Processes to dye and treat single bcf yarn

Abstract

Disclosed are processes for applying dyes, optional stain blocker and anti-soil compositions on single BCF yarns during rewinding, prior to twisting, weaving, knitting or tufting. 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 single BCF yarn with a dye composition comprising:
 a. providing single BCF yarn;   b. winding said BCF yarn on a rewind package; 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 rewind package.   
     
     
         2 . The process of  claim 1 , further comprising heat setting said BCF yarn after contacting said BCF yarn with said dye composition and prior to winding up on said rewind package. 
     
     
         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 single BCF yarn;   b. winding said BCF yarn on a rewind package;   c. contacting said BCF yarn with said dye composition;   d. optionally contacting said BCF yarn with a first performance enhancing composition; and   e. contacting said BCF yarn with a second performance enhancing composition prior to said BCF yarn contacting and winding up on said rewind package, wherein said BCF yarn is in motion while contacted with said dye composition; said optional first performance enhancing composition; and said second performance enhancing composition.   
     
     
         7 . The process of  claim 6 , wherein said second performance enhancing composition comprises 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 second performance enhancing composition comprises both an anti-stain component and an anti-soil component. 
     
     
         10 . The process of  claim 6 , wherein said first performance enhancing composition comprises an anti-stain component and said second performance enhancing composition comprises an anti-soil component. 
     
     
         11 . The process of  claim 6  further comprising heat setting said BCF yarn after contacting said BCF yarn with said second performance enhancing composition. 
     
     
         12 . 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. 
     
     
         13 . 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. 
     
     
         14 . The process of  claim 13 , 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. 
     
     
         15 . The process of  claim 13 , wherein said fluorochemical has less than or equal to six fluorinated carbons. 
     
     
         16 . The process of  claim 13 , wherein said fluorochemical is a fluorochemical urethane. 
     
     
         17 . The process  claim 8 , wherein said anti-stain component is present at an on weight of fiber from about 500 ppm to about 4%. 
     
     
         18 . The process of  claim 1 , wherein said dye composition has a pH from about 4 to about 9. 
     
     
         19 . The process of  claim 6 , wherein said second 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. 
     
     
         20 . The process of  claim 6 , wherein said second performance enhancing composition comprises a component selected from the group consisting of: dye auxiliaries, sequestrants, pH control agents, and surfactants. 
     
     
         21 . The process of  claim 7 , wherein said anti-soil component comprises fluorine present at an on weight of fiber from about 100 ppm elemental fluorine to about 1000 ppm elemental fluorine. 
     
     
         22 . The process of  claim 2 , wherein said heat setting is performed at a temperature from about 125° C. to about 200° C. 
     
     
         23 . The process of  claim 1 , wherein said BCF yarn comprises polyamide fiber. 
     
     
         24 . The process of  claim 23 , wherein said polyamide fiber is selected from the group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof. 
     
     
         25 . The process of  claim 1 , wherein said BCF yarn comprises polyester fiber. 
     
     
         26 . The process of  claim 25 , wherein said polyester fiber is selected from the group consisting of polyethylene terephthalate), poly(propylene terephthalate), poly(butylene terephthalate), copolymers, and blends thereof. 
     
     
         27 . The process of  claim 1 , wherein said BCF yarn comprises a polyamide component and a polyester component. 
     
     
         28 . The process of  claim 1 , wherein said contacting is performed by a device selected from the group consisting of: applicator pad, wet-wick, nip-roller, dip-tank, sprayer, and mister. 
     
     
         29 . An untufted, single BCF yarn comprising a dye component, wherein said dye component is present on said untufted, single BCF yarn. 
     
     
         30 . The untufted, single BCF yarn of  claim 29  further comprising an anti-soil component, wherein said anti-soil component is present on said untufted, single BCF yarn. 
     
     
         31 . The untufted, single BCF yarn of  claim 29  further comprising an anti-stain component, wherein said anti-stain component is present on said untufted, single BCF yarn. 
     
     
         32 . The untufted, single BCF yarn of  claim 31 , 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. 
     
     
         33 . The untufted, single BCF yarn of  claim 30 , wherein said anti-soil component 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. 
     
     
         34 . The untufted, single BCF yarn of  claim 33 , 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. 
     
     
         35 . The untufted, single BCF yarn of  claim 33 , 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. 
     
     
         36 . The untufted, single BCF yarn of  claim 29 , wherein said BCF yarn comprises polyamide fiber. 
     
     
         37 . The untufted, single BCF yarn of  claim 36 , wherein said polyamide fiber is selected from the group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof. 
     
     
         38 . The untufted, single BCF yarn of  claim 29 , wherein said BCF yarn comprises a polyamide component and a polyester component. 
     
     
         39 . The untufted, single BCF yarn of  claim 29 , wherein said BCF yarn comprises polyester fiber. 
     
     
         40 . The untufted, single BCF yarn of  claim 39 , wherein said polyester fiber is selected from the group consisting of: poly(ethylene terephthalate), poly(propylene terephthalate), poly(butylene terephthalate), copolymers, and blends thereof. 
     
     
         41 . A carpet comprising single BCF yarn, wherein said single BCF yarn comprises the single BCF yarn from  claim 31  that has been tufted. 
     
     
         42 . The carpet of  claim 41  having an AATCC 175-2003 Test rating of at least 7. 
     
     
         43 . A process for manufacturing carpet comprising:
 a. providing an untufted, single BCF yarn comprising a dye component and at least one optional performance enhancing composition present on a surface of said untufted, twisted BCF yarn;   b. tufting said BCF yarn; and   c. weaving said tufted BCF yarn into said carpet, wherein said process foregoes the need to further dye or treat said carpet with dyes and performance enhancing compositions.   
     
     
         44 . The process of  claim 43 , wherein said untufted, single BCF yarn comprises polyamide fiber. 
     
     
         45 . The process of  claim 44 , wherein said polyamide fiber is selected from the group consisting of: nylon 6,6, nylon 6, nylon 4,6, nylon 6,10, nylon 10,10, nylon 12, its copolymers, and blends thereof. 
     
     
         46 . The process of  claim 43 , wherein said untufted, single BCF yarn comprises polyester fiber. 
     
     
         47 . The process of  claim 46 , wherein said polyester fiber is selected from the group consisting of: poly(ethylene terephthalate), poly(propylene terephthalate), poly(butylene terephthalate), copolymers, and blends thereof. 
     
     
         48 . A system for applying a dye composition to single BCF yarn comprising:
 a. a yarn package that transmits a single yarn member;   b. a dye composition applicator disposed downstream of said yarn package that applies said dye composition to said single yarn member; and   c. a rewind package that receives a dyed single yarn member.   
     
     
         49 . A system for applying a dye composition and at least one performance enhancing composition to single BCF yarn comprising:
 a. a yarn package that transmits a single yarn member;   b. a dye composition applicator disposed downstream of said yarn package that applies said dye composition to said single yarn member;   c. an optional first performance enhancing composition applicator disposed downstream of said dye composition applicator,   d. a second performance enhancing composition applicator disposed downstream of said optional first performance enhancing composition applicator; and   e. a rewind package disposed downstream of said second performance enhancing composition applicator that receives a dyed single yarn member.