second group of spin pumps to achieve a second ratio of the polymers to be included in the filaments spun from the spinneret of the second spin station. In some implementations, the first ratio and the second ratio are different.
In some implementations, the system comprises M spin stations and M groups of N spin pumps upstream of the at least one spinneret for each M spin station, wherein each spin pump of each of the M groups of spin pumps is in fluid communication and is paired with one of the N extruders, and wherein the instructions further cause the processor to adjust the volumetric flow rate of the polymers pumped from each spin pump of each of the M groups of spin pumps to achieve M ratios of the polymers to be included in the filaments spun from the at least one spinneret of each M spin station. According to some implementations, at least two ratios of the M ratios are different. In other implementations, all of the M ratios are different.
In some implementations, the at least one spinneret is a single spinneret through which the N polymer streams are spun, and the N polymer streams are combined prior to being spun through the single spinneret.
In some implementations, the N polymer streams are at least partially mixed prior to being spun through the single spinneret.
In some implementations, an average denier per filament of each of the plurality of filaments varies by ±5% along a length of each filament.
In some implementations, the at least one spinneret comprises a first spinneret and a second spinneret, and each spin station comprises at least one manifold disposed between the spinnerets and the N pumps, the manifold directing at least two of the N polymer streams to the first spinneret and at least one of the N polymer streams to the second spinneret.
In some implementations, the manifold is a static manifold.
In some implementations, the manifold is a dynamic manifold.
In some implementations, the dynamic manifold comprises N inlets and at least N+1 outlets, wherein each inlet is in fluid communication with a respective one of N extruders, and at least one inlet is in communication with at least two outlets via channels that extend between the inlet and the outlets and comprises at least one valve that controls flow of the polymer stream between the at least one inlet and the at least two outlets.
In some implementations, the spin station further includes at least one mixing plate disposed between the at least one spinneret and the at least one manifold, the at least one mixing plate defining one or more channels through which one or more molten polymer streams flow through the at least one mixing plate to the at least one spinneret.
In some implementations, the filaments spun from the spinneret include at least a first group of filaments and a second group of filaments, wherein the first group of the filaments have a first color, hue, luster, and/or dyeability characteristic, the first color, hue, luster, and/or dyeability characteristic being extruded from a first of the N extruders, and the second group of the filaments have a second color, hue, luster, and/or dyeability characteristic, the second color, hue, luster, and/or dyeability characteristic being extruded from a second of the N extruders. In some implementations, the filaments spun from the spinneret further include a third group of filaments, wherein the third group of the filaments have a third color, hue, luster, and/or dyeability characteristic, wherein the third color, hue, luster, and/or dyeability characteristic is a mixture of the first color, hue, luster, and/or dyeability characteristic and the second color, hue, luster, and/or dyeability characteristic.
In some implementations, the system further comprises at least one drawing device to elongate said N bundles of spun filaments; an initial tacking device upstream to or integrated within the at least one drawing device to tack at least one of said N bundles of spun filaments prior to or during the elongation of the N bundles of spun filaments; at least one texturizer to texturize said N bundles of elongated spun filaments; and a final tacking device to tack said N bundles of texturized spun filaments to provide a BCF yarn.
In some implementations, the at least one texturizer comprises at least a first texturizer and a second texturizer, and at least one of said N bundles of spun filaments is texturized individually from the other N bundles of spun filaments through the first texturizer.
In some implementations, the at least one texturizer comprises N texturizers, and each of said N bundles of spun filaments are texturized individually from each other through respective N texturizers.
In some implementations, the system further comprises an intermediate tacking device and a mixing cam disposed between the at least one texturizer and the final tacking device, the intermediate tacking device for tacking at least one of said N bundles of texturized spun filaments and the mixing cam for positioning tacked and texturized bundles relative one to the other before reaching the final tacking device.
In some implementations, the system further comprises at least one drawing device to elongate said N bundles of spun filaments; at least a first texturizer and a second texturizer, wherein at least one of said N bundles of elongated spun filaments is texturized individually through the first texturizer separately from the other said N bundles of elongated spun filaments; and a final tacking device to tack said N bundles of texturized spun filaments to provide a BCF yarn.
In some implementations, the system further comprises an intermediate tacking device disposed between the at least one texturizer and the final tacking device, the intermediate tacking device for tacking at least one of said N bundles of texturized spun filaments.
In some implementations, the system further comprises a mixing cam disposed between the at least one texturizer and the final tacking device, the mixing cam for positioning tacked and texturized bundles relative to one to the other before reaching the final tacking device.
In some implementations, the system further comprises at least one drawing device to elongate said N bundles of spun filaments; at least one texturizer to texturize said N bundles of elongated spun filaments; a second tacking device disposed between the texturizers and the final tacking device, the second tacking device for tacking at least one of said N bundles of texturized spun filaments; and a final tacking device to tack said N bundles of texturized spun filaments to provide a BCF yarn.
In some implementations, the system further comprises a mixing cam disposed between the texturizers and the final tacking device, the mixing cam for positioning tacked and texturized bundles relative to one to the other before reaching the final tacking device.
In a second aspect, a bundle of filaments produced using the system above is provided.
In some implementations, a yarn comprising the bundle of filaments according to the second aspect is provided. In some implementations, the yarn is a bulked continuous filament (BCF) yarn. And, in some implementations, a carpet comprises pile made with the yarn.
In a third aspect, a method to produce at least one bundle of filaments is provided. The method includes (1) providing N streams of molten polymer, wherein N is an integer greater than 1, and each stream has a different color, hue, luster, and/or dyeability characteristic; (2) providing at least one spin station having N feeds for receiving the N streams of polymer, the spin station comprising at least one spinneret and a group of N spin pumps, each pump pumping one of the N streams of polymer to one of the N feeds, the N spin pumps being disposed upstream of the at least one spinneret and at least two of the N feeds being in fluid communication with one of the at least one spinnerets; and (3) adjusting a volumetric flow rate of each polymer stream pumped to the respective feed of the spin station to achieve a ratio of the polymer streams to be included in a yarn comprising the filaments spun from the at least one spinneret.
In some implementations, the at least one spin station comprises a first spin station and a second spin station, and the ratio is a first ratio, wherein the volumetric flow rate of each polymer stream pumped to the respective feed of the first spin station is based on the first ratio of the streams to be included in the filaments spun by the spinneret of the first spin station, and the volumetric flow rate of each polymer stream pumped to the respective feed of the second spin station is based on a second ratio of the streams to be included in the filaments spun by the spinneret of the second spin station. For example, in some implementations, the first ratio and the second ratio are different.
In some implementations, each of N streams of molten polymer are provided by one of N extruders such that each stream remains separated from other streams until reaching the spin station.
In a fourth aspect, a bundle of filaments produced using the method above is provided.
In some implementations, a yarn comprising the bundle of filaments according to the fourth aspect is provided. In some implementations, the yarn is a bulked continuous filament (BCF) yarn. And, in some implementations, a carpet comprises pile made with the yarn.
In a fifth aspect, a system for producing M yarns is provided, wherein M is an integer greater than 1. The system includes N extruders, M spin stations, and a processor. N is an integer greater than 1, and each extruder includes a polymer having a color, hue, luster, and/or dyeability characteristic. The colors, hues, lusters, and/or dyeability characteristics of the polymers in the N extruders are different from each other. Each spin station is for producing at least one bundle of filaments and for receiving molten polymer streams from the extruders. Each spin station comprises at last one spinneret through which a plurality of melt-spun filaments are spun from at least two of the molten polymer streams received by the respective spin station and a group of N spin pumps upstream of the spinneret for the respective spin station, wherein each spin pump is in fluid communication and is paired with one of the N extruders. The processor is in electrical communication with the N*M spin pumps and is configured to execute computer readable instructions that cause the processor to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in each of the M yarns comprising the filaments spun from the at least one spinneret of the respective M spin station.
In some implementations, for each of the M spin stations, the filaments spun from the respective at least one spinneret include at least a first group of filaments and a second group of filaments. The first group of the filaments have a first color, hue, luster, and/or dyeability characteristic, the first color, hue, luster, and/or dyeability characteristic being extruded from a first of the N extruders, and the second group of the filaments have a second color, hue, luster, and/or dyeability characteristic, the second color, hue, luster, and/or dyeability characteristic being extruded from a second of the N extruders.
In some implementations, the filaments spun from the respective at least one spinneret of each of the M spin stations further include a third group of filaments, the third group of the filaments have a third color, hue, luster, and/or dyeability characteristic, wherein the third color, hue, luster, and/or dyeability characteristic is a mixture of the first color, hue, luster, and/or dyeability characteristic and the second color, hue, luster, and/or dyeability characteristic.
In some implementations, the ratio to be included in each of the M yarns are different.
In a sixth aspect, a yarn comprising a plurality of filaments is provided, wherein each filament has a color, hue, luster, and/or dyeability characteristic that extends from an external surface to a center thereof and for at least a subset of the plurality of filaments, the color, hue, luster, and/or dyeability characteristic of each filament within the subset varies along a length of the filament. In some embodiments, the filaments are solid-dyed (also referred to herein as solution-dyed). In some embodiments, the plurality of filaments has at least a first set of filaments and a second set of filaments, wherein the first set of filaments has a first color, hue, luster, and/or dyeability characteristic at a radial cross section of the plurality of filaments and the second set of filaments has a second color, hue, luster, and/or dyeability characteristic at the radial cross section, and the first color, hue, luster, and/or dyeability characteristic is different than the second color, hue, luster, and/or dyeability characteristic. In some embodiments, the sixth aspect is a bulked continuous filament (BCF) yarn.
In a seventh aspect a yarn comprising a plurality of filaments is provided, wherein said plurality of filaments has at least a first set of filaments and a second set of filaments, wherein the first set of filaments has a first color, hue, luster, and/or dyeability characteristic at a radial cross section of the plurality of filaments and the second set of filaments has a second color, hue, luster, and/or dyeability characteristic at the radial cross section, and the first color, hue, luster, and/or dyeability characteristic is different than the second color, hue, luster, and/or dyeability characteristic. In some embodiments, the seventh aspect is a bulked continuous (BCF) yarn.
Clearly, the yarns of the sixth and/or seventh aspect may or may not be obtained using the methods, bundle of filaments, and/or systems of the aspects listed above. The yarns of the sixth and/or seventh aspect may further show preferred characteristics equal or similar to those of the yarns produced by such methods and/or systems, without necessarily having been obtained in that manner.
In an eight aspect, a carpet, rug, or carpet tile (collectively referred to herein as “carpet”) is provided comprising pile made with the yarn of the sixth and/or seventh aspect and/or obtained using the methods, bundle of filaments, and/or systems of any of the first through fifth aspects.
Example features and implementations are disclosed in the accompanying drawings. However, the present disclosure is not limited to the precise arrangements shown, and the drawings are not necessarily drawn to scale.
Various implementations include systems and methods for producing a bundle of filaments, yarn made therefrom, and carpets made from the yarn. The system allows for the color effect of or mix of colors within a bundle of filaments to be changed by altering the volumetric flow rate of spin pumps that are in fluid communication and paired with a plurality of extruders that each include a polymer having a different color, hue, luster, and/or dyeability characteristic than the other extruders.
For example, in various implementations, the system includes N extruders, wherein Nis an integer greater than 1, at least one spin station for receiving molten polymer streams from the N extruders, and a processor. Each extruder includes a polymer having a color, hue, luster, and/or dyeability characteristic, and colors, hues, lusters, and/or dyeability characteristics of the polymers in the N extruders are different from each other. Each spin station includes at least one spinneret through which a plurality of melt-spun filaments are spun from at least two of the molten polymer streams received by the spin station and a group of N spin pumps upstream of the spinneret. Each spin pump is in fluid communication and is paired with one of the N extruders. The processor is in electrical communication with the N spin pumps and is configured to execute computer readable instructions that cause the processor to adjust the volumetric flow rate of the polymers pumped by each spin pump to achieve a ratio of the polymers to be included in the filaments spun from the at least one spinneret.
In addition, in some implementations, each spin station also includes at least one manifold (static or dynamic) and at least one mixing plate wherein each mixing plate defines at least one channel. The at least one mixing plate is disposed between the at least one manifold and the at least one spinneret.
For example,
Each extruder 102a, 102b, 102c includes a polymer having a color, hue, luster, and/or dyeability characteristic. The colors, hues, lusters, and/or dyeability characteristics in each extruder 102a, 102b, 102c are different from each other. The manifold 105 of the spin station 106 receives molten polymer streams from the extruders 102a, 102b, 102c. Spin pumps 104a, 104b, 104c pump the molten polymer through the manifold 105, which feeds the molten polymer to the mixing plate 107 and then through the spinneret 108, and the spinneret 108 spins the molten polymer streams into melt-spun filaments 114.
In some implementations, the polymer of one or more of the N extruders may comprise a thermoplastic polymer. Examples of thermoplastic polymers that may be used for the filaments named in any of the first through seventh aspects include polyamides, polyesters, and/or polyolefins.
A polyamide is defined as a synthetic linear polymer whose repeating unit contains amide functional groups, wherein these amide functional groups are integral members of the linear polymer chain.
In some embodiments of any of the aspects described herein, the polyamide may have been formed by condensation polymerization of a dicarboxylic acid and a diamine. Representative examples of such dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-napthalene dicarboxylic acid, 3,4′-diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-naphthalenedicarboxylic acid, phthalic acid, 4,4′-methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediactic acid, fumaric acid, and maleic acid. Representative examples of such diamines include ethylene diamine, tetramethylene diamine, hexamethylene diamine, 1,9-nonanediamine, 2-methyl pentamethylene diamine, trimethyl hexamethylene diamine (TMD), m-xylylene diamine (MXD), and 1,5-pentanediamine.
In some embodiments of any of the aspects described herein, the polyamide may have been formed by condensation polymerization of an amino acid (such as 11-aminoundecanoic acid) or ring-opening polymerization of a lactam (such as caprolactam or ω-aminolauric acid).
Representative examples of polyamides as may be used in the present disclosure include: aliphatic polyamides such as polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide 610, polyamide 612, polyamide 6T, polyamide 6I, polyamide MXD6, polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212, polyamide 12T, polyamide PACM12, polyamide TMDT, polyamide 611, and polyamide 1012; polyphthalimides such as polyamide 6T/66, polyamide LT/DT, and polyamide L6T/6I; and aramid polymers.
In some particular embodiments, the first polymer comprises polyamide 6,6. In other particular embodiments, the first polymer comprises polyamide 6.
In some examples, the polymer may be aromatic or aliphatic polyamide, such as PA6, PA66, PA6T, PA10, PA12, PA56, PA610, PA612, PA510, or any combination thereof. The polyamide can be a homopolymer or a copolymer of amide monomers and/or can be partially recycled or fully based upon recycled polyamide.
A polyester is defined as a synthetic linear polymer whose repeating units contain ester functional groups, wherein these ester functional groups are integral members of the linear polymer chain.
Typical polyesters as used in the present disclosure may be formed by condensation of a dicarboxylic acid and a diol. Representative examples of such dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid, 3,4′-diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-napthalene dicarboxylic acid, phthalic acid, 4,4′-methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediacetic acid, fumaric acid, and maleic acid. Representative examples of such diols include monoethylene glycol, diethylene glycol, triethylene glycol, poly(ethylene ether)glycols, 1,3-propanediol, 1,4-butanediol, poly(butylene ether)glycols, pentamethylene glycol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, 1,14-tetradecanediol, 1,16-hexadecanediol, cis-1,4-cyclohexanedimethanol, and trans-1,4-cyclohexanedimethanol.
Representative examples of polyesters include poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(butylene terephthalate) (PBT), poly(ethylene isophthalate), poly(octamethylene terephthalate), poly(decamethylene terephthalate), poly(pentamethylene isophthalate), poly(butylene isophthalate), poly(hexamethylene isophthalate), poly(hexamethylene adipate), poly(pentamethylene adipate), poly(pentamethylene sebacate), poly(hexamethylene sebacate), poly(1,4-cyclohexylene terephthalate), poly(1,4-cyclohexylene sebacate), poly(ethylene terephthalate-co-sebacate), and poly(ethylene-co-tetramethylene terephthalate).
In some examples, the polyester can be polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT). The PET can be virgin PET or partially or fully based upon recycled PET, such as the PET described in U.S. Pat. No. 8,597,553.
In some examples, the polyolefin can be polyethylene (PE), polypropylene (PP), or an ethylene-propylene copolymer.
In certain implementations, the polymer is PET, PTT, PP, PA6, PA66 or PES.
In some implementations, the N extruders can comprise different thermoplastic polymers, for example, one or more of the N extruders can comprise polyamides, one or more of the N extruders can comprise polyesters, and/or one or more of the N extruders can comprise polyolefins. In other implementations, two or more N extruders can comprise different polyamides, two or more N extruders can comprise different polyesters, and/or two or more N extruders can comprise different polyolefins.
In other implementations according to any of the aspects described herein, the polymer may be a thermoset polymer. For example, a thermoset polymer may include polyurethane, polysiloxane, polyurea, melamine formaldehyde, polyepoxide, polyimide, polyoxybenzylmethylenglycolanhydride, polycyanurate, and urea-formaldehyde.
In some implementations of any of the first through seventh aspects, the bundles are made from the same polymer. However, in other implementations, bundles may be made from different polymers. For example, in certain implementations in which the bundles are made from different polymers, the bundles include filaments comprising a polyamide and filaments comprising a polyester. In further or additional implementations, the bundles include filaments comprising a polyolefin. The resulting bundle exhibits improved flammability performance from the filaments comprising polyester and increased staining performance from the filaments comprising polyamide, according to some implementations.
In some implementations of the systems and method described herein, the system includes a first extruder and a second extruder, wherein the first extruder comprises a first polymer and the second extruder comprises a second polymer that is different from the first polymer. For example, the first polymer includes a polyamide and the second polymer includes a polyester. In further implementations, the system includes a third extruder comprising a third polymer. The third polymer may, for example, comprise a polymer that is the same as or different from one or both of the polymers in the first and second extruders. For example, the second polymer may be deep-dye PET and the third polymer may be regular-dye PET.
In some implementations of the systems and methods described herein, the volumetric flow rate of the N extruders can be varied to vary the amount of each polymer in each bundle. For example, when the systems and method include three extruders, the volumetric flow rate can be adjusted by the processor such that the resulting bundles comprise from 0-100% of the first polymer, from 0-100% of the second polymer, and from 0-100% of the third polymer. For example, the resulting bundles may comprise from 0-60% of the first polymer, from 0-60% of the second polymer, and from 0-60% of the third polymer. In other examples, the resulting bundles may comprise from 0-50% of the first polymer, from 0-50% of the second polymer, and from 0-50% of the third polymer. For example, the filaments comprising the first polymer may be 50% of the filaments in the bundle, the filaments comprising the second polymer may be 25% of the filaments in the bundle, and the filaments comprising the third polymer may be 25% of the filaments in the bundle. In other examples, the filaments in the first, second, and third bundle can respectively, in %, be 10:10:80, 10:20:70, 10:30:60, 10:40:50, 20:10:70, 20:20:60, 20:30:50, 20:40:40, 30:10:60, 30:20:50, 30:30:40, 40:10:50, 40:20:40, 40:30:30, and the like. When the systems and methods include two extruders, the volumetric flow rate can be adjusted by the processor such that the resulting bundles comprise from 0-100% of the first polymer and from 0-100% of the second polymer. For example, the resulting bundle may comprise from 0-75% of the first polymer and from 0-75% of the second polymer. In some implementations, the resulting bundle may comprise 50% of the first polymer and 50% of the second polymer.
According to some implementations, the polymer of the filaments may be solution dyed polymer. In some implementations, the solution dyed polymer filaments are space dyed after processing (also referred to as “over dying”). And, in other implementations, the filaments are not solution dyed and are space dyed or dyed regularly after processing. A solution dyed polymer has a coloring agent added to the polymer prior to filament formation out of the spinneret. A space dyed polymer has a coloring agent that is added to the filament after formation out of the spinneret.
Dyeability characteristic refers to a filament's affinity to absorb a dye under the same processing conditions. For example, non-solution-dyed filaments may appear white after spinning due to the lack of presence of dye molecules, pigments, or other molecules that would provide a different color than the material substrate. When subjected to a dyeing process, for example PET using disperse dyes, a molten stream formed with a deep dye PET would have a darker color saturation than a molten stream produced with a traditional PET.
In some implementations of the systems and method described above, the N extruders comprise a first extruder comprising a first polymer capable of absorbing a first dye and a second extruder comprising a second polymer capable of absorbing a second dye. The first dye and/or second dye may comprise, for example disperse dyes, acid dyes, cationic dyes, azoic dyes, sulfur dyes, and/or mordant dyes. In certain embodiments, the first dye and the second dye are different. In additional implementations, the N extruders comprise a third extruder comprising a third polymer capable of absorbing a third dye. The third dye may be different from one or both of the first and second dye. For example, the third dye may comprise disperse dyes, acid dyes, cationic dyes, azoic dyes, sulfur dyes, and/or mordant dyes.
For example, in some implementations, the first polymer comprises one or more polyamide polymers. A polyamide is defined as a synthetic linear polymer whose repeating unit contains amide functional groups, wherein these amide functional groups are integral members of the linear polymer chain.
In some embodiments of any of the aspects described herein, the polyamide may have been formed by condensation polymerization of a dicarboxylic acid and a diamine. Representative examples of such dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-napthalene dicarboxylic acid, 3,4′-diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-naphthalenedicarboxylic acid, phthalic acid, 4,4′-methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediactic acid, fumaric acid, and maleic acid. Representative examples of such diamines include ethylene diamine, tetramethylene diamine, hexamethylene diamine, 1,9-nonanediamine, 2-methyl pentamethylene diamine, trimethyl hexamethylene diamine (TMD), m-xylylene diamine (MXD), and 1,5-pentanediamine.
In some embodiments of any of the aspects described herein, the polyamide may have been formed by condensation polymerization of an amino acid (such as 11-aminoundecanoic acid) or ring-opening polymerization of a lactam (such as caprolactam or ω-aminolauric acid).
Representative examples of polyamides as may be used in the present disclosure include: aliphatic polyamides such as polyamide 6, polyamide 11, polyamide 12, polyamide 46, polyamide 410, polyamide 4T, polyamide 510, polyamide D6, polyamide DT, polyamide DI, polyamide 66, polyamide 610, polyamide 612, polyamide 6T, polyamide 6I, polyamide MXD6, polyamide 9T, polyamide 1010, polyamide 10T, polyamide 1212, polyamide 12T, polyamide PACM12, polyamide TMDT, polyamide 611, and polyamide 1012; polyphthalimides such as polyamide 6T/66, polyamide LT/DT, and polyamide L6T/6I; and aramid polymers.
In some particular embodiments, the first polymer comprises polyamide 6,6. In other particular embodiments, the first polymer comprises polyamide 6.
In any of the aspects described herein, the polyamide polymer can absorb a first dye. For example, in some embodiments, the first dye comprises one or more acid dyes. Acid dyes are water-soluble anionic dyes that are applied to fibers using neutral to acid dye baths. Attachment to the fiber is attributed, at least partially, to salt formation between anionic groups in the dyes and cationic groups in the fiber. In some embodiments, the acid dye may be chosen from a leveling acid dye, a milling dye, or a metal complex acid dye. In some embodiments, the acid dye is chosen from an anthraquinone type due, an azo dye, or a triarylmethane dye. Representative examples of acid dyes which may be used in the present disclosure include, but are not limited to, Acid Yellow 7, Acid Yellow 17, Acid Yellow 23, Acid Yellow 34, Acid Yellow 36, Acid Yellow 40, Acid Yellow 42, Acid Yellow 49, Acid Yellow 73, Acid Yellow 99, Acid Yellow 127, Acid Yellow 129, Acid Yellow 151 Acid Orange 3, Acid Orange 7, Acid Orange 8, Acid Orange 10, Acid Orange 24, Acid Orange 52, Acid Orange 60, Acid Orange 74, Acid Orange 116, Acid Orange 156, Acid Red 1, Acid Red 4, Acid Red 14, Acid Red 50, Acid Red 52, Acid Red 73, Acid Red 87, Acid Red 88, Acid Red 92, Acid Red 94, Acid Red 99, Acid Red 114, Acid Red 119, Acid Red 131, Acid Red 151, Acid Red 249, Acid Red 266, Acid Red 299, Acid Red 337, Acid Violet 1, Acid Violet 3, Acid Violet 7, Acid Violet 12, Acid Violet 17, Acid Violet 19, Acid Violet 43, Acid Violet 48, Acid Violet 49, Acid Violet 90, Acid Green 1, Acid Green 3, Acid Green 9, Acid Green 16, Acid Green 20, Acid Green 25, Acid Green 92, Acid Brown 14, Acid Brown 44, Acid Brown 97, Acid Brown 98, Acid Blue 1, Acid Blue 7, Acid Blue 9, Acid Blue 15, Acid Blue 25, Acid Blue 40, Acid Blue 45, Acid Blue 62, Acid Blue 80, Acid Blue 83, Acid Blue 90, Acid Blue 92, Acid Blue 113, Acid Blue 145, Acid Blue 158, Acid Blue 185, Acid Black 1, Acid Black 2, Acid Black 24, Acid Black 52, Acid Black 58, Acid Black 60, Acid Black 62, Acid Black 107, Acid Black 131, Acid Black 132, Acid Black 172, and Acid Black 194.
In addition, the second polymer comprises one or more polyester polymers. A polyester is defined as a synthetic linear polymer whose repeating units contain ester functional groups, wherein these ester functional groups are integral members of the linear polymer chain.
Typical polyesters as used in the present disclosure may be formed by condensation of a dicarboxylic acid and a diol. Representative examples of such dicarboxylic acids include terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid, 3,4′-diphenylether dicarboxylic acid, hexahydrophthalic acid, 2,7-napthalene dicarboxylic acid, phthalic acid, 4,4′-methylenebis(benzoic acid), oxalic acid, malonic acid, succinic acid, methyl succinic acid, glutaric acid, adipic acid, 3-methyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,11-undecanedicarboxylic acid, 1,10-dodecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, hexadecanedioic acid, docosanedioic acid, tetracosanedioic acid, 1,4-cyclohexanedicarboxylic acid, 1,3-cyclohexanedicarboxylic acid, 1,2-cyclohexanediacetic acid, fumaric acid, and maleic acid. Representative examples of such diols include monoethylene glycol, diethylene glycol, triethylene glycol, poly(ethylene ether)glycols, 1,3-propanediol, 1,4-butanediol, poly(butylene ether)glycols, pentamethylene glycol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, 1,14-tetradecanediol, 1,16-hexadecanediol, cis-1,4-cyclohexanedimethanol, and trans-1,4-cyclohexanedimethanol.
Representative examples of polyesters include poly(ethylene terephthalate) (PET), poly(trimethylene terephthalate) (PTT), poly(butylene terephthalate) (PBT), poly(ethylene isophthalate), poly(octamethylene terephthalate), poly(decamethylene terephthalate), poly(pentamethylene isophthalate), poly(butylene isophthalate), poly(hexamethylene isophthalate), poly(hexamethylene adipate), poly(pentamethylene adipate), poly(pentamethylene sebacate), poly(hexamethylene sebacate), poly(1,4-cyclohexylene terephthalate), poly(1,4-cyclohexylene sebacate), poly(ethylene terephthalate-co-sebacate), and poly(ethylene-co-tetramethylene terephthalate).
In particular embodiments, the second polymer comprises polyethylene terephthalate.
In any of the aspects described herein, the second, polyester polymers can absorb a second dye. In some embodiments, the second polymers cannot absorb the first dye. In some embodiments of any of the aspects described herein, the second dye comprises one or more disperse dyes. Disperse dyes have low solubility in water, typically less than 1 mg/L, and are applied to the fibers as an extremely fine suspension. Upon attachment, the particles dissolve, and owing to their low molecular weight, migrate throughout. Disperse dyes are typically azo dyes or anthroquinone dyes. Representative examples of disperse dyes which may be used in the present disclosure include, but are not limited to, Disperse Yellow 1, Disperse Yellow 3, Disperse Yellow 5, Disperse Yellow 23, Disperse Yellow 42, Disperse Yellow 49, Disperse Yellow 54, Disperse Yellow 64, Disperse Yellow 82, Disperse Yellow 86, Disperse Yellow 163, Disperse Yellow 184, Disperse Yellow 211, Disperse Yellow 218, Disperse Yellow 224, Disperse Orange 3, Disperse Orange 25, Disperse Orange 29, Disperse Orange 30, Disperse Orange 37, Disperse Orange 41, Disperse Orange 44, Disperse Orange 73, Disperse Orange 76, Disperse Red 1, Disperse Red 4, Disperse Red 5, Disperse Red 15, Disperse Red 17, Disperse Red 50, Disperse Red 54, Disperse Red 55, Disperse Red 60, Disperse Red 65, Disperse Red 73, Disperse Red 82, Disperse Red 86, Disperse Red 91, Disperse Red 135, Disperse Red 153, Disperse Red 167, Disperse Red 177, Disperse Red 179, Disperse Red 184, Disperse Red 319, Disperse Red 338, Disperse Red 359, Disperse Violet 1, Disperse Violet 4, Disperse Violet 26, Disperse Violet 28, Disperse Violet 31, Disperse Violet 48, Disperse Violet 91, Disperse Green 9, Disperse Brown 1, Disperse Blue 3, Disperse Blue 7, Disperse Blue 26, Disperse Blue 27, Disperse Blue 35, Disperse Blue 55, Disperse Blue 56, Disperse Blue 60, Disperse Blue 64, Disperse Blue 73, Disperse Blue 79, Disperse Blue 87, Disperse Blue 102, Disperse Blue 165, Disperse Blue 183, Disperse Blue 281, Disperse Blue 291, and Disperse Black 9.
In certain implementations, for example, the first polymer comprises a polyamide, the second polymer comprises a PTT, and the third polymer comprises a PTT. The polyamide polymer absorbs an acid dye but the PTT does not, which leaves the PTT undyed in response to an acid dye being applied to the bundle of filaments comprising the polyamide and PTT polymers. As another example, a disperse dye may be applied to a bundle of filaments comprising the polyamide and PTT polymers, which is absorbed by both polymers but at different levels, providing tonal or chromatic differences. An acid dye may also be applied to this bundle of filaments, which would be absorbed by only the polyamide filaments and could lead to further tonal or chromatic differences.
In some implementations of the systems and methods described above, the dye level of the first, second, and/or third polymer may be different from each other. For example, the first polymer may have an affinity for dyes having a bright deep shade, the second polymer may have an affinity for dyes having a light dye shade, and the third polymer may have an affinity for cationic dyes. Accordingly, bundles may be produced containing tonal and chromatic differences.
Luster refers to the amount of refracted light from a material's surface. In certain implementations, each of the N extruders may comprise a polymer having a luster that is clear, bright, dull, semi-dull, extra dull, or super dull. For example, in some implementations, the N extruders may comprise a first extruder comprising a first polymer having a first luster type and a second extruder comprising a second polymer having a second luster type. The first luster type and the second luster type may be the same or may be different. For example, the first luster type may be clear, bright, dull, semi-dull, extra dull, or super dull, and the second luster type may be clear, bright, dull, semi-dull, extra dull, or super dull, wherein the first luster type and second luster type are different. In some implementations, a third extruder comprising a third polymer having a third luster type may be included. In certain implementations, the third luster type is different than the first luster type and the second luster type. In this regard, the system may produce a bundle of filaments exhibiting a luster effect that is varied along the length of the bundle of filaments and/or within a radial cross section of the bundle of filaments.
In some implementations, the luster of a polymer may be modified by the addition of a delustering agent. A delustering agent is an additive configured to change the refractivity index of a polymer. Some examples of delustering agents include titanium oxide, kaolin, talc, calcium carbonate, silica, zinc sulfide, and zinc white. In one implementation, the delustering agent comprises titanium oxide.
In one implementation, the first luster type may be full dull, the second luster type may be semi dull, and the third luster type may be full bright. Accordingly, the resulting bundle of filaments will contain a unique color perception compared to a bundle of filaments containing a single luster type. Various combinations of the first, second, and optionally third luster types are included in the present disclosure.
In some implementations, a combination of the above techniques may be used to achieve a desired result. For example, various dye levels and lusters of each of the polymers in the N extruders may be included to produce a bundle of filaments exhibiting a color, hue, luster, and/or dyeability characteristic effect that is varied along the length of the bundle of filaments and/or within a radial cross section of the bundle of filaments. Other combinations can be used according to the desired result.
The processor 110 is configured to execute computer readable instructions that cause the processor 110 to adjust the volumetric flow rate of the polymer pumped by each spin pump 104a-c to achieve a ratio of the polymers to be included in the filaments 114 spun from the spinneret 108. Adjusting the volumetric flow rate of the polymer extruded from each of the extruders 102a, 102b, 102c adjusts the ratio of the polymers in the filaments 114, which changes the overall color, hue, luster, and/or dyeability characteristic of the bundle of filaments 114 spun through the spinneret 108. The ratio of the polymers to be included in the filaments 114 refers to the ratio of colors, hues, lusters, and/or dyeability characteristics from each extruder that are included in the bundle of the filaments 114. The colors, hues, lusters, and/or dyeability characteristics of the spun filaments 114 may include filaments having the color, hue, luster, and/or dyeability characteristic of the polymer in the first extruder 102a, filaments having the color, hue, luster, and/or dyeability characteristic of the polymer in the second extruder 102b, filaments having the color, hue, luster, and/or dyeability characteristic of the polymer in the third extruder 102c, and/or filaments having a color, hue, luster, and/or dyeability characteristic that is a mixture of the colors, hues, lusters, and/or dyeability characteristics from the extruders 102a, 102b, 102c. For example, the filaments 114 may include a first group of filaments that have the color, hue, luster, and/or dyeability characteristic of the polymer from the first extruder 102a, a second group of filaments that have the color, hue, luster, and/or dyeability characteristic of the polymer from the second extruder 102b, a third group of filaments that have the color, hue, luster, and/or dyeability characteristic of the polymer from the third extruder 102c, and/or a fourth group of filaments that have a color, hue, luster, and/or dyeability characteristic that is a mixture of the colors, hues, lusters, and/or dyeability characteristics from the extruders 102a, 102b, and/or 102c. For example, at least a portion of the filaments in the fourth group may have a color, hue, luster, and/or dyeability characteristic that is a mixture of two or more colors, hues, lusters, and/or dyeability characteristics of the streams. In addition or in the alternative, at least a portion of the filaments in the fourth group may have different colors, hues, lusters, and/or dyeability characteristics along different portions of a length of the filament and/or within a radial cross section of at least one filament within each of the portions along the length of the filament. For example, a first portion of a length of a filament may have a first color and a second portion of the length of the filament may have a second color. As another example, a portion of the length of the filament may have a color that is a mixture of two or more colors. And, as another example, a radial cross section of a filament through one portion of the length of the filament may have two or more different colors than the radial cross section of the filament at another portion of the length of the filament. When brought together into one yarn, the groups of filaments provide a blended color appearance.
This system 100 allows for filaments to be made having more colors, hues, lusters, and/or dyeability characteristics than the number of extruders providing each color, hue, luster, and/or dyeability characteristic. For example, if the extruders 102a-102c each have polymers solution dyed red, blue, and yellow, various ratios of these polymers yield filaments having these colors and combinations thereof, such as purple, orange, and green.
For example, in some implementations, the speed of each spin pump 104a-104c is at least 2 RPM. And, in certain implementations, a maximum speed of each spin pump 104a-104c is 30 RPM. However, in other implementations, the maximum speed of each spin pump may be higher. If other process controls are the same, increasing the RPM of the spin pump 104a-104c increases the linear density, or titer (e.g., also referred to as “denier per filament”, “denier per fiber” or “DPF”)) per filament.
In addition, the average denier of each bundle of filaments can be increased or decreased by changing the speed of the pumps. In some implementations, once selected, the average denier of the bundle of filaments spun through the spinneret 108 of the spin station 106 is constant or does not vary more than ±5%, according to some implementations. By increasing the average denier of a bundle, the color from that bundle is visibly more prevalent in the yarn. For example, the speed of the pump providing at least one of the molten polymer streams to the spin station may be increased while the speed of the pumps providing the other molten polymer streams to the spin station may be kept the same or decreased, resulting in the yarn having more of the color of the stream being pumped at a higher speed than the other streams. Increasing and decreasing the speed of at least one or more pumps can also be varied according to a certain frequency and amplitude, in some implementations, creating portions of a length of the bundle that have a different color(s), hue(s), and/or dyeability characteristic(s) than other portions of the length.
In some implementations, the instructions also cause the processor 110 to adjust the timing of the volumetric flow rate changes and hence adjust the corresponding denier and/or color changes in the yarn. For example, the following description is for a sequence of steps performed by the processor 110. At step 1, the instructions cause the spin pump 104a to be at a higher speed (for example, 50% of maximum speed) and the spin pump 104b and 104c to be at a lower speed (for example, each at 25% of maximum speed) for an initial ×1 seconds (for example, ×1 is 1 sec, 2 secs, 3 secs, 4, secs, 5 secs, 6 secs, 7 secs, 8 secs, and so on). The amount of time that a specific combination of spin pump speeds is held determines the length of the particular color pattern produced by the combination of the spin pump speeds in the yarn. After the initial ×1 seconds, at step 2, the instructions cause the processor 110 to change the speeds of the pumps such that the spin pumps 104a and 104b are at a lower speed (for example 25% of maximum speed) and the spin pump 104c is at a higher speed (for example 50% of maximum speed) for ×2 seconds. In some embodiments, ×1=×2, and in other embodiments, ×1 is different from ×2. At step 3, after the ×2 seconds elapses, the instructions cause the processor 110 to change the speeds of the pumps such that the spin pumps 104a and 104c are at a lower speed (for example at 25% of maximum speed) and spin pump 104b is at a higher speed (for example at 50% of maximum speed) for ×3 seconds. Again, ×3 can be equal to ×1 and/or ×2. In other embodiments, ×3 can be different from ×1 and/or ×2. After ×3 seconds, at step 4, the instructions cause the processor 110 to change the speeds of the pumps such that the spin pumps 104a, 104b, 104c are at the same speed (for example, each at 33.33% of the maximum speed). The above sequence or a variation thereof is repeated to produce the desired color variation in the yarn.
In another example implementation, the instructions cause the processor 110 to randomize the above steps to produce random color variation in the yarn. For example, an internal clock associated with the processor 110 selects an overall timer with a first random number greater than 0 and to and including y secs (for example, y can be 5 secs, 6 secs, 7 secs, 7.5 secs, 8 secs, 9 secs, 10 secs, and so on). Then the instructions cause the processor 110 to select a second set of random numbers for each of ×1, ×2, ×3, and ×4 in step 1-4 above (for example, ×1=2 secs, ×2=3 secs, ×3=1 sec, ×4=2 sec). As the instructions cause the processor to execute steps 1-4, the overall timer based on the first random number (for example, y=7.5 secs) decides when the process is reset. In the above example, when the time associated with the overall timer elapses, the instructions cause the processor 110 to terminate step 4 at ×4=1.5 secs and restart the process steps from step 1 to step 4. In other embodiments, the steps 1-4 described above can be executed by the processor 110 in any order. The processor can also randomize the sequence of steps 1-4. In other embodiments, the speed of the pumps 104a, 104b, 104c for each of the above steps is randomized. For example, at step 1, the instructions cause the processor 110 to change the speed of the pumps such that pumps 104a and 104b are at a random lower speed (for example, at 20% of maximum speed and 28% maximum speed respectively) and spin pump 104c is at a higher speed (for example, at 52% of maximum speed).
In some implementations, the instructions also cause the processor 110 to determine the volumetric flow rate of each polymer to be pumped by each spin pump 104a, 104b, 104c to achieve the desired ratio and generate the instructions to the spin pumps 104a, 104b, 104c based on the volumetric flow rate determinations. However, in other implementations, the volumetric flow rate for each spin pump 104a, 104b, 104c may be determined by another processor or otherwise input into the system 100. In addition, in other implementations, the instructions to the spin pumps 104a, 104b, 104c may be generated by another processor or otherwise input into the system 100.
In some implementations, the computer readable instructions are stored on a computer memory that is in electrical communication with the processor 110 and disposed near the processor (e.g., on the same circuit board and/or in the same housing). And, in other implementations, the computer readable instructions are stored on a computer memory that is in electrical communication with the processor but is remotely located from the processor. In some instances, the processor 110 and memory form a computer device such as that shown in
The radial cross-sectional shape of each filament in any of the first through seventh aspects may be the same as the other filaments or different, e.g. depending on the shapes of the openings defined by the spinneret through which each filament is spun. For example, the filaments may have radial cross sections that are circular, oval, trilobal, fox, or other suitable shape. In addition, the filaments may be solid or define at least one hollow void. Similarly, the size of the spinneret openings may be the same or different, depending on the desired denier per filament for each filament.
In some implementations, the volumetric flow rate being extruded by one of the pumps may be reduced by 90% relative to a baseline volumetric flow rate, which is the total volumetric flow rate being extruded divided by the number of pumps for each spin station. And, in some implementations, the volumetric flow rate may be reduced to zero, assuming that the polymer would not overheat in the spinning station.
The manifold 105 in
Valves 221, 222 are disposed within channels 816 and 817, respectively. Valves 221, 222 are selectively opened and closed to regulate the flow of the polymer stream from pump 802 to the outlets 822, 824. As shown in
As shown in
As shown in
As shown in
Although
In other implementations, other inlets in the dynamic manifold may have more than one channel between the inlet and multiple outlets and valves within the channels to control the volumetric flow rate of polymer flowing to each spinneret. And, in other implementations, inlets that are in communication with more than one channel may include one valve within the inlet that controls the flow of the polymer stream to the channels that are in fluid communication with the respective inlet.
In addition, the system 100 may be run at a speed of at least 2600 meters per minute, which is faster than prior art systems, since the denier per filament is not changed during a color change. The speed may be increased or decreased based on the desired appearance. And depending on the operating parameters of the system, a change in speed may not affect the appearance of the yarn.
Filaments produced using the system 100 have better wear properties because the color, luster, and/or dye extends through the full mass of the filament. Having the color, luster, and/or dye extend through the entire filament also improves the appearance of cut pile in carpets. In addition, the system 100 is faster and less expensive than prior art systems because the average denier per filament and/or the average denier per bundle can be kept substantially constant and the pumps 104a-104c do not have to stop to allow for changes in the color of the yarn produced. This system 100 also produces less waste by avoiding the need to stop and start at each color change.
Various implementations also include a yarn that includes a plurality of filaments. Each filament has a color, hue, luster, and/or dyeability characteristic from an external surface to a center thereof, and for at least a subset of the plurality of filaments, the color, hue, luster, and/or dyeability characteristic of each filament within the subset varies along a length of the filament. For example, in some implementations, the plurality of filaments has at least a first set of filaments and a second set of filaments, wherein the first set of filaments has a first color, hue, luster, and/or dyeability characteristic at a radial cross section of the plurality of filaments and the second set of filaments has a second color, hue, luster, and/or dyeability characteristic at the radial cross section, and the first color, hue, luster, and/or dyeability characteristic is different than the second color, hue, luster, and/or dyeability characteristic. In some implementations, the yarn is bulked continuous filament (BCF) yarn. The yarn is made according to any of the processes described above and/or by any of the systems described above. In addition, some implementations include a carpet that includes pile made with this yarn.
Various implementations also include a yarn that includes a plurality of filaments that have at least a first set of filaments and a second set of filaments. The first set of filaments has a first color, hue, luster, and/or dyeability characteristic at a radial cross section of the plurality of filaments, and the second set of filaments has a second color, hue, luster, and/or dyeability characteristic at the radial cross section, and the first color, hue, luster, and/or dyeability characteristic is different than the second color, hue, luster, and/or dyeability characteristic. In some implementations, the yarn is bulked continuous filament (BCF) yarn. The yarn may be made according to any of the processes described above and/or by any of the systems described above. In addition, some implementations include a carpet that includes pile made with this yarn.
In addition, in some implementations, carpet having changing colors, such as the carpet described above, can be made from one continuous BCF yarn, instead of having to stop the process to switch out yarn having a different color.
The yarn may be a bulked continuous filament (BCF) yarn that may be (1) extruded and drawn in a continuous operation, (2) extruded, drawn, and textured in a continuous operation, (3) extruded and taken up in one step and is then later unwound, drawn, and textured in another step, or (4) extruded, drawn, and textured in one or more operations.
Furthermore, in some implementations, the BCF yarn could be used as yarn in carpet or in apparel, for example.
Although the system shown in
According to some implementations, at least two ratios of the M ratios are different. In other implementations, all of the M ratios are different.
For example, the system 200 in
In some implementations, there is a desire to maintain a constant throughput, or total volumetric flow rate, for each extruder. The total volumetric flow rate extruded from each extruder 202a-202c is the sum of the volumetric flow rates pumped by the spin pumps 204a1-204c2 that are paired with the respective extruder 202a-202c. For example, the total volumetric flow rate extruded from extruder 202a is the sum of the volumetric flow rates pumped by spin pumps 204al and 204a2. Similarly, the total volumetric flow rate extruded from the extruder 202b is the sum of the volumetric flow rates pumped by spin pumps 204b1 and 204b2. And, the total volumetric flow rate extruded from extruder 202c is the sum of the volumetric flow rates pumped by spin pumps 204cl and 204c2. However, in other implementations, the volumetric flow rate of each pump that is paired with a particular extruder is not limited relative to the volumetric flow rate of the other pumps paired with that particular extruder.
The processor 210 is configured to execute computer readable instructions that cause the processor 210 to (1) adjust the volumetric flow rate of the polymers pumped from each spin pump 204a1-204cl of the first group of spin pumps to achieve a first ratio of polymers to be included in the first bundle of filaments 214a spun from the first spinneret 208a of the first spin station 206a and (2) adjust the volumetric flow rate of the polymers pumped from each spin pump 204a2-204c2 of the second group of spin pumps to achieve a second ratio of the polymers to be included in the second bundle filaments 214b spun from the second spinneret 208b of the second spin station 206b. In some instances, the processor 210 and memory form a computer device such as that shown in
In some implementations, the ratio to be included in each of the bundles of filaments 214a, 214b are different.
The colors, hues, lusters, and/or dyeability characteristics of the bundle of filaments 214a, 214b may include filaments having the color, hue, luster, and/or dyeability characteristic of the polymer in the first extruder 202a, filaments having the color, hue, luster, and/or dyeability characteristic of the polymer in the second extruder 202b, filaments having the color, hue, luster, and/or dyeability characteristic of the polymer in the third extruder 202c, and/or filaments having a color, hue, luster, and/or dyeability characteristic that is a mixture of the colors, hues, lusters, and/or dyeability characteristics from the extruders 202a-202c.
The average denier of the bundle of filaments spun through each spinneret 208a, 208b is constant or does not vary more than ±5%. However, the average denier per filament of the filaments spun through the first spinneret 208a of the first spin station 206a may be different from the average denier per filament of the filaments spun through the second spinneret 208b of the second spin stations 206b.
In some implementations in which the system has at least three extruders, the polymer streams from at least two of the extruders are spun together but separately from the polymer stream from at least one other extruder. For example,
According to some implementations, if the polymer from one extruder is not being mixed with a polymer from another extruder prior to spinning, such as the stream extruded from extruder 302c in
In addition, the average denier of the yarn that is made with the bundles 314a, 314b can be kept substantially constant (e.g., ±5% variation) if the sum of volumetric flow rate of the pumps 304a and 304b remains substantially constant and if the volumetric flow rate of pump 304c remains substantially constant. However, changing the sum of the volumetric flow rate of pumps 304a and 304b or changing the volumetric flow rate displaced by pump 304c may change the average denier of the yarn.
The bundles 314a, 314b produced by system 300 in
As shown in
The tacking devices 315, 325 are air entanglers that use room temperature air for entangling the filaments. In other embodiments, the tacking devices include heated air entanglers (e.g., air temperature is higher than room temperature) or steam entanglers, for example.
The bundles of tacked filaments 316, 326 are drawn to the final titer by drawing device 360, which is a plurality of godets. The godets are each turned at a different speed, according to some embodiments. The draw ratio is typically 1.5 to 4.5. Each filament is drawn to a titer of 2 to 40 titer (or DPF). Two bundles of elongated spun filaments 317, 327 are provided after drawing.
When looking along the axial length of the yarn 391, the position of the filaments originating from bundles 314a, 314b are more pronounced in the yarn 391 than if the bundles of filaments 314a 314b had not been individually tacked with tacking devices 315, 325.
In alternative embodiments (not shown in
And, in yet another embodiment (not shown in
Next, to further enhance the color of each bundle within the yarn, each bundle of tacked and drawn filaments 317, 327 are texturized separately through texturizers 371, 372, respectively. Following this step, bundles 318, 328 of texturized filaments are provided.
The texturizers 371, 372 may apply air, steam, heat, mechanical force, or a combination of one of more of the above to the filaments to cause the filaments to bulk (or crimp/shrink). The bundles 317, 327 are texturized to have a bulk (or crimp or shrinkage) of 5-20%. Texturizing individual bundles of filaments separately, when using bundles with different colors, hues, lusters, and/or dyeability characteristics, provides a more pronounced color, hue, luster, and/or dyeability characteristic along the axial length of the BCF yarn. The filaments that are texturized separately tend to stay more grouped together during the rest of the production steps to make the BCF yarn, which results in the color, hue, luster, and/or dyeability characteristic of this bundle of spun filaments being more pronounced along the length of the BCF yarn.
Next, the texturized filaments 318, 328 are provided to an individual color entanglement process prior to the final tacking at tacking device 380. In this individual color entanglement process, the bundles 318, 328 of texturized filaments are fed into separate tacking devices 319, 329 to tack individually each bundle of texturized spun filaments.
Tacking devices 319, 329 are air entanglers that use room temperature air applied at 2 bar to 6 bar pressure, for example, for entangling the filaments every 15 to 155 mm. But the pressure may increase with an increased number of filaments, increased denier per filament, and/or increased speed of filament production. And, in other embodiments, the tacking devices 319, 329 include heated air entanglers (e.g., air temperature is higher than room temperature) or steam entanglers, for example. The tacking may be done more frequently for a specific look desired. For example, with more frequent tacking, the yarn looks less bulky and the color separation is reduced, which results in a more blended look for the colors.
After being individually tacked with tacking devices 319, 329, the bundles 320, 321 are guided to a mixing cam 400. The mixing cam 400 positions bundles tacked by tacking devices 319, 329 relative to each other prior to being tacked together in final tacking device 380. The mixing cam 400 is cylindrical and has an external surface defining a plurality of grooves for receiving and guiding the texturized and tacked bundles.
The mixing cam 400 is rotatable about its central axis or can be held stationary. If rotated, the mixing cam 400 varies which side of the bundles are presented to the tacking jet in the tacking device 380, which affects how the bundles (and filaments therein) are layered relative to each other. In some embodiments, the positions are randomly varied. The speed of rotation can be changed to provide a different appearance in the yarn 391. For example, one or more of the bundles 320, 321 may have a first color on one side of the bundle 320, 321 and a second color on another side of the bundle 320, 321, wherein the sides of the bundle are circumferentially spaced apart but intersected by the same radial plane. It may be desired to have the first color on an exterior facing surface of an arc in a carpet loop in one area of the carpet and the second color on an exterior facing surface of an arc in a carpet loop in another area of the carpet. Rotating the cam 400 may “flip” one or more of the bundles 320, 321 about its axis such that the desired color is oriented on a portion of the outer surface of the yarn 391 such that the desired color is on the exterior facing surface of the arc in the carpet loop. The undesired color for that portion of the carpet is hidden on the inside facing surface of the loop. Rotation of the cam 400 ensures that the filaments that run on the outside of the loop are changing due to a specific mechanical means and not necessarily natural occurrences in downstream processes.
When stationary, the positions of the bundles 320, 321 are directed by the mixing cam 400 to the final tacking device 380 but their relative positions are not varied. In alternative embodiments, the bundles 320, 321 are fed to the tacking device 380 directly or they are fed via a stationary guide disposed between the intermediate tacking devices 319, 329 and the tacking device 380.
The tacked texturized bundles 320, 321 positioned by mixing cam 400 are thereafter tacked together by tacking device 380 into a BCF yarn 391. This tacking is done with air entangling every 12 to 80 mm.
Tacking device 380 is an air entangler that uses room temperature air applied at 2 bar to 6 bar pressure, for example, for entangling the filaments. But the pressure may increase with an increased number of filaments, increased denier per filament, and/or increased speed of filament production. And, in other embodiments, the tacking device 380 includes heated air entanglers (e.g., air temperature is higher than room temperature) or steam entanglers, for example. The bundles 320, 321 are tacked and as such provide a BCF yarn 391 comprising an average of 24-360 filaments of 2 to 40 DPF each. The tacking may be done more frequently for a specific look desired. For example, with more frequent tacking, the yarn looks less bulky and the color separation is reduced, which results in a more blended look for the colors.
The effect of this individual tacking and guidance via a mixing cam cause the colors and/or hues in the yarn to be more structured and positioned. When such yarn is used as for example, a tufting yarn in a tufted carpet, the positioning of the colored bundles in the yarn cause bundles to be more pronounced in the final carpet surface. The positioning of the color, hue, luster, and/or dyeability characteristic in the BCF yarn has as effect that this color, hue, luster, and/or dyeability characteristic can be locally more present on the top side of the tuft oriented upwards, away from the backing of the carpet, or hidden at the low side of the tuft oriented towards the backing of the carpet. The effect is the provision of very vivid and pronounced color zones on the carpet.
In the implementations of
Like
In some embodiments of any of the first through seventh aspects, the DPF of the filaments in each of the bundles are equal. However, in other embodiments, at least some of the filaments in one bundle may have a different DPF than the other filaments in the bundle. Or, in some embodiments, the filaments in one bundle may have the same DPF as other filaments in the bundle but the DPF of those filaments may be different from the DPF of the filaments in another bundle. And, in some embodiments, the number of filaments in the bundles are equal. And, in other embodiments, the number of filaments in each bundle may differ.
It is remarked that where notice is made of different or varying colors or hue, at least a color or hue difference as expressed with a Delta E value of 1.0 is preferred. Even better the difference or variation at least encompasses a color or hue difference as expressed by Delta E of at least 5.0 or at least 10.0. Delta E is a measure of change in visual perception of two given colors.
Processor 1021 may include one or more processors, each configured to execute instructions and process data to perform one or more functions associated with a computer for producing at least one bundle of filaments and/or at least one yarn. Processor 1021 may be communicatively coupled to RAM 1022, ROM 1023, storage 1024, database 1025, I/O devices 1026, and interface 1027. Processor 1021 may be configured to execute sequences of computer program instructions to perform various processes. The computer program instructions may be loaded into RAM 1022 for execution by processor 1021.
RAM 1022 and ROM 1023 may each include one or more devices for storing information associated with operation of processor 1021. For example, ROM 1023 may include a memory device configured to access and store information associated with the computer, including information for identifying, initializing, and monitoring the operation of one or more components and subsystems. RAM 1022 may include a memory device for storing data associated with one or more operations of processor 1021. For example, ROM 1023 may load instructions into RAM 1022 for execution by processor 1021.
Storage 1024 may include any type of mass storage device configured to store information that processor 1021 may need to perform processes consistent with the disclosed embodiments. For example, storage 1024 may include one or more magnetic and/or optical disk devices, such as hard drives, CD-ROMs, DVD-ROMs, or any other type of mass media device.
Database 1025 may include one or more software and/or hardware components that cooperate to store, organize, sort, filter, and/or arrange data used by the computer and/or processor 1021. For example, database 1025 may store computer readable instructions that cause the processor 1021 to adjust the volumetric flow rate of the polymers pumped by each spin pump to achieve a ratio of the polymers to be included in the filaments spun from the at least one spinneret. It is contemplated that database 1025 may store additional and/or different information than that listed above.
I/O devices 1026 may include one or more components configured to communicate information with a user associated with computer. For example, I/O devices may include a console with an integrated keyboard and mouse to allow a user to maintain a database of digital images, results of the analysis of the digital images, metrics, and the like. I/O devices 1026 may also include a display including a graphical user interface (GUI) for outputting information on a monitor. I/O devices 1026 may also include peripheral devices such as, for example, a printer for printing information associated with the computer, a user-accessible disk drive (e.g., a USB port, a floppy, CD-ROM, or DVD-ROM drive, etc.) to allow a user to input data stored on a portable media device, a microphone, a speaker system, or any other suitable type of interface device.
Interface 1027 may include one or more components configured to transmit and receive data via a communication network, such as the Internet, a local area network, a workstation peer-to-peer network, a direct link network, a wireless network, or any other suitable communication platform. For example, interface 1027 may include one or more modulators, demodulators, multiplexers, demultiplexers, network communication devices, wireless devices, antennas, modems, and any other type of device configured to enable data communication via a communication network.
Various implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the description. Accordingly, other implementations are within the scope of the following claims.
Disclosed are materials, systems, devices, methods, compositions, and components that can be used for, can be used in conjunction with, can be used in preparation for, or are products of the disclosed methods, systems, and devices. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutations of these components may not be explicitly disclosed, each is specifically contemplated and described herein. For example, if a device is disclosed and discussed every combination and permutation of the device, and the modifications that are possible are specifically contemplated unless specifically indicated to the contrary. Likewise, any subset or combination of these is also specifically contemplated and disclosed. This concept applies to all aspects of this disclosure including, but not limited to, steps in methods using the disclosed systems or devices. Thus, if there are a variety of additional steps that can be performed, it is understood that each of these additional steps can be performed with any specific method steps or combination of method steps of the disclosed methods, and that each such combination or subset of combinations is specifically contemplated and should be considered disclosed.
The terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2022/061694 | 12/2/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63361389 | Dec 2021 | US |
