EP3957782A1

EP3957782A1 - Bulked continuous side-by-side bi-component filament yarn, method for making, and floor covering material made therefrom

Info

Publication number: EP3957782A1
Application number: EP20202322.2A
Authority: EP
Inventors: Khushboo Abhishek Mandawewala
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-08-21
Filing date: 2020-10-16
Publication date: 2022-02-23
Also published as: CA3187836A1; US20230304219A1; EP4200467A1; AU2021327176A1; WO2022038570A1

Abstract

Disclosure provides a Bulked Continuous side-by-side bi-component Filament (BCF) yarn including a plurality of side-by-side bi-component filaments, each includes first and second polymer components. The first polymer component forms a first side of the side-by-side bi-component filaments, and includes polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn. Further, the second polymer component forms a second side of the side-by-side bi-component filaments, and includes one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn. The BCF yarn is obtained by a single-step continuous process, and subsequently followed by steps of cabling and heat-setting. The BCF yarn as obtained includes an elongation in a range of 40% to 65%, and a Hexapod rating after 12000 cycles is of more than 2.

Description

FIELD OF THE DISCLOSURE

The present disclosure relates to a textile industry, and, more particularly, to a bulked continuous side-by-side bi-component filament (BCF) yarn, a method for making such BCF yarn, and a floor covering material made from such BCF yarn.

BACKGROUND OF THE DISCLOSURE

Continuous filament yarn comprises a group of filaments, wherein each such filaments are made of a polymer material that is extruded as a long fiber. Continuous filament yarn may be a continuous mono-component filament yarn or a continuous bi-component filament yarn. Depending upon the requirements and usages, the continuous mono-component filament yarn or the continuous bi-component filament yarn are chosen for respective purposes. The continuous bi-component filament yarn may be available is various arrangements, such as a sheath-core arrangement and a side-by-side arrangement. In the sheath-core arrangement, each filament of the continuous bi-component filament yarn includes one of the two polymers forming a core while the other forming a sheath. In the side-by-side arrangement, each filament of the continuous bi-component filament yarn includes the two polymers arranged side-by-side to each other. While both types of continuous bi-component filament yarns are widely used and have specific requirements in a textile industry, the present disclosure discuss about the continuous side-by-side bi-component filament yarn and articles made therefrom.
The continuous side-by-side bi-component filament yarns are used for making various kinds of articles, including, but not limited to, carpets, as an alternative to carpets made using spun yarn comprised of staple fibers. Generally, such continuous side-by-side bi-component filament yarns are texturized for increasing bulkiness and for better wear resistance, prior to making the carpet therefrom. However, the articles, such as, the carpets, made from such continuous side-by-side bi-component filament yarns may undergo delamination over time, a degradation process wherein the bi-component polymers begin to separate from one another, particularly, when such carpets are subject to high level of wear and tear, affecting integrity and long-term durability of such articles.
Accordingly, there exists a need to provide such bulk continuous side-by-side bi-component filament yarns or articles made therefrom that may be able to withstand high level of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.

SUMMARY OF THE DISCLOSURE

In view of the foregoing disadvantages inherent in the prior art, the general purpose of the present disclosure is to provide a bulked continuous side-by-side bi-component filament (BCF) yarn, a method for making such BCF yarn, and a floor covering material made from such BCF yarn, to include all advantages of the prior art, and to overcome the drawbacks inherent in the prior art.
Therefore, an object of the present disclosure is to provide such bulk continuous side-by-side bi-component filament yarns that may be able to withstand high level of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.
Another object of the present disclosure is to provide a method for making such bulk continuous side-by-side bi-component filament yarns that may be able to withstand high level of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.
Yet another object of the present disclosure is to provide a floor covering material, such as, carpets that may be able to withstand high level of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.
In light of the above objects, in one aspect of the present disclosure, a Bulked Continuous side-by-side bi-component Filament (BCF) yarn is provided. The BCF yarn may include a plurality of side-by-side bi-component filaments. Each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments may include a first polymer component and a second polymer component. The first polymer component may form a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn. Further, the second polymer component may form a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn. The BCF yarn may be obtained by a single-step continuous process, and subsequently, after the single-step continuous process, is followed by steps of cabling and heat-setting at predetermined parameters. The BCF yarn as obtained may include an elongation in a range of 40% to 65%, and a Hexapod rating after 12000 cycles is of more than 2.
In one another aspect of the present disclosure, a method for forming a Bulked Continuous side-by-side bi-component Filament (BCF) yarn is provided. The method may include: extruding the first polymer component and the second polymer component at a gradual temperature having a range of 240°C to 300°C through a plurality of temperature zones, and at a pressure range of 60 bars to 130 bars to obtain a plurality of side-by-side bi-component filaments grouped together to obtain a continuous side-by-side bi-component filament yarn. Each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments may include a first polymer component and a second polymer component. The first polymer component may form a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn. Further, the second polymer component may form a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn. The method may further include: cabling the continuous side-by-side bi-component filament yarn in a range of 40 TPM (Twist Per meter) to 350 TPM, with at least one ply to obtain the continuous side-by-side bi-component filament yarn having twists; and heat setting the continuous side-by-side bi-component filament yarn with the twists in a range of 100°C to 200°C to obtain a twisted heat set BCF yarn having: an elongation in a range of 40% to 65%, and a Hexapod rating after 12000 cycles is more than 2.
In one another aspect of the present disclosure, a floor covering material is provided. The floor covering material may include a base backing, and a plurality of Bulked Continuous side-by-side bi-component Filament (BCF) yarn configured on the base backing. The BCF yarn may include a plurality of side-by-side bi-component filaments. Each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments may include a first polymer component and a second polymer component. The first polymer component may form a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn. Further, the second polymer component may form a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn. The BCF yarn may be obtained by a single-step continuous process, and subsequently, after the single-step continuous process, is followed by steps of cabling and heat-setting at predetermined parameters. The BCF yarn as obtained may include an elongation in a range of 40% to 65%, and a Hexapod rating after 12000 cycles is of more than 2.
This together with the other aspects of the present disclosure, along with the various features of novelty that characterize the present disclosure, is pointed out with particularity in the claims annexed hereto and forms a part of the present disclosure. For a better understanding of the present disclosure, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages and features of the present disclosure will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawings, in which:

FIG. 1 illustrates a cross-sectional perspective view of a Bulked Continuous side-by-side bi-component Filament (BCF) yarn, in accordance with an exemplary embodiment of the present disclosure;
FIGS. 2A to 2L illustrate various cross-sectional views of a side-by-side bi-component filaments, in accordance with an exemplary embodiment of the present disclosure;
FIG. 3 illustrates a block diagram of a method for forming a Bulked Continuous side-by-side bi-component Filament (BCF) yarn, in accordance with an exemplary embodiment of the present disclosure; and
FIG. 4 illustrate an article, such a floor covering material made from Bulked Continuous side-by-side bi-component Filament (BCF) yarns, in accordance with an exemplary embodiment of the present disclosure.

Like reference numerals refer to like parts throughout the description of several views of the drawing.

DETAILED DESCRIPTION OF THE DISCLOSURE

The exemplary embodiments described herein detail for illustrative purposes are subject to many variations in implementation. The present disclosure provides a bulked continuous side-by-side bi-component filament (BCF) yarn, a method for making such BCF yarn, and a floor covering material made from such BCF yarn. It should be emphasized, however, that the present disclosure is not limited to an antiviral and antibacterial textile material and method for preparing the same. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the present disclosure.
The terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The terms "having", "comprising", "including", and variations thereof signify the presence of a component.
The present disclosure provides a Bulked Continuous side-by-side bi-component Filament (BCF) yarn is provided. The BCF yarn may include a plurality of side-by-side bi-component filaments. Each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments may include a first polymer component and a second polymer component. The first polymer component may form a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn. Further, the second polymer component may form a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn. The BCF yarn may be obtained by a single-step continuous process, and subsequently, after the single-step continuous process, is followed by steps of cabling and heat-setting at predetermined parameters. The BCF yarn as obtained may include an elongation in a range of 40% to 65%, and a Hexapod rating after 12000 cycles is of more than 2.
A Bulked Continuous side-by-side bi-component Filament (BCF) yarn will now be explained in conjunction with FIGS. 1A to 4 as below, in accordance with various exemplary embodiment of the present disclosure. Without departing from the scope of the present disclosure, the drawings as shown herein are only for better understanding of the disclosure and may not be in anyway considered to be limiting only to the diagrams as disclosed herein. There may be various other forms that may be covered by the claims of the present disclosure.
Referring now to FIG. 1, a cross-sectional perspective view of a Bulked Continuous side-by-side bi-component Filament (BCF) yarn 100 is illustrated in accordance with an exemplary embodiment of the present disclosure. The BCF yarn 100 may include a plurality of side-by-side bi-component filaments 110. Each side-by-side bi-component filament 110, as shown in FIG. 2A, of such plurality of side-by-side bi-component filaments may include a first polymer component 112 and a second polymer component 114. The first polymer component 112 may form a first side 110a of the side-by-side bi-component filaments 110. Further, the second polymer component 114 may form a second side 110b of the side-by-side bi-component filaments 110. In one preferred embodiment of the present disclosure, the first polymer component 110 may include polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament 110 in the BCF yarn 100. Further, in one preferred embodiment of the present disclosure, the second polymer component 114 may include one of polyethylene terephthalate (PET) or polylactic acid (PLA) or recycled PET in at least about 75 to 25 volume percent of the filament 110 in the BCF yarn 100. However, without departing from the scope of the present disclosure, the first and second polymer components 112, 114 may be in any desired volume percent of the filament 110 in the BCF yarn 100 depending upon the requirement.
The BCF yarn 100 may include various shapes of the side-by-side bi-component filament 110, such as shown in FIGS. 2A to 2L. As shown in FIGS. 2A and 2B, the side-by-side bi-component filament 110, respectively, include a side-by-side full semi-circular cross-sectional shape, a side-by-side hollow semi-circular cross-sectional shape. Further, as shown in FIGS. 2C and 2D, the side-by-side bi-component filament 110, respectively, include a side-by-side full tri-lobal cross-sectional shape and a side-by-side hollow tri-lobal cross-sectional shape. Further, as shown in FIGS. 2E and 2F, the side-by-side bi-component filament 110, respectively, include a side-by-side full delta cross-sectional shape and a side-by-side hollow delta cross-sectional shape. Further, as shown in FIGS. 2G and 2H, the side-by-side bi-component filament 110, respectively, include a side-by-side full concave cross-sectional shape and a side-by-side hollow concave cross-sectional shape. Further, as shown in FIGS. 2I and 2J, the side-by-side bi-component filament 110, respectively, include a side-by-side full octa-lobal cross-sectional shape and a side-by-side hollow octa-lobal cross-sectional shape. Further, as shown in FIGS. 2K and 2L, the side-by-side bi-component filament 110, respectively, include a side-by-side full elliptical cross-sectional shape and a side-by-side hollow elliptical cross-sectional shape. However, without departing from the scope of the present disclosure, the side-by-side bi-component filament 110 may include various other shapes, such as, a side-by-side full multi-lobal cross-sectional shape, a side-by-side hollow multi-lobal cross-sectional shape, or any other shape as required. Further, without departing from the scopes of the present disclosure, the first and the second sides together as a whole comprises a side by side full circle cross sectional shape, a side by side hollow circular cross-sectional shape.
The BCF yarn 100, as described, may be obtained by a single-step continuous process that may include steps of extruding, spinning, quenching, spin finish application, drawing, and/or texturing, cooling, intermingling and winding at the predetermined parameters. Subsequently, after the single-step continuous process, steps of cabling and heat-setting at predetermined parameters are followed. Single-step process means that all such steps are performed on a single machine having various machine sections, and may also be referred to as single machine process. Referring now to FIG. 3, to describe a method 200 of making the BCF yarn 100 via the single-step continuous process 300, and subsequently followed by steps of cabling or twisting 210 and heat-setting 220.
The method 200 as shown in FIG. 3 will be described in conjunction with FIGS. 1 and 2A. As shown, the method 200 includes the single-step continuous process 300, which starts at 310 by extruding the first polymer component 112 via a first extruder E1 and the second polymer component 114 via a second extruder E2. The first polymer component 112 and the second polymer component 114 are extruded at a predetermined parameter, such as gradual temperature and pressure to obtain a plurality of side-by-side bi-component filaments 110 grouped together to obtain a continuous side-by-side bi-component filament yarn. In one embodiment of the present disclosure, the first polymer component 112 and the second polymer component 114 are extruded at the gradual temperature having a range of 240°C to 305°C through a plurality of temperature zones (t1...tn), and at the pressure range of 60 bars to 130 bars. Further, at 320 spinning of the continuous side-by-side bi-component filament yarn is performed. Further, at 330, the continuous side-by-side bi-component filament yarn is gradually quenched, at the predetermined parameters, via, an air flow. In one embodiment the predetermined parameters of the quenching air flow may include: a quenching air flow temperature in a range of 10°C to 25°C, quenching air flow rate in a range of 0.1mps to 0.8mps, and quenching air flow pressure in a range of 1 mbars to 4 mbars. After quenching, spin finish application is performed at 340 on the continuous side-by-side bi-component filament yarn. Furthermore, at 350, after the spin finish application, the spin finish application yarn is sequentially drawn at predetermined parameters, such as drawing speed and drawing temperature. In one embodiment of the present disclosure, the drawing speed may be in a range of 760mpm to 3500mpm, and the drawing temperature range may be in a range of 75°C to 200°C. Thereafter, at 360, the drawn yarn may be optionally textured at a texturing temperature range of 130°C to 200°C and a texturing vacuum pressure range of -50 mbars to -150 mbars. Moreover, at 370, the continuous side-by-side bi-continuous filament yarn is cooled at a cooling drum speed having a range of 10rpm to 60rpm and a cooling drum vacuum having a range of -20mbars to -80mbars. The cooled continuous side-by-side bi-continuous filament may further be intermingled at 380 and wounded at 390.
In one embodiment of the present disclosure, the at least one of the first and second polymer components 112, 114 are solution-dyed, either using pigments or solvent dyes or a combination thereof. Further, in one embodiment of the present disclosure, the at least one of the first and second polymer components are one of hank-dyed, space-dyed or yarn-dyed. One way to dye the at least one of the first and second polymer components 112, 114 is to dip them in a vat of dye after or before they are extruded.
Subsequently to the single-step process, the continuous side-by-side bi-continuous filament yarn is cabled or twisted at step 210. In the twisting or cabling step at 210, the continuous side-by-side bi-component filament yarn is imparted with parament and distinctive texture in the form of twists. In addition, cabling or twisting improves tip definition and integrity. The tip is that end of the yarn which are extending vertically from the carpet backing and visually and physically apparent to the consumer. Twists are generally expressed as twists per meter or TPM. Such cabling/twisting of the continuous side-by-side bi-component filament yarn may be done in a range of 40TPM to 350 TPM; preferably 100TPM-300TPM; more preferably 200TPM-250TPM, for example about 230TPM, to obtain the continuous side-by-side bi-component filament yarn having such twists. One of the example table is presented below to illustrate cabling or twisting parameters with respect the combination of types of the first and second polymer components 112, 114:

Polymer PET-50% & PBT-50% PET-33% & PBT-67% PET-67% & PBT-33%

TPM 230 230 230

Twist Direction "s" "s" "s"

Spindle Rpm 5000 5000 5000
As defined above in the table: 'Twist direction' "S" refers a yarn spun in counter-clockwise direction and is normally used to create right-handed twill. Further, 'spindle rpm' refers to speed to spindle where the twisting is done.

As described above, cabling or twisting imparts twists to the yarn, however, increases the tendency of undesirable torqueing in the yarn. Therefore, after twisting and cabling, at step 220, the continuous side-by-side bi-component filament yarn with the twists is heat set. Heat treating of the fibers, filaments or yarn of the present invention is carried out by a fluid, such as air, steam, or any other compressible liquid or vapor capable of transferring heat to the twisted yarn as it continuously travels through a heat setting device. The temperature of such fluid must be such that the yarn does not melt. If the temperature of the yarn is above the melting point of the yarn it is necessary to shorten the time in which the yarn dwells in the heat setting device. This step of heat setting utilizes such stream capable of transferring heat to the twisted yarn as it continuously travels through the heat setting device, at a temperature 85°C to 200°C; preferably 100°C to 190°C; more preferably 130°C to 180°C, for example about 130°C or 140°C. This process is affected by the length of time during which the twisted yarn is exposed to the heating medium (time/temperature effect). Generally, useful exposure times are from 30 seconds to 3 minutes; preferably from 45 seconds to 1½ minutes; for example, about 1 minute. One of the example table is presented below to illustrate cabling or heat setting parameters with respect the combination of types of the first and second polymer components 112, 114:

Polymer	PET-50% & PBT-50%	PET-33% & PBT-67%	PET-67% & PBT-33%
Twist Direction	"s"	"s"	"s"
Over feed speed	285	285	285
Delivery speed	250	250	250
Dwell time	60 Sec	60 Sec	60 Sec
Stuffing pressure 1	32%	32%	32%
GKK temp 1&2	170°C	170°C	170°C
Dew point set 1&2	90°C	90°C	90°C
Cooling fan on/off	ON	ON	ON
Accumulator basic speed	215	215	215
Accumulator jump speed	225	225	225
no. of ends per tunnel	10	10	10

As defined above in the table:
"Twist direction" as "S" represents a yarn is twisted in counter-clockwise and is normally used to create right-handed twill. However, without departing from the scope of the present disclosure, the twist direction may also be "Z", which represents that a yarn is twisted in clockwise and is normally used to create left-handed twill.
"Over feed Speed" represents the speed at which the overfeed rollers in the heat set machine runs. This is normally 10-30% more than the delivery speed, to keep the yarn slack before entering the actual heat set process.
"Delivery Speed" represents the feed speed of the yarn at the heat set machine.
"Dwell time" represents the total time yarn stays inside the actual heat setting process.
"Stuffing pressure 1" represents the level of additional crimp (known as friese) given in the yarn during the heat setting process.
"GKK temp 1&2" represents the actual temperature yarn is exposed for heat setting.
"Dew point set 1&2" represents the moisture level inside the actual heat setting tunnel.
"Accumulator basic speed" represents the normal speed of the yarn outlet from the heat setting tunnel.
"Accumulator jump speed" represents the higher speed of the yarn outlet from the heat setting tunnel.
"No of ends per tunnel" represents total number of yarns which are heat set together in each heat setting tunnel.
Heat setting for the twisted yarns stabilizes the twist and often causes the BCF yarn 100 to lock in the twists and gain volume in the PCF yarn 100. This volume growth is may be described as "bulk development". Heat setting also retains the twist during use and there is no such a loss of resilience and of overall appearance due to matting. The unique yarn and carpet made therefrom based on the side-by-side bi-component filaments disclosed herein, results in an ability to thermally lock in the twist structure and enables to gain volume in the BCF yarn 100. In the present invention, the BCF yarn is produced have number of the side-by-side bi-component filaments in in the range of 25 filaments to 1000 filaments. Further, the BCF yarn 100 exhibits a denier per filament (DPF) ratio measuring in the range of 0.5 DPF to 50 DPF, and a linear density in a range of 600denier to 6000denier.
Moreover, In the present invention, the BCF yarn 100 that is produced using above process have an elongation in a range of 40% to 65%.
More importantly, BCF yarn 100 and/or carpet produced with compositions of the first and second polymers 112, 114 arranged in side-by-side arrangements of the invention were tested for performance in a Hexapod Tumble Test typically used in the art to evaluate carpet performance and found to have a Hexapod rating after 12000 cycles to be more than 2.
Such Hexapod rating of more than 2 after 12000 cycles of the BCF yarn 100 are obtained due to the unique combination the first polymer component 112 forming the first side 110a in at least about 25 to 75 volume percent, and the second polymer component 114 forming the second side 110a in at least about 75 to 25 volume percent of the filament in the BCF yarn, along with the heat setting of such yarn.

One of the example table is presented below to illustrate various combination of the first and second polymer components 112, 114 and resulting properties (mainly "elongation" "Hexapod rating") as obtained in the BCF heat set yarns 100 in comparation to other available yarn in the prior arts:

Bi-Component filament		Percentage of Polymers		Heat-Setting Parameter (degree C)	Denier/Filament	Final Product	% Elongation	Hexa Pod Rating after 12000 cycles
Polymer A	Polymer B	Polymer A%	Polymer B%
PBT	PET	25	75	140	1200/120
PBT	PET	50	50	140	1200/120	2 Ply 230 TPM Heat set	54.56	2.5
PBT	PET	75	25	140	1200/120
PBT	Recycled PET	25	75	140	1200/120
PBT	Recycled PET	50	50	140	1200/120	2 Ply 230 TPM Heat set	55.2	3
PBT	Recycled PET	75	25	140	1200/120
PBT	PLA	25	75
PBT	PLA	50	50	130	1200/120	2 Ply 230 TPM Heat set	58.4	2
PBT	PLA	75	25
Mono Component Filament
100% PET				140	1200/120	2 Ply 230 TPM Heat set	39.48	1
10.0% PBT				140	1200/120	2 Ply 230 TPM Heat set	40.2	1.5
PBT	PET	50	50	Without Heat setting	1200/120	1 ply BCF	33.55	1.5
PBT	Recycled PET	50	50	Without Heat setting	1200/120	1 ply BCF	35.5	1.5
Mono Component Filament
100% PET				Without Heat setting	1200/120	1 ply BCF	28.54	1
100% PBT				Without Heat setting	1200/120	1 ply BCF	29.3	1

Referring now to FIG. 4, a floor covering material 400 is shown in accordance with an exemplary embodiment of the present disclosure. The floor covering material 400 may include a base backing 410, and the plurality of Bulked Continuous side-by-side bi-component Filament (BCF) yarn 100 configured on the base backing 410, as described above and excluded from the description herein for the sake of brevity of the disclosure and avoid reputation of the subject matter. The floor covering material 400 may include, but not limited to, carpets, rugs, mats and so forth. In one embodiment of the present disclosure, the BCF yarns 100 are tufted on the base backing 410 to form the floor covering material 400. In one embodiment of the present disclosure, the BCF yarns 100 are knitted on the base backing 410 to form the floor covering material 400. In one embodiment of the present disclosure, the BCF yarns 100 are woven on the base backing 410 to form the floor covering material 400. In one embodiment of the present disclosure, the BCF yarns 100 are knotted on the base backing 410 to form the floor covering material 400.
As presented, the present disclosure is advantageous in providing such bulk continuous side-by-side bi-component filament yarns or carpets that may be able to withstand high level of wear and tear and avoid delamination of bi-components from each other over the maximum period of time.
The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present disclosure and its practical application, and to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the spirit or scope of the present disclosure.

Claims

A Bulked Continuous side-by-side bi-component Filament (BCF) yarn, comprising:
a plurality of side-by-side bi-component filaments, each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments having:
a first polymer component forming a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament in the BCF yarn, and

a second polymer component forming a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at least about 75 to 25 volume percent of the filament in the BCF yarn,

wherein the BCF yarn is obtained by a single-step continuous process and subsequently followed by steps of cabling/twisting and heat-setting at predetermined parameters, and

wherein the BCF yarn comprises:
an elongation in a range of 40% to 65%, and

a Hexapod rating after 12000 cycles of more than 2.
The BCF yarn of claim 1, wherein the second polymer component further comprises a recycled polyethylene terephthalate (PET).
The BCF yarn of claim 1, wherein the first and the second sides together as a whole comprises a side by side full circle cross sectional shape, a side by side hollow circular cross sectional shape, a side-by-side full semi-circular cross-sectional shape, a side-by-side hollow semi-circular cross-sectional shape, a side-by-side full tri-lobal cross-sectional shape, a side-by-side hollow tri-lobal cross-sectional shape, a side-by-side full delta cross-sectional shape, a side-by-side hollow delta cross-sectional shape, a side-by-side full concave cross-sectional shape, a side-by-side hollow concave cross-sectional shape, a side-by-side full octa-lobal cross-sectional shape, a side-by-side hollow octa-lobal cross-sectional shape, a side-by-side full elliptical cross-sectional shape, a side-by-side hollow elliptical cross-sectional shape, a side-by-side full multi-lobal cross-sectional shape and a side-by-side hollow multi-lobal cross-sectional shape.
The BCF yarn of claim 1, wherein at least one of the first and second polymer components are solution-dyed, either using pigments or solvent dyes or a combination thereof.
The BCF yarn of claim 1, wherein at least one of the first and second polymer components are one of hank-dyed, space-dyed or yarn-dyed.
The BCF yarn of claim 1, wherein number of the side-by-side bi-component filaments in the BCF yarn is in the range of 25 filaments to 1000 filaments.
The BCF yarn of claim 1, wherein the BCF yarn exhibits:
a denier per filament (DPF) ratio measuring in the range of 0.5 DPF to 50 DPF, and

a linear density in a range of 600 denier to 6000 denier.
The BCF yarn of claim 1, wherein the BCF yarn is obtained by the single-step continuous process comprising the steps of: extruding, spinning, quenching, spin finish application, drawing, and/or texturing, cooling, intermingling and winding at the predetermined parameters.
The BCF yarn of claim 8, wherein, to obtain the BCF yarn, the first polymer and the second polymer are extruded, to obtain the plurality of side-by-side bi-component filaments that are grouped together to obtain a continuous side-by-side bi-component filament yarn, at the predetermined parameters comprising: a gradual temperature having a range of 240°C to 305°C through a plurality of temperature zones, and at a pressure range of 60 bars to 130 bars.
The BCF yarn of claim 9, wherein, to obtain the BCF yarn, the continuous side-by-side bi-component filament yarn is gradually quenched, at the predetermined parameters, via, an air flow comprising: a quenching air flow temperature having a range of 10°C to 25°C, quenching air flow rate having a range of 0.1mps to 0.8mps, and quenching air flow pressure having a range of 1 mbars to 4 mbars.
The BCF yarn of claim 10, wherein, to obtain the BCF yarn, the continuous side-by-side bi-component filament yarn is applied with spin finish and thereafter sequentially drawn at the predetermined parameters comprising: a drawing speed having a range of 760mpm to 3500mpm, and a drawing temperature range having a range of 75°C to 200°C.
The BCF yarn of claim 11, wherein, to obtain the BCF yarn, the continuous side-by-side bi-component filament yarn is optionally textured at the predetermined parameters comprising: a texturing temperature range of 130°C to 200°C and a texturing vacuum pressure range of -50 mbars to -150 mbars, and the continuous side-by-side bi-component filament yarn is cooled at a cooling drum speed having a range of 10mpm to 60mpm and a cooling drum vacuum having a range of -20 mbars to -80 mbars, and
wherein, thereafter, to obtain the BCF yarn, the continuous side-by-side bi-component filament yarn is intermingled and wound.
The BCF yarn of claim 12, wherein, to obtain, the BCF yarn subsequent to the single-step continuous process, the continuous side-by-side bi-component filament yarn is cabled/twisted in a range of 40 TPM (Twist per Meter) to 350 TPM, with at least one ply to obtain the continuous side-by-side bi-component filament yarn comprising twists, and,
wherein, the continuous side-by-side bi-component filament yarn with twists is heat set in a heat setting temperature range of 85°C to 200°C to obtain a twisted heat set BCF yarn.
A method for forming a Bulked Continuous side-by-side bi-component Filament (BCF) yarn, the method comprising:
extruding the first polymer component and the second polymer component at a gradual temperature having a range of 240°C to 305°C through a plurality of temperature zones, and at a pressure range of 60 bars to 130 bars to obtain a plurality of side-by-side bi-component filaments grouped together to obtain a continuous side-by-side bi-component filament yarn, each side-by-side bi-component filament of the plurality of side-by-side bi-component filaments having,
the first polymer component forming a first side of the side-by-side bi-component filaments, wherein the first polymer component comprises polybutylene terephthalate (PBT) in at least about 25 to 75 volume percent of the filament of the BCF yarn, and

the second polymer component forming a second side of the side-by-side bi-component filaments, wherein the second polymer component comprises one of poly(ethylene terephthalate) (PET) or recycled PET or poly-lactic acid (PLA) in at least about 75 to 25 volume percent of the filament of the BCF yarn;

cabling/twisting the continuous side-by-side bi-component filament yarn in a range of 40TPM (Twist Per meter) to 350 TPM to obtain the continuous side-by-side bi-component filament yarn having twists;

heat setting the continuous side-by-side bi-component filament yarn with the twists in a range of 85°C to 200°C to obtain the BCF yarn having:
an elongation in a range of 40% to 65%, and

a Hexapod rating after 12000 cycles is more than 2.
The method of claim 14 further comprising, after extrusion of the first polymer component and the second polymer component, and prior to cabling /twisting and heat setting:
spinning the continuous side-by-side bi-component filament yarn;

gradually quenching the continuous side-by-side bi-component filament yarn via an air flow comprising a quenching air flow temperature having a range of 10 °C to 25 °C, quenching air flow rate having a range of 0.1mps to 0.8mps, and quenching air flow pressure having a range of 1 mbars to 4 mbars;

spin finishing the continuous side-by-side bi-component filament yarn;

sequentially drawing the continuous side-by-side bi-component filament yarn at a drawing speed having a range of 760mpm to 3500mpm, and a drawing temperature range having a range of 75°C to 200°C.;

optionally texturing the plurality of continuous side-by-side bi-component filament yarn at a texturing temperature range of 130°C to 200°C and a texturing vacuum pressure range of -50 mbars to -150 mbars;

cooling the continuous side-by-side bi-component filament yarn at a cooling drum speed having a range of 10rpm to 60rpm and a cooling drum vacuum having a range of -20mbars to -80mbars;

intermingling the continuous side-by-side bi-component filament yarn; and

winding the continuous side-by-side bi-component filament yarn.