CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application claims benefit to provisional application U.S. Provisional No. 62/900,677, filed September 16, 2019, the entire contents of which are incorporated herein by reference. The present application claims further benefit to provisional application U.S. Provisional No. 62/907,732, filed September 30, 2019, the entire contents of which are incorporated herein by reference.

FIELD

[0002] The field of the disclosure generally relates to synthetic fiber extrusion, and, more particularly, to yarns and carpets of random variable color aesthetic and methods of manufacture.

BACKGROUND

[0003] Synthetic extrusion of fibers to make yams for carpets has been practiced for many years, originally relying on the same technologies used in traditional wool constructions, including staple spinning into yarn, dyeing, and so forth. Broad loom carpets are often dyed in solid colors, but yarn dyeing continues for designer rugs and carpets. Originally following the wool process for making carpets of staple fiber, synthetic fibers have transitioned away from short length crimped (staple) fibers to bulked continuous filament (BCF) synthetic fibers, avoiding the staple spinning step and ultimately making a more durable carpet. BCF then began to be extruded with dyes and pigments included, along with stain and soil repellent compositions, making durable and attractive colored fabrics more affordable. [0004] There are several techniques available to achieve attractive color designs with multifilament yam in carpets. As examples, small lot Yam Dyeing, Space Dying (intermittently spray-dyed yarn) and Air Entanglement of colored fibers, can produce coloring effects in almost infinite combinations. Residential carpet mills create “heathered” aesthetics of colored air entangled yams, which are currently on trend and significant for sales velocity when used in high design styles, and space dying remains the primary method to deliver small scale color variation today. However, both processes, space-dyeing and heathering, engender significant processing costs, which hinder a designer’s ability to fully embrace the wide variety of alternatives for color.

[0005] Conventional methods to impart aesthetic effects along the fiber typically require post processing steps (space dye, slubbing, etc.), see for example US5307616 or EP1364084. Other attempts have been made to vary “color” along the yarn end but have not been applied effectively to individual fibers on the spinning faceplate. Producer colored yams, which are synthetic fibers formed from a melt comprised of polymer(s), pigments, dyes, and additives, have thus far not been made successfully in a single production step with the level and kind of variation needed for creative fabric design.

[0006] Premium performance carpets are also restricted in their application of space dyed fiber owing to the performance limitations of dyed yarns compared to melt spun solution dyed BCF yarns where the color is melted into the polymer fiber. Consequently, designers today are unable to deliver high- style multicolor heathered designs at an appropriate price point for some of the more demanding applications. The present disclosure seeks to address this problem. SUMMARY

[0007] In an aspect of the disclosure, there is provided a yam comprising: i) a first continuous filament fiber produced by a method comprising: (a) extruding molten polymer through an orifice; (b) quenching the extruded molten polymer to form at least one fiber; (c) drawing said fiber; and (d) winding said fiber into a package, whereby the rate of polymer extrusion through the orifice in (a) is increased and decreased to create variation in filament denier along the length of the first continuous filament fiber, and (ii) a second continuous filament fiber different from the first continuous filament fiber.

BRIEF DESCRIPTION OF THE FIGURES

[0008] The present disclosure is described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present disclosure.

[0009] Figure 1 illustrates a carpet made with a plurality of colors and including a plurality of bands made with yams in accordance with aspects of the present disclosure and another band made with conventional yarn.

[00010] Figure 2 illustrates a cut pile carpet made with a plurality of colors and having one band made with yarn in accordance with aspects of the present disclosure and another band made with conventional yarn.

[00011] Figure 3 illustrates a loop pile carpet made with a plurality of colors and having one band made with yarn in accordance with aspects of the present disclosure and another band made with conventional yarn.

[00012] Figure 4 is a graph illustrating denier changes at various extmsion pump settings in accordance with aspects of the present disclosure. [00013] Figure 5 is a graph illustrating yam bulk changes at various extrusion pump speed settings in accordance with aspects of the present disclosure.

[00014] Figure 6 is a graph illustrating filament cross-section changes at various extrusion pump speed settings in accordance with aspects of the present disclosure. [00015] Figure 7 is a graph illustrating the relationship between actual pump speed and pump speed setting in accordance with aspects of the present disclosure when the pump is set to cycle between operation at a speed of 3100 rpm and operation at a speed of 7500 rpm at one second intervals.

[00016] Figure 8 is a graph illustrating settings the relationship between actual pump speed and pump speed setting in accordance with aspects of the present disclosure when the pump is set to cycle between operation at a speed of 3100 rpm and operation at a speed of 7500 rpm at three second intervals.

DETAILED DESCRIPTION

[00017] The present disclosure describes yams, and processes for making the same, comprising continuous filaments with variable filament properties useful for creating carpets with novel aesthetics. In particular, the present disclosure provides a yam including (i) a first continuous filament fiber and (ii) a second continuous filament fiber different from the first continuous filament fiber (i), wherein the fiber (i) is produced by a method comprising: (a) extruding molten polymer through an orifice; (b) quenching the extruded molten polymer to form at least one fiber; (c) drawing said fiber; and (d) winding said fiber into a package, wherein the rate of polymer extmsion through the orifice in (a) is increased and decreased to create variation in filament denier along the length of the first continuous filament fiber. The disclosure is especially useful for designs comprising producer colored yarns for which yam space dyeing is either impractical or undesirable. [00018] In embodiments, processes disclosed herein involve varying a rate of polymer extrusion flow with time, thereby causing a denier (thickness) of an extruded fiber to oscillate between small and large along its length, while maintaining a constant polymer flow from the extruder. When combined with different fibers, either with or without denier oscillation, the fibers produced by the present process provide yams exhibiting a unique aesthetic effect in a carpet by breaking up a carpet uniformity typically associated with cabled yams. Moreover, because the desired color and variation are both imparted during fiber extrusion, yam processing after spinning, as required by conventional techniques, becomes optional. In this way, the fibers of the present disclosure enable a wide range of color designs never before possible with solution dyed fibers. Furthermore, different combinations of conventional fibers with the fibers of the inventive process can also create a wide variety of carpet aesthetics.

[00019] In embodiments, variations in an output of a spinning pump impart a primary physical property of the denier oscillating (changing) along the fiber length. Additionally, secondary fiber properties along the fiber length, including changes in a cross-sectional shape of the fiber, a bulk of the fiber, and a color depth of the fiber along a length of the fiber in concert with the denier variation, are also affected by the denier variation. In this way, the primary fiber property measured for control using the processes described herein is fiber denier. However, the standard fiber property measurements also quantify fiber properties along the fiber.

[00020] Useful effects of oscillating denier along the fiber length include variations of color intensity in the yarn, variations of fiber color prominence in processed yarns, e.g., as seen in a carpet, and variable color patterns or streaks. In embodiments, the fiber with the oscillating denier can combined with other variable fibers of the same type, or mixed with uniform fibers, or mixed with variable fibers having a different shape or period of variation, for different desired aesthetics. In this way, aspects of the disclosure provide a novel approach for achieving unique yam and fabric aesthetics which cannot be obtained by conventional techniques. Accordingly, fibers with variations in denier, cross-section, bulk, and color depth allow for a higher level of creativity in fabric design, with a lower cost and improved performance over methods currently utilized. These property variations are exploitable to create unique aesthetics, depending how the subject fibers are employed. Advantageously, once combined with other fibers and made into a carpet, the deliberate variation of the fiber and properties of the yam implementing the fiber affects the appearance of the carpet to a surprising degree.

[00021] The processes of the present disclosure involve varying a mnning speed of spinning pumps of a continuous filament spinning process at various amplitudes (percentage of standard speed) and frequencies during a spinning process to introduce periodic property variations along the fiber length. In embodiments, the fiber is formed from a melt-spinnable polymer. Examples of suitable melt-spinnable polymers include polyamides, polyesters, and olefins, amongst other examples. In embodiments, the melt- spinnable polymer is melted and extruded by at least one spinning pump through a spinneret having at least one orifice. In this way, a positive displacement melt extrusion spinning pump forces the polymer melt through spinnerets to form the filaments.

[00022] To create the desirable variations in denier, cross-section, bulk, and color depth, the processes described herein cycle a mnning speed, e.g., revolutions per minute (rpm), of at least one spinning pump used in the extrusion of the polymer melt. Specifically, in the processes of the subject disclosure, it has been discovered that imposing amplitude changes, i.e., mnning speed variations, at certain intervals imparts distinguishable property differences in the fiber and the yarn implementing the fiber. In this way, the disclosed processes involve cycling meter spinning pumps at various amplitudes, i.e., a percentage of standard speed, and frequencies during the spinning process to introduce at least one of a sinusoidal pattern property variation, a cyclic pattern property variation, and a square pattern property variation, and along the fiber length. In this way, an increase and decrease in polymer extrusion rate varies in a regular pattern including at least one of a cyclic; a sinusoidal; and a square.

[00023] In embodiments, a throughput of one spinning pump position is balanced against a throughput of another spinning pump position to maintain a constant output of the two spinning pumps. In further embodiments, the balancing is extended to permit variation at a positional level, with a changing of an extrusion rate at one spinning position in the opposite sense of its neighboring spinning pump, while maintaining constancy of a total flow rate at the melt extruder feeding both positions. In this way, constant extruder throughput ensures that extruder pressures, temperatures, pigment additions, viscosities, etc., remain constant to maintain polymer uniformity and relatively good spinning efficiencies. Thus, along-end property variations may be affected while maintaining constant throughput from the spinning machine and/or position.

[00024] In embodiments, the increase and decrease in a period of the polymer flow extrusion rate is irregular. In this way, the period of the polymer flow rate increase and decrease is irregular. In further embodiments, the changing of the polymer flow extrusion rate occurs in random and set interval breaks. In even further embodiments, the changing of the polymer flow extrusion rate occurs with respect to complex wave functions.

[00025] Examples of running speed variations include increasing and decreasing the polymer flow rate by a magnitude greater than ± 15% of an average or an initial polymer extrusion flow rate of the polymer melt. In this way, an increase and decrease in the rate of polymer extrusion is greater than plus 15% and minus 15%, respectively, of an average polymer extrusion flow rate. In embodiments, aspects of the present disclosure achieve a fiber having denier variation along a length of the fiber of at least plus 10% and minus 10% within a fiber length of 2000 meters. In this way, first continuous filament fiber has a denier variation along its length of at least plus 10% and minus 10% within a fiber length of 2000 meters.

[00026] In another example, running speed variations include a change of ± 20% or more in running speed. In a specific example, aspects of the present disclosure achieve a BCF fiber having denier variation along a length of the BCF fiber of at least plus 20% and minus 20% within a fiber length of 4000 meters. In this way, a first continuous filament fiber has a denier variation along its length of at least plus 20% and minus 20% within a fiber length of 4000 meters.

[00027] In a further example, a running speed variation of ± 25% or more is observable when the fiber is cabled into yarn and converted into a carpet fabric. In another example, a running speed variation includes increasing and decreasing the polymer extrusion flow rate by a magnitude greater than ± 30%. In this way, an increase and decrease in the rate of polymer extrusion is greater than plus 30% and minus 30%, respectively, of the average polymer extrusion rate. In embodiments, variations in running speed of about ± 30-40%, or even ± 50% or more, are aesthetically interesting.

[00028] In addition to running speed variations, the rate (frequency) at which the spinning pump rate (rpm amplitude) changes further determines a number and degree of property variations along a given fiber length. In one non-limiting example, the amplitudes of the spinning pumps are varied by ± 30% and ± 50% at 1-3 second cycles (or frequencies of 0.33-1 Hz). In embodiments, an improved cycling effect was obtained with higher amplitude variation and cycling at < 1 Hz.

[00029] The following examples illustrate that for spinning machines having typical polymer configurations, i.e., pressure and hold up volume from pump to spinneret, the following settings are effective in the processes of the disclosure for creating fibers, yams and articles of aesthetic interest. As an example, a change in spinning speed in a range of ± 30-50% and at a cycle of two through three seconds allows for a broad fiber. In embodiments, the color of this broad fiber is a mid-dark color. As another example, a change in spinning speed in a range of ± 35-45% at a cycle of two through three seconds also allows for a medium sample. In embodiments, the color of this medium fiber is mid dark color. As another example, a change in spinning speed of ± 40% at a cycle of three seconds allows for a preferred fiber. In embodiments, the color of the preferred fiber is a dark variant color. In further embodiments, to achieve desired aesthetics in an article, such as a carpet, where all the fibers are of the same color, for example grey, it is preferred that the fibers having the denier variation are of a relatively darker shade of the desired color, while the other fibers without denier variation are relatively of a lighter shade of the color. Using the CIELAB color shade scale, it is preferred there is a difference in the L* values between the fibers having denier variation and the homogeneous fibers of at least 7, preferably 7 to 10.

[00030] In embodiments, the spinning pumps of the present disclosure are synchronized via programing code so that an overall spinning machine throughput remains constant, thereby preventing interruption in the polymer melt extrusion process. In this way, the overall spinning machine throughput remains constant because of the synchronization of spinning pumps via programing code. This maintains consistency in the extrusion process and in a face-plate draw-bulk process for optimal process continuity with maximum variation in secondary yarn properties, i.e., bulk, cross-section, and color depth. Additionally, face-plate processes of finish application, drawing, heating, bulk texturizing, interlace formation and winding remain essentially constant. Together, these process elements being constant propagates variation in the secondary property effects, i.e., bulk, cross-section, color depth, and minimizes process interruptions.

[00031] Following melt extrusion and spinning, the filaments are quenched by flowing air and then finished with a lubricating oil or mixture of oils, for example. The filaments are then processed, including but not limited to cabled, air entangled, or air twisted, with other fibers to give yarns having a variety of aesthetic appearances not achievable by simple conventional methods. In embodiments, a yarn includes a first continuous filament fiber produced by extruding molten polymer through an orifice, quenching the extruded molten polymer to form at least one fiber, drawing said fiber, and winding said fiber into a package. In further embodiments, a rate of polymer extrusion through the orifice is increased and decreased to create variation in filament denier along the length of first continuous filament the fiber. In even further embodiments, the yam includes a second continuous filament fiber different from the first continuous filament fiber.

[00032] In embodiments, tonal aesthetics can be achieved where the desired subtle variations can be perceived within a room-sized carpet. Fiber from the inventive processes can be used independently; in phase, out of phase, or randomly paired with another modified fiber; or in conjunction with fiber from standard, uniform production to affect the degree of variation in the final article, e.g., carpet. Moreover, combining fiber produced in this manner invites creative design based on combinations of dominant and recessive colors allowing multiple design aesthetics. In embodiments, the processes described herein include an additional bulk texturing step after the drawing step and before a winding step. In this way, a first continuous filament fiber is produced by a method which includes a bulk texturing step after the drawing step and before the winding step (d).

[00033] Figures 1-3 illustrate examples of the color contrast carpet samples showing how various fiber combinations of the disclosed processes appear by cabling with other fibers of the disclosed process, and with homogenous fibers, and then tufted into carpets. [00034] Referring to Figure 1, a carpet is shown having four bands of yam indicated by the numerals 1-4 in Figure 1. In embodiments, bands 1, 2, and 4 illustrate yams created using the novel fiber with changing (oscillating) denier described herein, while band 3 illustrates a control yarn made from a fiber without an oscillating denier. Specifically, band 1 illustrates a carpet made with inventive fibers having the denier variation. Band 2 illustrates a carpet made from a standard fiber and the inventive fiber with denier variation. In one example, the standard fiber is an alabaster color, while the denier variation fiber with denier variation is another color. In this way, the second continuous filament fiber has a different variation in filament denier along its length as compared with the first continuous filament fiber.

[00035] Band 3 illustrates a control carpet made from two fibers without denier variation. Band 4 illustrates a carpet made from the inventive fiber with denier variation and a homogeneous fiber without denier variation. In one example, the inventive fiber with denier variation is an alabaster color, while the homogeneous fiber is another color. In this way, the second continuous filament fiber has a homogenous filament denier along its length.

[00036] Referring to Figure 2, a cut pile carpet is shown having two bands of yarn indicated by the numerals la and 2a. In embodiments, the cut pile carpet is made from fibers having two colors/barber pole, such as a lighter color and a darker color. In band la, the cut pile carpet is made from inventive fibers with denier variation. In embodiments, the inventive fibers are the soft pewter color. In band 2a, the cut pile carpet is a control made from two fibers without denier variation. In embodiments, one fiber without denier variation is a lighter color, while the second fiber is a darker color.

[00037] Referring to Figure 3, a loop pile carpet made from two bands of yarn indicated by the numerals lb and 2ab. In embodiments, the loop pile carpet is made from fibers having two colors/barber pole, such as a lighter and a darker color. In band lb, the cut pile carpet is made from inventive fibers with denier variation. In embodiments, the inventive fibers are the soft pewter color. In band 2b, the loop pile carpet is a control made from two fibers without denier variation.

[00038] Figure 4 illustrates the effects of spinning pump speed variability with respect to fiber denier along the length of the fiber. In embodiments, the spinning pump speed variability settings are in a range of ± 15-40%, with increasing maxima and decreasing minima as speed variability settings increase. In one example, at ± 15% spinning pump speed change, the minimum denier is between 700 to 800, while the maximum denier is between 1100 to 1200. In another example, at ± 25% spinning pump speed change, the minimum denier is between 800 to 900, while the maximum denier is between 1200 to 1300. In a further example, at ± 40% spinning pump speed change, the minimum denier is about 600, while the maximum denier is about 1400.

[00039] Figure 5 illustrates the effects of spinning pump speed variability with respect to bulk. In embodiments, bulk can be defined by standard ASTM D4031 - 07 (2018) Standard Test Method for Bulk Properties of Textured Yarn. In embodiments, the spinning pump speed variability settings are in a range of ± 15-40%, with bulk changing more gradually. In one example, at ± 15% spinning pump speed change, the minimum bulk is between 16 to 17, while the maximum bulk is between 20 to 21. In another example, at ± 25% spinning pump speed change, the minimum bulk is between 15 to 16, while the maximum bulk is between 20 to 21. In a further example, at ± 40% spinning pump speed change, the minimum bulk is between 15 to 16, while the maximum bulk is between 20 to 21.

[00040] Figure 6 illustrates the effects of spinning pump speed variability with respect to filament cross-sections, as measured by the modification ratio, which is the ratio obtained by dividing an outer diameter of a fiber by an inner diameter of the fiber. As illustrated in Figure 6, the values of the x-axis illustrate the variation in spinning pump speed, while the y-axis represents values which correlate to the modification ratio. In embodiments, the higher the value in the y-axis, the higher the modification ratio. In an example, the higher the modification ratio, the greater the change in cross-section of the fiber. Alternatively, the lower the value in the y-axis, the lower the modification ratio, thereby resulting in a less amount of change in the cross-section of the fiber. Figure 6 shows there is a gradual increase in the variation in modification ratio as the spinning pump speed variability settings are increased from ± 15 to + 40%

[00041] Figure 7 illustrates the relationship between actual pump speed and pump speed setting when the polymer extrusion pump is set to cycle between operation at a speed of 3100 rpm and operation at a speed of 7500 rpm at 1 second intervals. In Figure 7, the square wave curve represents desired settings for changing the polymer extrusion flow rate at the spinneret, while the triangle wave illustrates the actual variation in pump speed. As shown in Figure 7, the actual settings are offset from the desired settings. Since the polymer extrusion flow rate change (amplitude) is delayed, the flow rate change is always incomplete as the spinning pump speed change happens before the polymer extrusion flow can equilibrate. In embodiments, the triangle wave illustrates that 1 second occurs between a minimum value of the triangle wave and a subsequent minimum value of the triangle wave. Alternatively, 1 second occurs between a maximum value of the triangle wave and a subsequent maximum value of the triangle wave.

[00042] Figure 8 illustrates the relationship between actual pump speed and pump speed setting when the polymer extrusion pump is set to cycle between operation at a speed of 3100 rpm and operation at a speed of 7500 rpm at 3 second intervals. Again, the square wave curve represents desired settings for changing the polymer extrusion flow rate at the spinneret, while the triangle wave illustrates the actual variation in pump speed. It will be seen that, with the pump and spinneret combination employed in this embodiment, there is better correlation between pump speed setting and actual pump speed variation when the setting is varied at 3 second intervals.

[00043] While the illustrative embodiments of the disclosure have been described with particularity, it will be understood that various other modifications will be apparent to and may be readily made by those skilled in the art without departing from the spirit and scope of the disclosure. Accordingly, it is not intended that the scope of the claims hereof be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present disclosure, including all features which would be treated as equivalents thereof by those skilled in the art to which the disclosure pertains.