High bulk yarn and method of manufacturing thereof

Abstract

A method of manufacturing high bulk continuous multi-filament yarn comprises a number of distinct steps. In a first step, a plurality of filaments of polymer are melt spun to form a partially oriented yarn (POY). In a second step, the POYs are drawn and textured to form a draw textured yarn, wherein texturing is carried out in a friction texturing process. Subsequently at least two plies of the draw textured yarn are twisted and/or cabled together and subsequently heat set to obtain the high bulk continuous multifilament yarn.

1 . A method of manufacturing a high bulk continuous multifilament yarn for use as pile in a floor covering, comprising:
 in a first step, melt spinning a plurality of filaments of polymer to form a partially oriented yarn;   in a second step, drawing and texturing one or more partially oriented yarns in a friction texturing process to form a draw textured yarn; and   in a third step, twisting or cabling at least two plies of the draw textured yarn together in a range between 30 and 400 twists per meter and heat setting the twisted plies to obtain the high bulk continuous multifilament yarn having a weight of at least 1000 denier, wherein at the end of the second step and prior to the third step, the draw textured yarn is wound to a bobbin or hank.   
     
     
         2 . The method according to  claim 1 , wherein the method includes an intermediate step after the second step, wherein two, three or four draw textured yarns are intermingled together to form a single ply of draw textured yarn. 
     
     
         3 . The method according to  claim 1 , wherein the drawing and texturing is performed at a temperature in a range between 130° C. and 200° C. 
     
     
         4 . (canceled) 
     
     
         5 . The method according to  claim 1 , wherein the heat setting is performed at a temperature in a range between 80° C. and 220° C. 
     
     
         6 . The method according to  claim 1 , wherein the first step includes quenching of the partially oriented yarn and wherein, an effective quench length is in more than 1.2 m. 
     
     
         7 . The method according to  claim 1 , wherein the plies of draw textured yarn each have a weight of more than 500 denier. 
     
     
         8 . The method according to  claim 1 , wherein the high bulk yarn has a bulk of at least 12 cm 3 /gm. 
     
     
         9 . The method according to  claim 1 , further comprising applying a frieze effect to the high bulk continuous multifilament yarn. 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . The method according to  claim 1 , wherein, the friction texturing is carried out with a friction disk at a friction disk diameter to yarn speed (D/Y) ratio of greater than 1.5. 
     
     
         13 . The method according to  claim 1 , wherein the filaments in the partially oriented yarn at completion of the first step have a weight of greater than 2 denier per filament (dpf). 
     
     
         14 . The method according to  claim 1 , wherein the first step takes place at a speed that is at least double the speed of the second step. 
     
     
         15 . The method according to  claim 1 , wherein heat setting the twisted plies to obtain the high bulk continuous multifilament yarn takes place in a fourth step subsequent to twisting or cabling the at least two plies of the draw textured yarn together. 
     
     
         16 . (canceled) 
     
     
         17 . A high bulk yarn for use as pile in a floor covering comprising a plurality of plies, wherein; each ply further comprises at least one draw textured yarn and wherein, the at least one draw textured yarn further comprises continuous filaments of polymer wherein,
 the at least one draw textured yarn is false-twist friction textured;   the plurality of plies are twisted or cabled together in a range between 30 and 400 twists per meter and heat set in the twisted or cabled state, wherein a weight of the high bulk yarn is at least 1000 denier, and   the bulk of the high bulk yarn is at least 12 cm 3 /gm.   
     
     
         18 . The high bulk yarn according to  claim 17 , wherein the filaments are single-component filaments. 
     
     
         19 . The high bulk yarn according to  claim 17  having a weight of greater than 2000 denier. 
     
     
         20 . The high bulk yarn according to  claim 17 , wherein the high bulk yarn has a bulk of at least 16 cm 3 /gm. 
     
     
         21 . The high bulk yarn according to  claim 17 , wherein the polymer includes at least one of a polyethylene terephthalate (PET) and a polybutylene terephthalate (PBT). 
     
     
         22 . The high bulk yarn according to  claim 17 , wherein a weight of the filaments is greater than 2 dpf. 
     
     
         23 . A floor covering material comprising:
 a base backing; and   a pile comprising a high bulk yarn that is tufted, knitted, knotted or woven to the base backing,   wherein the high bulk yarn comprises a plurality of plies of false-twist friction textured yarn formed from continuous filaments of polyester, wherein the plurality of plies are twisted or cabled together in a range between 30 and 400 twists per meter and heat set in the twisted or cabled state, such that a weight of the high bulk yarn is at least 1000 denier and the bulk of the high bulk yarn is at least 12 cm 3 /gm.   
     
     
         24 . (canceled) 
     
     
         25 . The floor covering material according to  claim 23  wherein, the high bulk yarn is cut to form a cut pile floor covering material.