Processes to dye and treat bcf yarn

Abstract

Disclosed are processes for applying dyes, stain blocker and anti-soil compositions on BCF yarns during cable or air twisting processes, or heat setting processes, prior to weaving, knitting or tufting. Further discloses are process for applying dyes, stain blocker and anti-soil compositions on BCF yarns prior to heat setting. The processes forego the need to dye and otherwise treat carpets and other textiles made from the BCF yarn using current methods. Also disclosed are systems, BCF yarns, and carpets made from the BCF yarn treated by the disclosed process.

1 . A process for treating twisted bulked continuous filament (BCF) yarn with a dye composition comprising:
 a. providing twisted BCF yarn;   b. winding said BCF yarn on a take-up reel; and   c. contacting said BCF yarn with said dye composition while said BCF yarn is in motion and prior to said BCF yarn contacting and winding up on said take-up reel   wherein said BCF yarn is selected from the group consisting of cationic dyeable nylon and polyester.   
     
     
         2 . The process of  claim 1 , further comprising heat setting said BCF yarn after contacting said BCF yarn with said dye composition. 
     
     
         3 . The process of  claim 1 , wherein said dye composition comprises one or more acid dye components. 
     
     
         4 . The process of  claim 1 , wherein said dye composition comprises one or more disperse dye components. 
     
     
         5 . The process of  claim 1 , wherein said dye composition comprises at least one performance enhancing composition. 
     
     
         6 . A process for treating twisted BCF yarn with a dye composition and at least one performance enhancing composition comprising:
 a. providing twisted BCF yarn;   b. winding said BCF yarn on a take-up reel;   c. contacting said BCF yarn with said dye composition; and   d. contacting said BCF yarn with a performance enhancing composition prior to said BCF yarn contacting and winding up on said take-up reel, wherein said BCF yarn is in motion while contacted with said dye composition and said first performance enhancing composition.   
     
     
         7 . The process of  claim 6 , wherein said performance enhancing composition excludes an anti-soil component. 
     
     
         8 . The process of  claim 6 , wherein said first performance enhancing composition comprises an anti-stain component. 
     
     
         9 . The process of  claim 6 , wherein said first performance enhancing composition comprises both an anti-stain component and an anti-soil component. 
     
     
         10 . The process of  claim 6  further comprising contacting said BCF yarn with a second performance enhancing composition after contacting with said first performance enhancing composition and prior to said BCF yarn contacting and winding up on said take-up reel. 
     
     
         11 . The process of  claim 10 , wherein said first performance enhancing composition comprises an anti-stain component and said second performance enhancing composition comprises an anti-soil component. 
     
     
         12 . The process of  claim 6  further comprising heat setting said BCF yarn after contacting said BCF yarn with said first performance enhancing composition. 
     
     
         13 . The process of  claim 10  further comprising heat setting said BCF yarn after contacting said BCF yarn with said second performance enhancing composition. 
     
     
         14 . The process of  claim 8 , wherein said anti-stain component is one or more selected from the group consisting of: syntans, sulfonated novolacs, sulfonated aromatic aldehyde condensation products (SACs) and/or reaction products of formaldehyde, phenolics, substituted phenolics, thiophenolics, sulfones, substituted sulfones, polymers or copolymers of olefins, branched olefins, cyclic olefins, sulfonated olefins, acrylates, methacrylates, maleic anyhydride, and organosulfonic acids. 
     
     
         15 . The process of  claim 7 , wherein said anti-soil component is selected from the group consisting of fluorochemicals, silicones, silsesquioxanes, silane-modified particulates, organosilane-modified particulates, alkylated particulates, anionic non-fluorinated surfactants, and anionic hydrotrope non-fluorinated surfactants. 
     
     
         16 . The process of  claim 15 , wherein said fluorochemical is selected from the group consisting of: fluorochemical allophanates, fluorochemical polyacrylates, fluorochemical urethanes, fluorochemical carbodiimides, fluorochemical guanidines, and fluorochemicals incorporating C2 to C8 chemistries. 
     
     
         17 . The process of  claim 15 , wherein said fluorochemical has one or more monomeric repeat units bearing less than or equal to six perfluorinated carbons. 
     
     
         18 . The process of  claim 15 , wherein said fluorochemical is a fluorochemical urethane. 
     
     
         19 . The process of one of  claim 8 , wherein said anti-stain component is present at an on weight of fiber from about 500 ppm to about 4%. 
     
     
         20 . The process of  claim 1 , wherein said dye composition has a pH from about 4 to about 9.0. 
     
     
         21 . The process of  claim 6 , wherein said first performance enhancing composition comprises a component selected from the group consisting of: odor control agents, anti-microbial agents, anti-fungal agents, fragrance agents, bleach resist agents, softeners, and UV stabilizers. 
     
     
         22 . The process of  claim 6 , wherein said first performance enhancing composition comprises a component selected from the group consisting of: dye auxiliaries, sequestrants, pH control agents, and surfactants. 
     
     
         23 . The process of one of  claim 7 , wherein said anti-soil component is present at an on weight of fiber from about 100 ppm elemental fluorine to about 1000 ppm elemental fluorine. 
     
     
         24 . The process of  claim 2 , wherein said heat setting is performed at a temperature from about 125° C. to about 200° C. 
     
     
         25 . The process of  claim 1 , wherein said polyester fiber is selected from the group consisting of poly(ethylene terephthalate), poly(propylene terephthalate), polybutylene terephthalate), copolymers, and blends thereof. 
     
     
         26 . The process of  claim 1 , wherein said BCF yarn comprises a polyamide component and a polyester component. 
     
     
         27 . The process of, wherein said contacting is performed by a device selected from the group consisting of: applicator pad, wet-wick, dip-tank, sprayer, and mister.