Pbt automotive yarn and method of manufacturing thereof

Abstract

The present disclosure discloses a high resilience and stain resistant bulked continuous filament yarn. The yarn comprises a plurality of continuous filaments of polybutylene terephthalate (PBT), wherein the polybutylene terephthalate (PBT) has intrinsic viscosity in the range of 0.8 to 1.3. The yarn is obtained by a process comprising melt spinning of the plurality of continuous filaments of PBT; extrusion of the plurality of continuous filaments; quenching of the extruded filaments; drawing of the quenched filaments; texturizing of the drawn filaments; cooling of the texturized filaments, overfeeding of the cooled-texturized filaments; and winding of the overfeed filaments with or without tangling for obtaining the high resilience and stain resistant bulked continuous filament yarn. The high resilience and stain resistant bulked continuous filament yarn has a stain resistance rating of more than 3 and a hexapod rating of 2 or more after 12000 cycles.

We claim: 
     
         1 . A high resilience and stain resistant bulked continuous filament yarn, the yarn comprising a plurality of continuous filaments of polybutylene terephthalate (PBT), wherein the polybutylene terephthalate (PBT) has intrinsic viscosity in the range of 0.8 to 1.3, wherein the yarn is obtained by a process comprising:
 i. melt spinning of the plurality of continuous filaments of PBT;   ii. extrusion of the plurality of continuous filaments;   iii. quenching of the extruded filaments;   iv. drawing of the quenched filaments;   v. texturizing of the drawn filaments;   vi. cooling of the texturized filaments,   vii. overfeeding of the cooled-texturized filaments; and   viii. winding of the overfeed filaments with or without tangling for obtaining the high resilience and stain resistant bulked continuous filament yarn,   
       wherein the high resilience and stain resistant bulked continuous filament yarn has a stain resistance rating of more than 3 and a hexapod rating of 2 or more after 12000 cycles. 
     
     
         2 . The yarn of  claim 1 , wherein the extrusion of the plurality of continuous filaments is performed at a temperature in a range of 230° C.-300° C. 
     
     
         3 . The yarn of  claim 1 , wherein the quenching of the extruded filaments is performed at a temperature in a range of 2° C.-20° C. 
     
     
         4 . The yarn of  claim 1 , wherein the drawing of the quenched filaments is performed at a draw ratio (DR) in a range of 2 -4.5. 
     
     
         5 . The yarn of  claim 1 , wherein the texturizing of the drawn filaments is performed at a temperature in a range of 200° C.-280° C. and at an air pressure in a range of 5 - 9 bar. 
     
     
         6 . The yarn of  claim 1 , wherein the overfeeding of the cooled-texturized filaments is performed in a range of 10 -30%. 
     
     
         7 . A method of (for) manufacturing a high resilience and stain resistant bulked continuous filament yarn, wherein the yarn includes a plurality of continuous filaments of polybutylene terephthalate (PBT), wherein the polybutylene terephthalate (PBT) has intrinsic viscosity in the range of 0.8 to 1.3, the method comprising:
 i. melt spinning of the plurality of continuous filaments of PBT;   ii. extrusion of the plurality of continuous filaments;   iii. quenching of the extruded filaments;   iv. drawing of the quenched filaments;   v. texturizing of the drawn filaments;   vi. cooling of the texturized filaments,   vii. overfeeding of the cooled-texturized filaments; and   viii. winding of the overfeed filaments with or without tangling for obtaining the high resilience and stain resistant bulked continuous filament yarn,   
       wherein the high resilience and stain resistant bulked continuous filament yarn has a stain resistance rating of more than 3 and a hexapod rating of 2 or more after 12000 cycles.