Process for heat setting twisted, bulked continuous filament yarn

Abstract

A multi-step process is disclosed for heat setting twisted, bulk continuous filament (BCF) yarn comprising the steps of developing crimp in the yarn under hot atmospheric air and heat setting the yarn by saturated steam treatment.

1 . A multi-step process for heat setting twisted, bulk continuous filament (BCF) yarn comprising the steps of:
 a) developing crimp in the yarn under hot atmospheric air; and   b) heat setting the yarn from step (a) by pressurized steam treatment.   
     
     
         2 . The process of  claim 1  wherein step (a) is performed under hot air at a temperature in the range from about 140° C. to about 210° C. 
     
     
         3 . The process of  claim 1  wherein step (b) is achieved with saturated steam at a temperature in the range from about 110° C. to about 130° C. 
     
     
         4 . The process of  claim 1  the yarn is treated in step (a) for a period of about 3 to about 7 seconds. 
     
     
         5 . The process of  claim 1  wherein the yarn is heat set in step (b) for a period of about 25 to about 60 seconds. 
     
     
         6 . The process of  claim 1  wherein the yarn is formed from a synthetic polymer selected from the group consisting of nylon, polyester, polyolefin and copolymers and blends thereof. 
     
     
         7 . The process of  claim 1  wherein the yarn is formed from nylon 6,6 or nylon 6 polymer. 
     
     
         8 . The process of  claim 1  wherein the yarn is made from cationic dyeable nylon polymer. 
     
     
         9 . The process of  claim 8  wherein the cationic dyeable nylon polymer comprises a stain blocking additive capable of disabling acid dye sites in the polymer. 
     
     
         10 . The process of  claim 9  wherein the stain blocking additive is present in a range from about 1 to 10 percent by weight. 
     
     
         11 . The process of  claim 9  wherein the stain blocking additive is an aromatic sulfonate or an alkali metal salt thereof. 
     
     
         12 . The process of  claim 9  wherein the yarn is solution dye nylon yarn. 
     
     
         13 . An article formed from the yarn treated by process of  claim 1 . 
     
     
         14 . A carpet formed from the yarn treated by process of  claim 1 . 
     
     
         15 . The carpet of  claim 14  wherein the carpet has a stain rating of 8 or higher according to the 24 hour stain test. 
     
     
         16 . The carpet of  claim 14  wherein the carpet has a stain rating of 7 or higher according to the WAQE stain test. 
     
     
         17 . An apparatus for heat setting twisted, bulk continuous filament (BCF) yarn comprising:
 a) a bulking apparatus configured to bulk the yarn with hot atmospheric air to develop crimp; and   b) a heat setting tunnel configured to heat set the yarn by pressurized steam injection.   
     
     
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         27 . An article from the yarn treated by apparatus of  claim 17 . 
     
     
         28 . A carpet from the yarn treated by apparatus of  claim 17 . 
     
     
         29 . (canceled) 
     
     
         30 . (canceled)