Synthetic fibers with enhanced stain resistance and methods of making the same

Abstract

Synthetic fibers with enhanced stain resistance, yarns and carpets prepared from these fibers and compounds and methods for their production are provided.

1 . A synthetic fiber comprising:
 a) a first fiber forming polymer present in a range from about 80 to 98 percent by weight   b) a second polymer present in a range from about 1 to 10 percent by weight, wherein the second polymer has a melt point which is lower than the melt point of the first fiber forming polymer; and   c) a stain blocking additive present in a range from about 1 to 10 percent by weight.   
     
     
         2 . The synthetic fiber of  claim 1 , wherein the presence of the second polymer does not cause the synthetic fiber to fibrillate. 
     
     
         3 . The synthetic fiber of  claim 1 , wherein the first fiber forming polymer is selected from the group consisting of a polyamide, polyester, polyolefin and combinations thereof. 
     
     
         4 . The synthetic fiber of  claim 1 , wherein the first fiber forming polymer is nylon 6. 
     
     
         5 . The synthetic fiber of  claim 1  wherein the second polymer is present in a range from about 1 to 5 percent by weight. 
     
     
         6 . The synthetic fiber of  claim 1  wherein the second polymer is a polyolefin, polylactic acid, polystyrene, or a blend or copolymer thereof. 
     
     
         7 . The synthetic fiber of  claim 1 , wherein the second polymer is an unmodified polyolefin. 
     
     
         8 . The synthetic fiber of  claim 1  wherein the second polymer is polypropylene. 
     
     
         9 . The synthetic fiber of  claim 1 , wherein the stain blocking additive is present in a range from about 1 to 5 percent by weight. 
     
     
         10 . The synthetic fiber of  claim 1 , wherein the stain blocking additive is an aromatic sultanate or an alkali metal salt thereof. 
     
     
         11 . The synthetic fiber of  claim 10 , wherein the stain blocking additive is 5-sulphoisophthalic acid, sodium salt. 
     
     
         12 . A yarn formed from the synthetic fiber of 
     
     
         13 . A fabric knitted from the synthetic fiber of  claim 1 . 
     
     
         14 . A carpet formed from the yarn of  claim 12 . 
     
     
         15 . A process for forming a synthetic fiber with enhanced stain resistance, said process comprising the steps of:
 a) forming a polymer melt of a first fiber forming polymer and a masterbatch compound, wherein the masterbatch compound comprises a second polymer having a melting point which is less than the melting point of the first fiber forming polymer, and a stain blocking additive, wherein the first fiber forming polymer is present in a range from about 80 to 98 percent by weight, and the masterbatch compound is present in a range from about 2 to 20 percent by weight; and   b) forming a synthetic fiber with enhanced stain resistance from the polymer melt.   
     
     
         16 . The process of  claim 15 , wherein the masterbatch compound has a moisture content less than about 200 ppm. 
     
     
         17 . The process of  claim 15 , wherein the masterbatch compound has a moisture content less than about 50 ppm. 
     
     
         18 . The process of  claim 15 , wherein the masterbatch compound is not dried or conditioned prior to forming the polymer melt. 
     
     
         19 . (canceled) 
     
     
         20 . The process of  claim 15 , wherein the presence of the second polymer does not cause the synthetic fiber to fibrillate. 
     
     
         21 . The process of  claim 15 , wherein the first fiber forming polymer is selected from the group consisting of a polyamide, polyester, polyolefin and combinations thereof. 
     
     
         22 . The process of  claim 15 , wherein the first fiber forming polymer is nylon 6. 
     
     
         23 . The process of  claim 15 , wherein the second polymer is present in the masterbatch compound in a range from about 20 to 80 percent by weight. 
     
     
         24 . The process of  claim 15 , wherein the stain blocking additive is present in the masterbatch compound in a range from about 20 to 80 percent by weight. 
     
     
         25 . The process of  claim 15 , wherein the second polymer is present in the synthetic fiber in a range from about 1 to 10 percent by weight 
     
     
         26 . The process of  claim 15 , wherein the second polymer is present in the synthetic fiber in a range from about 1 to 5 percent by weight. 
     
     
         27 . The process of  claim 15 , wherein the second polymer is a polyolefin. 
     
     
         28 . (canceled) 
     
     
         29 . The process of  claim 15 , wherein the second polymer s polypropylene. 
     
     
         30 . The process of  claim 15 , wherein the stain blocking additive is present n the synthetic fiber in a range from about 1 to 10 percent by weight. 
     
     
         31 . The process of  claim 15 , wherein the stain blocking additive is present in the synthetic fiber in a range from about 1 to 5 percent by weight. 
     
     
         32 . The process of  claim 15 , wherein the stain blocking additive is an aromatic sulfonate or an alkali metal salt thereof. 
     
     
         33 . The process of  claim 32 , wherein the stain blocking additive is 5-sulphoisophthalate, sodium salt. 
     
     
         34 . The process of  claim 15 , wherein forming a synthetic fiber further comprises:
 a) extruding said polymer melt through a spinneret to form one or a plurality of filaments, and   b) drawing the fiber.   
     
     
         35 . A yarn formed from the process of  claim 15 . 
     
     
         36 . A fabric knitted from the synthetic fiber produced from  claim 15 . 
     
     
         37 . A carpet formed from the yarn of  claim 35 . 
     
     
         38 . A rug formed from the yarn of  claim 35 . 
     
     
         39 . A masterbatch compound comprising:
 a thermoplastic carrier; and   a stain blocking additive,   wherein the moisture content of the masterbatch compound is lower than about 200 ppm.   
     
     
         40 . The masterbatch compound of  claim 39 , wherein the masterbatch compound has a moisture content less than about 50 ppm. 
     
     
         41 . The masterbatch compound of  claim 39 , wherein the thermoplastic carrier is present in the masterbatch compound in a range from about 20 to 80 percent by weight. 
     
     
         42 . The masterbatch compound of  claim 39 , wherein the stain blocking additive is present in the masterbatch compound in a range from about 20 to 80 percent by weight. 
     
     
         43 . The masterbatch compound of  claim 39 , wherein the thermoplastic carrier is a polyolefin. 
     
     
         40 . (canceled) 
     
     
         45 . The masterbatch compound of  claim 39 , wherein the thermoplastic carrier is polypropylene. 
     
     
         46 . The masterbatch compound of  claim 39 , wherein the stain blocking additive is an aromatic sulfonate or an alkali metal salt thereof. 
     
     
         47 . The masterbatch compound of  claim 39 , wherein the stain blocking additive is 5-sulphoisophthalic acid, sodium salt. 
     
     
         48 . The masterbatch compound of  claim 39 , further comprising a component selected from the group consisting of inorganic pigments, optical brightening agents, ultraviolet light stabilizers, and combinations thereof.