Processes to dye and treat bcf yarn

Abstract

Disclosed are processes for applying dyes, stain blocker and anti-soil compositions on BCF yarns during cable or air twisting processes, or heat setting processes, prior to weaving, knitting or tufting. Further discloses are process for applying dyes, stain blocker and anti-soil compositions on BCF yarns prior to heat setting. The processes forego the need to dye and otherwise treat carpets and other textiles made from the BCF yarn using current methods. Also disclosed are systems, BCF yarns, and carpets made from the BCF yarn treated by the disclosed process.

1 . A process for treating twisted BCF yarn with a dye composition comprising:
 a. providing twisted BCF yarn;   b. winding said BCF yarn on a take-up reel; and   c. contacting said BCF yarn with said dye composition while said BCF yarn is in motion and prior to said BCF yarn contacting and winding up on said take-up reel.   
     
     
         2 . The process of  claim 1 , further comprising heat setting said BCF yarn after contacting said BCF yarn with said dye composition. 
     
     
         3 . The process of  claim 1 , wherein said dye composition comprises one or more acid dye components. 
     
     
         4 . The process of  claim 1 , wherein said dye composition comprises one or more disperse dye components. 
     
     
         5 . The process of  claim 1 , wherein said dye composition comprises at least one performance enhancing composition. 
     
     
         6 . A process for treating twisted BCF yarn with a dye composition and at least one performance enhancing composition comprising:
 a. providing twisted BCF yarn;   b. winding said BCF yarn on a take-up reel;   c. contacting said BCF yarn with said dye composition; and   d. contacting said BCF yarn with a first performance enhancing composition prior to said BCF yarn contacting and winding up on said take-up reel, wherein said BCF yarn is in motion while contacted with said dye composition and said first performance enhancing composition.   
     
     
         7 . The process of  claim 6 , wherein said first performance enhancing composition comprises an anti-soil component. 
     
     
         8 . The process of  claim 6 , wherein said first performance enhancing composition comprises an anti-stain component. 
     
     
         9 . The process of  claim 6 , wherein said first performance enhancing composition comprises both an anti-stain component and an anti-soil component. 
     
     
         10 . The process of  claim 6  further comprising contacting said BCF yarn with a second performance enhancing composition after contacting with said first performance enhancing composition and prior to said BCF yarn contacting and winding up on said take-up reel. 
     
     
         11 . The process of  claim 10 , wherein said first performance enhancing composition comprises an anti-stain component and said second performance enhancing composition comprises an anti-soil component. 
     
     
         12 . The process of  claim 6  further comprising heat setting said BCF yarn after contacting said BCF yarn with said first performance enhancing composition. 
     
     
         13 . The process of  claim 10  further comprising heat setting said BCF yarn after contacting said BCF yarn with said second performance enhancing composition. 
     
     
         14 . The process of  claim 8 , wherein said anti-stain component is one or more selected from the group consisting of: syntans, sulfonated novolacs, sulfonated aromatic aldehyde condensation products (SACs) and/or reaction products of formaldehyde, phenolics, substituted phenolics, thiophenolics, sulfones, substituted sulfones, polymers or copolymers of olefins, branched olefins, cyclic olefins, sulfonated olefins, acrylates, methacrylates, maleic anyhydride, and organosulfonic acids. 
     
     
         15 . The process of  claim 7 , wherein said anti-soil component is selected from the group consisting of fluorochemicals, silicones, silsesquioxanes, silane-modified particulates, organosilane-modified particulates, alkylated particulates, anionic non-fluorinated surfactants, and anionic hydrotrope non-fluorinated surfactants. 
     
     
         16 . The process of  claim 15 , wherein said fluorochemical is selected from the group consisting of: fluorochemical allophanates, fluorochemical polyacrylates, fluorochemical urethanes, fluorochemical carbodiimides, fluorochemical guanidines, and fluorochemicals incorporating C2 to C8 chemistries. 
     
     
         17 . The process of  claim 15 , wherein said fluorochemical has one or more monomeric repeat units bearing less than or equal to six perfluorinated carbons. 
     
     
         18 . The process of  claim 15 , wherein said fluorochemical is a fluorochemical urethane. 
     
     
         19 . The process of  claim 8 , wherein said anti-stain component is present at an on weight of fiber from about 500 ppm to about 4%. 
     
     
         20 . The process of  claim 1 , wherein said dye composition has a pH from about 4 to about 9.0. 
     
     
         21 . The process of  claim 6 , wherein said first performance enhancing composition comprises a component selected from the group consisting of: odor control agents, anti-microbial agents, anti-fungal agents, fragrance agents, bleach resist agents, softeners, and UV stabilizers. 
     
     
         22 . The process of  claim 6 , wherein said first performance enhancing composition comprises a component selected from the group consisting of: dye auxiliaries, sequestrants, pH control agents, and surfactants. 
     
     
         23 . The process of  claim 7 , wherein said anti-soil component is present at an on weight of fiber from about 100 ppm elemental fluorine to about 1000 ppm elemental fluorine. 
     
     
         24 . The process of  claim 2 , wherein said heat setting is performed at a temperature from about 125° C. to about 200° C. 
     
     
         25 . The process of  claim 1 , wherein said BCF yarn comprises polyamide fiber. 
     
     
         26 . The process of  claim 25 , wherein said polyamide fiber is selected from the group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof. 
     
     
         27 . The process of  claim 1 , wherein said BCF yarn comprises polyester fiber. 
     
     
         28 . The process of  claim 27 , wherein said polyester fiber is selected from the group consisting of poly(ethylene terephthalate), polypropylene terephthalate), poly(butylene terephthalate), copolymers, and blends thereof. 
     
     
         29 . The process of  claim 1 , wherein said BCF yarn comprises a polyamide component and a polyester component. 
     
     
         30 . The process of  claim 1 , wherein said contacting is performed by a device selected from the group consisting of: applicator pad, wet-wick, dip-tank, sprayer, and mister. 
     
     
         31 . An untufted, twisted BCF yarn comprising a dye component, wherein said dye component is present on said untufted, twisted BCF yarn. 
     
     
         32 . The untufted, twisted BCF yarn of  claim 31  further comprising an anti-soil component, wherein said anti-soil component is present on said untufted, twisted BCF yarn. 
     
     
         33 . The untufted, twisted BCF yarn of  claim 31  further comprising an anti-stain component, wherein said anti-stain component is present on said untufted, twisted BCF yarn. 
     
     
         34 . The untufted, twisted BCF yarn of  claim 33 , wherein said anti-stain component is selected from the group consisting of: syntans, sulfonated novolacs, sulfonated aromatic aldehyde condensation products (SACs) and/or reaction products of formaldehyde, phenol, polymethacrylic acid, maleic anyhydride, and sulfonic acid. 
     
     
         35 . The untufted, twisted BCF yarn of  claim 32 , wherein said anti-soil component selected from the group consisting of fluorochemicals, silicones, silsesquioxanes, silanted particulates, alkylated particulates, anionic non-fluoronated surfactants, and anionic hydrotrope non-fluoronated surfactants. 
     
     
         36 . The untufted, twisted BCF yarn of  claim 35 , wherein said fluorochemical is selected from the group consisting of: fluorochemical allophanates, fluorochemical polyacrylates, fluorochemical urethanes, fluorochemical carbodiimides, fluorochemical guanidines, and fluorochemicals incorporating C2 to C8 chemistries. 
     
     
         37 . The untufted, twisted BCF yarn of  claim 35 , wherein said anti-soil component is present at an on weight of fiber from about 100 ppm elemental fluorine to about 1000 ppm elemental fluorine. 
     
     
         38 . The untufted, twisted BCF yarn of  claim 31 , wherein said BCF yarn comprises polyamide fiber. 
     
     
         39 . The untufted, twisted BCF yarn of  claim 38 , wherein said polyamide fiber is selected from the group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof. 
     
     
         40 . The untufted, twisted BCF yarn of  claim 31 , wherein said BCF yarn comprises a polyamide component and a polyester component. 
     
     
         41 . The untufted, twisted BCF yarn of  claim 31 , wherein said BCF yarn comprises polyester fiber. 
     
     
         42 . The untufted, twisted BCF yarn of  claim 41 , wherein said polyester fiber is selected from the group consisting of: polyethylene terephthalate), poly(propylene terephthalate), polybutylene terephthalate), copolymers, and blends thereof. 
     
     
         43 . A carpet comprising twisted BCF yarn, wherein said twisted BCF yarn comprises the twisted BCF yarn from  claim 31  that has been tufted. 
     
     
         44 . The carpet of  claim 43  having an AATCC 175-2003 Test rating of at least 7. 
     
     
         45 . A process for manufacturing carpet comprising:
 a. providing an untufted, twisted BCF yarn comprising a dye component and at least one optional performance enhancing composition present on a surface of said untufted, twisted BCF yarn;   b. tufting said BCF yarn; and   c. weaving said tufted BCF yarn into said carpet, wherein said process foregoes the need to further dye or treat said carpet with dyes and performance enhancing compositions.   
     
     
         46 . The process of  claim 45 , wherein said untufted, twisted BCF yarn comprises polyamide fiber. 
     
     
         47 . The process of  claim 46 , wherein said polyamide fiber is selected from the group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof. 
     
     
         48 . The process of  claim 45 , wherein said untufted, twisted BCF yarn comprises polyester fiber. 
     
     
         49 . The process of  claim 48 , wherein said polyester fiber is selected from the group consisting of: polyethylene terephthalate), poly(propylene terephthalate), polybutylene terephthalate), copolymers, and blends thereof. 
     
     
         50 . A system for applying a dye composition to twisted BCF fiber comprising:
 a. a first yarn take-up device that transmits a single yarn member made from at least two individual yarn members;   b. a dye composition applicator disposed downstream of said yarn take-up device that applies said dye composition to said single yarn member; and   c. a second yarn take-up device that receives a dyed single yarn member.   
     
     
         51 . A system for applying a dye composition and at least one performance enhancing composition to twisted BCF fiber comprising:
 a. a first yarn take-up device that transmits a single yarn member made from at least two individual yarn members;   b. a dye composition applicator disposed downstream of said yarn take-up device that applies said dye composition to said single yarn member;   c. a performance enhancing composition applicator disposed downstream of said dye composition applicator, and   d. a second yarn take-up device disposed downstream of said performance enhancing composition applicator that receives a dyed single yarn member.   
     
     
         52 . The process of  claim 6 , wherein said dye composition has a pH from about 4 to about 9. 
     
     
         53 . The process of  claim 6 , wherein said BCF yarn comprises polyester fiber. 
     
     
         54 . The process of  claim 6 , wherein said BCF yarn comprises a polyamide component and a polyester component. 
     
     
         55 . The untufted, twisted BCF yarn of  claim 31  further comprising an anti-soil component and an anti-stain component, wherein said anti-soil component and said anti-stain component are present on said untufted, twisted BCF yarn.