Processes to make water and oil repellent bcf yarn

Abstract

Disclosed are processes for applying anti-soil compositions on BCF yams during cable or air twisting processes prior to weaving, knitting or tufting. The process foregoes the need for downstream environmentally unfavorable dyeing and low pH chemical treatment processes on the finished carpet. The anti-soil composition can be comprised of a high specific surface energy chemical or other material, for example a fluorochemical. Further, the anti-soil composition can further comprise an anti-stain component. 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 an anti-soil composition comprising an anti-soil component comprising:
 a. providing twisted BCF yarn;   b. contacting said BCF yarn with said anti-soil composition while said BCF yarn is in motion; and   c. dry heat setting said BCF yarn.   
     
     
         2 . The process of  claim 1 , wherein said anti-soil component is selected from the group consisting of: fluorochemicals, silicones, silsesquioxanes, silane-modified particulates, organosilane-modified particulates, alkylated particulates, anionic surfactants, and anionic hydrotropes. 
     
     
         3 . The process of  claim 2  wherein said anti-soil component comprises a fluorochemical. 
     
     
         4 . The process of  claim 1 , wherein the anti-soil composition has a pH from about 3 to about 8. 
     
     
         5 . The process of  claim 3 , wherein said fluorochemical is selected from the group consisting of: fluorochemical allophanates, fluorochemical polyacrylates, fluorochemical urethanes, fluorochemical carbodiimides, fluorochemical guanidines, fluorochemical perfluoropolyethers, and fluorochemicals incorporating C2 to C8 chemistries. 
     
     
         6 . The process of  claim 3 , wherein said fluorochemical has less than or equal to six fluorinated carbons. 
     
     
         7 . The process of  claim 3 , wherein said fluorochemical is a fluorochemical urethane. 
     
     
         8 . The process of  claim 1 , wherein said anti-soil composition further 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. 
     
     
         9 . The process of  claim 1 , wherein said anti-soil composition further comprises an anti-stain component. 
     
     
         10 . The process of  claim 9 , 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, phenolics, substituted phenolics, thiophenolics, sulfones, substituted sulfones, polymers or copolymers of olefins, branched olefins, cyclic olefins, sulfonated olefins, acrylates, methacrylates, maleic anhydride, and organosulfonic acids. 
     
     
         11 . The process of  claim 9 , wherein said anti-stain component is present at an on weight of fiber from about 500 ppm to about 4%. 
     
     
         12 . The process of  claim 9 , wherein said anti-soil composition further comprises a component selected from the group consisting of: dye auxiliaries, sequestrants, pH control agents, and surfactants. 
     
     
         13 . The process of  claim 1 , wherein said heat setting is performed at a temperature from about 125° C. to about 200° C. 
     
     
         14 . The process of  claim 1 , wherein said BCF yarn comprises polyamide fiber. 
     
     
         15 . The process of  claim 14 , 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. 
     
     
         16 . The process of  claim 1 , wherein said BCF yarn comprises a polyester. 
     
     
         17 . The process of  claim 1 , 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. 
     
     
         18 . 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. 
     
     
         19 . The process of  claim 1 , wherein said BCF yarn is dyed or pigmented prior to contacting with said anti-soil composition. 
     
     
         20 . A system for applying an anti-soil 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. an anti-soil composition applicator disposed downstream of said yarn take-up device that applies said anti-soil composition to said single yarn member;   c. a yarn dry heat setting apparatus disposed downstream from said anti-soil composition applicator; and   d. a second yarn take-up device that receives said single yarn member.