Carpet yarns and carpets with improved balance of newness retention and bulk

Bulked continuous filament carpet yarns having high levels of bulk are disclosed. When ply-twisted together at unusually high twist levels and tufted into carpets, such yarns produce cut-pile carpets having a superior balance of carpet bulk and newness retention when compared to carpets of identical construction made with yarns having conventional levels of yarn bulk and/or twist.

TECHNICAL FIELD 
The present invention relates to highly bulked continuous filament yarns 
which can be ply-twisted together at high-twist levels and tufted into 
cut-pile carpets which exhibit a superior balance of newness retention and 
carpet bulk. 
BACKGROUND OF THE INVENTION 
The great majority of residential carpets sold in the United States use 
synthetic polymeric pile yarns in a construction known as saxony. Two or 
more nylon, polyester, or polypropylene crimped "singles" yarns are 
twisted together and set in the ply-twisted configuration either in 
saturated steam or in dry heat, and such twisted yarns are tufted into a 
primary carpet backing and cut to form a cut-pile. The carpet is then dyed 
in an aqueous bath near 100.degree. C. or on a continuous dye range, 
rinsed and dried. A latex adhesive is applied to the underside of all 
tufted carpets to retain the tufts in position, and the tufts are then 
sheared to a uniform pile height. 
Cut-pile saxony carpets made from synthetic fibers have excellent bulk and 
durability versus similar carpets made from natural fibers such as wool. 
Carpet yarns comprised of synthetic fibers typically have higher bulk than 
carpet yarns comprised of natural fibers, making it possible to produce 
carpets from synthetic fibers having higher bulk at lower face weight than 
carpets made from natural fibers. 
In a new cut-pile saxony carpet, each ply-twisted yarn is seen as an 
individual tuft, and the tufts are said to have "pencil point" or "pin 
point" definition. However, as the carpet becomes worn, the plied yarn 
components begin to untwist and the individual filaments in each yarn 
separate from the bundle and intermingle with those from neighboring 
tufts. As this process progresses, the tufts are no longer seen as 
individuals and the surface of the carpet takes on a matted appearance. 
The contrast between a high-traffic, matted portion of a carpet and a 
low-traffic portion (near furniture, for example) which has retained its 
tuft definition, becomes undesirable. Therefore, appearance or newness 
retention is a carpet property on which consumers place considerable value 
in that carpets with poor wear properties must be replaced more 
frequently. 
Several methods for improving the wear properties of carpets have been 
disclosed in the art. Hatt U.S. Pat. No. 3,900,623 describes carpets 
having a cut-pile in which the filaments in the tufts become unwound and 
entangled at the tips to form strong coherent tufts. Wilkie & Talley U.S. 
Pat. Nos. 4,839,211 and 4,882,222 disclose saxony carpets made from blends 
of conventional and high shrinkage fibers which have improved appearance 
retention properties when compared to saxony carpets of the same 
construction without the high shrinkage fibers. The use of heat-activated 
binder fibers in carpet yarns to improve retention of tuft identity is 
disclosed in the published patent applications Sekiya JP Kokai 60-224,831, 
Hackler PCT-WO 88/03969, and Watt & Fowler GB 2205116-A. The binder fibers 
melt during twist-setting or latexing operations and bond the filaments of 
the yarn together, resulting in improved twist retention and enhanced wear 
properties. Hackler, U.S. Pat. No. 4,871,604 describes carpets in which 
the pile yarn has been coated with a heat-activated binder fiber powder 
resulting in improved wear performance. Binder fibers and binder powders, 
however, tend to give the finished carpet an undesirably harsh hand. 
Appearance retention and bulk in conventional cut-pile carpets are related 
to various yarn properties and carpet construction parameters, the most 
important of these being the yarn modification ratio, yarn bulk, denier 
per filament (dpf), total yarn denier, degree of ply twist, carpet pile 
height and pile weight. Other variables that may affect carpet appearance 
retention include dyeing method, heatsetting method, type of backing, and 
whether or not padding is used under the installed carpet. Hollow-filament 
yarns of rectangular-shaped cross-sections which have yarn bulk values as 
high as 30-35 are made and used for commercial carpet constructions which 
are characterized by having high pile densities (greater than 4000 
oz/yd.sup.3), where pile density is calculated by dividing the weight of 
the carpet in ounces per square yard by the pile height measured in 
inches, and multiplying by 36. Such yarns are not suitable for cut-pile 
residential carpets, however, where pile densities are typically much 
lower (less than 3600 oz/yd.sup.3). Yarn bulk values (% bulk crimp 
elongation, as measured and described hereinafter) for trilobal 
cross-section yarns used in residential cut-pile carpets have not exceeded 
20-25 because, typically, initial appearance is poor and as yarn bulk or 
carpet bulk increases, newness retention decreases. For these reasons, no 
effort has been made to produce yarns having extremely high bulk values 
which are suitable for use in residential cut-pile carpets. 
One method for improving newness retention is to increase ply twist levels. 
However, with current carpet yarns, increasing the ply twist to high 
levels results in a significant reduction in carpet bulk, giving the 
carpet a "lean" appearance and undesirable hand, thus requiring 
significantly increased pile weight in order to obtain an aesthetically 
acceptable carpet. 
The current invention provides carpet yarns having new levels of high bulk 
which when ply-twisted at high twist levels and tufted into cut-pile 
saxony carpets yield carpets having an improved balance of bulk and 
appearance retention versus prior art carpets of equal carpet 
construction. While addition of high twist is known to reduce carpet bulk 
and improve appearance retention proportionately, we have found that high 
bulk yarns, while they also lose bulk and gain newness retention upon 
twisting, achieve a better balance of bulk and newness retention than 
lower bulk conventional yarns. Thus, the current invention involves carpet 
yarns having new, high levels of bulk ply-twisted together at unusually 
high twist levels. Carpets tufted from such yarns surprisingly exhibit an 
improved and high level of newness retention and bulk when compared with 
carpets of equal construction made with yarns of conventional bulk and 
twist levels. 
SUMMARY OF THE INVENTION 
The high bulk yarns of the present invention include bulked continuous 
filament nylon yarns comprised of filaments having a denier per filament 
of 10-25 and a trilobal filament cross-section of modification ratio 
between 1.4 and 4.0, the yarn having a relationship between bulk level and 
modification ratio corresponding to a point above line A on FIG. 1. They 
further include bulked continuous filament nylon yarns, irrespective of 
filament cross-section, which have a yarn bulk level of at least 35. 
The ply-twisted yarns of this invention include ply-twisted yarns comprised 
of two to four bulked continuous filament nylon ply yarns each having a 
denier per filament of 10-25 and a trilobal filament cross-section of 
modification ratio between 1.4 and 4.0 wherein the relationship between 
bulk level and modification ratio for each of the plies corresponds to a 
point above line A on FIG. 1 and wherein the relationship between twist 
level and modification ratio corresponds to a point on or above line E or, 
preferably line F, as shown on FIG. 2. Particularly useful in making 
carpets with excellent properties are those ply-twisted yarns wherein each 
ply corresponds to a point above line B or line C on FIG. 1 and where the 
relationship between twist level and modification ratio corresponds to a 
point on or above line E or, even more preferably, line F shown on FIG. 2. 
Cut-pile carpets made from these high-bulk, high-twist yarns exhibit a 
superior combination of newness retention and carpet bulk when compared to 
carpets of the same construction having conventional levels of bulk and/or 
twist. These properties are observed in carpets throughout the entire 
range of pile weights typically used in residential applications, i.e. 
from very low weights such as 20 oz/yd.sup.2 (0.68 kg/m.sup.2) up through 
"upper end" constructions having 50 oz/yd.sup.2 (1.70 kg/m.sup.2) or more. 
Similarly, such properties are found in cut-pile constructions having pile 
heights of 7/16 inch (1.11 cm) or more. 
While the figures and examples discussed hereinafter relate to nylon 6,6 
yarns and carpets, other polymers useful in residential carpet 
applications, notably other nylons such as nylon 6 and nylon copolymers, 
polyester, polypropylene and their copolymers may similarly be used. 
Appropriate adjustments would, of course, be required for the bulk levels 
and newness retention values shown in these figures.

DETAILED DESCRIPTION 
The carpet yarns of the current invention have bulk levels higher than 
those previously available in the art. The relationship between bulk level 
and modification ratio (MR) for the trilobal yarns of the invention is 
detailed in FIG. 1. The bulk levels were measured using the process of 
Robinson & Thompson, U.S. Pat. No. 4,295,252 which is described below. 
Yarns having deniers of approximately 800-2000 and denier per filament 
(dpf) of approximately 10-25 and comprised of fibers having trilobal cross 
sections with MR values of 1.4 to 4.0 are useful in the current invention. 
MR values of 1.4 to 2.8 are preferred for use in making carpets with high 
levels of newness retention. 
The area below line A depicts the range of bulk levels for typical trilobal 
residential carpet yarns present in the marketplace prior to the current 
invention. As can be seen, yarn bulk level tends to decrease as 
modification ratio increases. Line A itself, with bulk levels of 20-25, 
depending on modification ratio, represents the previous upper limit for 
bulk in trilobal carpet yarns. Hollow filament yarns having square cross 
sections, with typical bulk levels up to as high as about 30-35 have been 
used in high pile density commercial carpet constructions. The yarns of 
the current invention have bulk levels corresponding to points lying above 
line A. Lines B and C correspond to yarns of the current invention for 
different process conditions which are described more fully in the 
Examples below. 
It has been found that using two or more, though preferably two, of the 
high bulk singles yarns of the current invention and twisting them 
together at high twist levels produces ply-twist yarns which can be tufted 
into carpets having an improved balance of carpet bulk and newness 
retention over carpets of the same construction tufted from yarns of lower 
bulk and/or lower twist. The bulked yarns are ply-twisted using 
conventional methods known in the art prior to tufting into carpets. The 
degree of twist required in order to achieve the desired balance of 
properties in the tufted carpet depends on the modification ratio of the 
yarn. Typically, yarns having higher modification ratios require more 
twist in order to obtain good carpet performance. FIG. 2 is a plot of 
twist versus modification ratio. Twist levels corresponding to points on 
or above line E shown in FIG. 2 are required in order to produce the 
twisted yarns of the current invention which when tufted into cut-pile 
carpets have the desired balance of carpet bulk and newness retention. 
Twist levels corresponding to points on or above line F in FIG. 2 are 
preferred to provide carpets having superior newness retention (at least 
2.5) while still exhibiting good bulk. Twist levels of as high as 7 tpi 
(2.8 twists/cm) have been shown to produce carpets having excellent 
properties. 
While typically each yarn bundle has filaments of identical cross-section 
and two or more such identical yarns are ply-twisted together, singles 
yarns having mixed modification ratios or ply-twisted yarns made from 
singles yarns having different modification ratios are also considered to 
be within the scope of the present invention. In such cases, the 
modification ratio should be considered to be the weighted average of the 
modification ratios of all the filaments in the singles or ply-twisted 
yarn. 
A spinning and bulking apparatus useful in preparing the yarns of the 
current invention is outlined in FIG. 3. The polymer is spun at 
temperatures of from about 300.degree. C. using a spinneret assembly 1 
into a quench zone where they are rapidly quenched at 2 using cross-flow 
air (4-21.degree. C.). After quenching, the filaments are treated with 
finish by contacting finish roller 3 which is partially immersed in a 
finish trough (not shown). The yarn is then wrapped around motor-driven 
feed roll 4 and its associated separator roll 4', passed around draw pin 
assembly 5,5' and then wrapped around draw rolls 6 (internally heated to 
produce a surface temperature of from 200.degree. to 220.degree. C. and 
enclosed in a hot chest 7) and stretched to from two to four times its 
original length before entering the bulking jet 8. The yarn is crimped in 
jet 8 using air which is heated to 200-240.degree. C. and exits the jet to 
impinge upon a rotating drum 9 which has a perforated surface on which the 
yarn cools in the form of a bulky caterpillar 10 to set the crimp. Cooling 
of the yarn is facilitated by pulling a vacuum through the perforated drum 
and using a room-temperature water mist quench 11 (typically 80.+-.20 
ml/threadline/min). Chilled water may also be used for more effective 
cooling. From the drum, the threadline passes under stationary pin 
assembly 12,12' to motor-driven takeup roll 13 and its associated 
separator roll 13'. The speed of takeup roll 13 is adjusted to maintain 
the caterpillar 10 at the desired length by changing the take off point 
from the drum. The caterpillar take off point is also controlled by the 
position of pins 12. The residence time of the yarn on the bulking drum is 
controlled by the length of the caterpillar, with longer residence times 
resulting in better cooling of the yarn and higher bulk in the final yarn 
product. The yarn then proceeds to a winder where it is wound in the 
desired package configuration. 
The above conditions are useful in spinning nylon 6,6 yarns. Other 
polyamides and polymers such as polypropylene or polyester may be spun in 
a similar process, however the temperatures used will differ due to the 
different melting points of the various polymers. Other variations to the 
above-described apparatus and spinning process may be envisioned by those 
skilled in the art. 
In general, increasing hot roll and bulking air temperatures results in 
yarns having increased bulk. However, the higher the bulking temperature, 
the more difficult it is to set the crimp. It is important to cool the 
yarn sufficiently in order to achieve high bulk in the final yarn product. 
The mist quench and residence time of the yarn on the rotating drum are 
important factors determining the degree of cooling. It is possible to 
achieve higher yarn bulk levels for yarns having higher denier per 
filament (dpf). Low dpf filaments have lower crimping force and the crimp 
is more easily pulled out during the winding process. The nature of the 
finish used may also have a small effect on the bulk level obtained, with 
low-friction ethoxylated ester-type finishes tending to result in 
increased bulk. 
TEST METHODS 
Yarn bulk was measured using the method described in Robinson & Thompson 
U.S. Pat. No. 4,295,252. Unless otherwise indicated, yarn bulk levels are 
reported herein as % bulk crimp elongation (% BCE) as described in 
Robinson & Thompson. The bulk measurements were made at 11 m/min for 1.5 
minutes using a sample length of 16.5 meters. The tensioning weight used 
was 0.1 gram/denier (0.11 g/dtex). The pressure of the air in the heating 
chamber was 0.05 inches of water, and the temperature of the heating air 
was 170.+-.3.degree. C. 
An alternate method which may be used to measure yarn bulk levels is 
percent yarn crimp elongation (% YCE). This method will be particularly 
useful for polymers other than nylon 6,6 in that the properties of such 
other polymers would require temperature adjustments to the process for 
measuring % BCE as set forth in the Robinson & Thompson patent. In this 
method, each of three relaxed yarn specimens approximately 1 meter in 
length are extended manually until just taut and then coiled. 2.5 liters 
of water are placed in a 12 liter bucket and brought to an active boil. A 
brass sieve, U.S. Sieve Series No. 10 with 2.00 mm openings, Tyler 
equivalent 9 mesh, is placed into the boiling water. The yarn specimens 
are uncoiled and dropped slowly into the boiling water and left for 1-2 
minutes. The sieve is removed from the boiling water and placed in a 
bucket of cold water for 0.5 minute. The yarn samples are then removed and 
blotted gently between paper towels to remove excess moisture. The 
specimens are then placed into aluminum foil cups and dried in an oven at 
105 (.+-.5) degrees C. for 1 hour. The specimens are conditioned at 70 
(.+-.2) degrees F. (21.+-.1.degree. C.) and 65 (.+-.2) % relative humidity 
for a minimum of 2 hours before testing. The specimens are separated and 
one end of a specimen taped to the inner surface of a toggle clamp which 
is mounted 50 cm above the zero line of a vertically mounted meter stick. 
The specimen is allowed to hang freely and cut at the 55 cm mark. A small 
piece of 1/4 inch (0.64 cm) masking tape is wrapped around the yarn so 
that it coincides with the zero line on the meter stick. For yarn deniers 
below 1300 denier (1444 dtex), a 125 gram weight is used. For other 
deniers, a weight equal to 0.1 g/denier is used. The weight is clamped 
onto the yarn so that the tape tab is just inside the clamp and the weight 
lowered so that the yarn specimen just supports the total load. The 
specimen is allowed to hang for a minimum of 3 minutes and the extended 
length (specimen elongation) is measured at the top edge of the masking 
tape. The process is repeated for each of the additional specimens. The 
percent yarn crimp elongation=% YCE is calculated as (specimen 
elongation/50 cm).times.100. % YCE values are typically determined using 
the average value of the three specimens. % YCE may be converted into % 
BCE using the equation % YCE=(0.96) % BCE+4.9. 
Modification ratio is as defined and measured in Bankar et al., U.S. Pat. 
No. 4,492,731, the disclosure of which is incorporated herein by 
reference. 
Carpet bulk was measured as the compressed pile height in inches of a 
carpet sample that is loaded with a pressure of 1 lb/in.sup.2 (703 
kg/m.sup.2). The carpet sample is placed on a platform which is attached 
to a vibrator which vibrates the sample lightly for 10 seconds prior to 
measuring the pile height using a thickness gauge, which is also attached 
to the vibrating platform. The vibration allows the foot of the thickness 
gauge to settle into the surface of the carpet. 
Carpet appearance retention may be measured by subjecting a carpet to a 
specified number of human traffics and visually determining a rating based 
on the degree of matting versus a control sample. Wear tests which closely 
correlate to floor trafficking were conducted in a Vetterman drum test 
apparatus, Type KSG manufactured by Schoenberg & Co. (Baumberg, Fed. Rep. 
of Germany), according to ISO (International Standards Organization) 
document TC38/12/WG 6 N 48. As specified, the drum is lined with carpet 
samples with the pile facing inwards and contains a steel ball having 
fourteen (14) rubber buffers which rolls randomly inside the rotating 
drum. A circular brush within the drum is in light contact with the carpet 
surface and removes loose pile fibers which are continuously removed by 
suction. After 20,000 cycles, the samples are removed and inspected to 
evaluate texture retention. Texture retention is reported on a scale of 
1-5 with a rating of 5 corresponding to an untested control sample, 4 
corresponding to a lightly worn sample, 3 to a moderately worn sample, 2.5 
to the turning point from acceptable to unacceptable wear, a rating of 2 
corresponding to clearly unacceptable wear, and 1 corresponding to an 
extremely matted control sample. 
EXAMPLES 
EXAMPLES 1-3 
Nylon 6,6 polymer with 70 relative viscosity (RV) was spun at 290.degree. 
C. through a 160 hole 1.75 modification ratio (MR) spinneret at 73 lb/hr 
(33 kg/hr) throughput. The extruded filaments were separated into two 80 
filament bundles and were quenched by 300 cubic ft/min (8.5 cubic 
meters/min) of chilled cross-flow air at 48.degree. F. (9.degree. C.) in a 
chimney approximately 6 ft (1.8 m) long. The filaments were coated with a 
low-friction, ethoxylated ester-type lubricant and pulled by a rotating 
feed roll at 853 ypm (775 m/min). The two filament bundles were drawn by a 
pair of heated draw rolls operating at 2388 ypm (2171 m/min). A set of 
stainless steel draw pins was used between the feed roll and the draw 
rolls to localize the draw point. The draw rolls were heated internally by 
condensing vapor to 170.degree. C. The draw rolls serve to draw and heat 
the filament before jet/screen crimping. After making eight wraps around 
the draw rolls, each heated filament bundle was pulled by a separate 
dual-impingement bulking jet of the type described in Coon, U.S. Pat. No. 
3,525,134, where 200.degree. C., 100 psi (690 kPa) hot air was impinged on 
the filaments at a 30 degree angle to crimp and interlace the filaments. 
The crimped yarns were relaxed in a compact form (caterpillar) on a 15 in 
(0.38m) diameter perforated rotating drum at 60 rpm. The caterpillar was 
cooled by air on the bulking drum from the 11 to 1 o'clock position by 
pulling a vacuum of 10 inches of water on the drum and was then removed by 
a take-up roll at 2027 ypm (1853 m/min), and an additional lubricant was 
applied prior to winding on a package. The yarn produced in this example 
was 1220 denier (1356 dtex), 15 dpf (16.7 dtex/filament), had a 
modification ratio of 1.75 and a yarn bulk level (% BCE) of 23. 
The BCF yarn of Example 2 was similar to Example 1 except that the draw 
roll temperature was raised to 210.degree. C. The resulting yarn had a 
1.75 MR cross section and a 38.5 yarn bulk level (% BCE). 
The yarn of Example 3 was prepared in a similar process to Example 2 except 
that a 1.45 MR spinneret was used. The resulting yarn had a bulk level (% 
BCE) of 40. 
The yarns produced in Examples 1-3 were converted into two-ply cable 
twisted yarns having 3.5, 4.5, 5.5 twist per inch (1.4, 1.8, and 2.2 
twists/cm), heatset in a Superba heat-setting apparatus using saturated 
steam at 270.degree. C. and tufted into 1/8 in 0.32 cm) gauge, 9/16 in 
(1.4 cm) pile height cut-pile carpets at 28 and 34 oz/sq yd (0.95 and 1.15 
kg/m.sup.2) and 5/8 in (1.6 cm) pile height at 40 oz/sq yd (1.36 
kg/m.sup.2). The tufted carpets were then dyed by passing though a Gaston 
County/Zima Fluidyer on a continuous carpet dyeing range. The carpet 
passed first through a Pad/Wet out bath at 100.degree. F. (38.degree. C.). 
It then passed through a dyebath at 80.degree. F. (26.7.degree. C.) and a 
pH of 6. The running speed of the carpet was 5 ypm (4.5 mpm) with a 100% 
wet-out pickup and a 350% wet pickup of dye. Pad squeeze out pressure was 
45 lbs in the wet out bath, while in the Fluidyer the cushion pressure was 
0.25 bar and the air pressure brake was 0.5 bar. The carpets then passed 
through a vertical steamer at 212.degree. F. (100.degree. C.) for 6 min. 
The wet carpets were then passed through a Flexnip to apply a fluorocarbon 
antisoil treatment and air dried at 250.degree. F. (121.degree. C.). The 
dry carpets were then over-sprayed with an antistain treatment and dried 
again, followed by machine latexing, curing and shearing. The finished 
carpets were tested for carpet bulk and for newness retention (NR) in a 
Vetterman drum according to the procedures described above and 
subjectively rated for newness retention by a panel of experienced 
researchers. The test results are summarized in Table 1 below. 
TABLE 1 
______________________________________ 
Yarn Twist Carpet Wt 
Carpet 
Item MR % BCE (tpi) (oz/sq yd) 
Bulk NR 
______________________________________ 
1 A 1.75 23 3.5 28 0.282 2.3 
1 A' 1.75 23 3.5 34 0.321 2.5 
1 A" 1.75 23 3.5 40 0.375 2.7 
1 B 1.75 23 4.5 28 0.259 2.7 
1 B' 1.75 23 4.5 34 0.289 2.8 
1 B" 1.75 23 4.5 40 0.343 3.5 
1 C 1.75 23 5.5 28 0.224 3.0 
1 C' 1.75 23 5.5 34 0.253 3.4 
1 C" 1.75 23 5.5 40 0.292 4.0 
2 A 1.75 38 3.5 28 0.328 2.2 
2 A' 1.75 38 3.5 34 0.371 2.1 
2 A" 1.75 38 3.5 40 0.436 2.1 
2 B 1.75 38 4.5 28 0.296 2.6 
2 B' 1.75 38 4.5 34 0.348 2.5 
2 B" 1.75 38 4.5 40 0.409 2.7 
2 C 1.75 38 5.5 28 0.274 3.3 
2 C' 1.75 38 5.5 34 0.298 3.9 
2 C" 1.75 38 5.5 40 0.366 3.4 
3 A 1.45 40 3.5 28 0.312 2.0 
3 A' 1.45 40 3.5 34 0.360 2.1 
3 A" 1.45 40 3.5 40 0.438 2.2 
3 B 1.45 40 4.5 28 0.284 3.0 
3 B' 1.45 40 4.5 34 0.341 2.8 
3 B" 1.45 40 4.5 40 0.387 3.0 
3 C 1.45 40 5.5 28 0.256 3.7 
3 C' 1.45 40 5.5 34 0.294 3.6 
3 C" 1.45 40 5.5 40 0.340 3.7 
______________________________________ 
The above results for 34 oz/sq yd (1.15 kg/m.sup.2) carpets are plotted in 
FIG. 4 in the form of newness retention as a function of carpet bulk. The 
low-bulk yarn and carpets of Example 1 are considered to be part of the 
prior art. Carpets corresponding to points 2A' and 3A', although showing 
very high bulk, fall outside the invention because they were prepared from 
yarns of only 3.5 tpi (1.4 twists/cm), and consequently have poor newness 
retention. It is apparent from FIG. 4 that at a given carpet bulk the 
carpets constructed from yarns of the current invention in Examples 2 and 
3 have a much higher newness retention rating than those of Example 1. 
Similarly, at a given newness retention rating, the carpets constructed 
from yarns of the current invention have much higher bulk than those of 
Example 1. 
EXAMPLES 4-6 
Nylon 6,6 polymer (70 RV) was spun at 290.degree. C. through a 160 hole 
1.75 MR spinneret at 67 lb/hr (30.4 kg/hr) throughput in a process similar 
to that used for Examples 1-2. The feed roll was operated at 785 ypm (718 
m/min) and the draw roll speed was 2197 ypm (2009 m/min; 2.8 draw ratio). 
The bulking jet air temperature was 200.degree. C. The yarn was cooled by 
air on the bulking drum from the 11 o'clock position to the 1 o'clock 
position. For Example 4 the hot roll temperature was 170.degree. C., for 
Example 5 the hot roll temperature was 190.degree. C., and for Example 6 
the hot roll temperature was 210.degree. C. 
The yarns produced in Examples 4-6 were converted into two-ply, 
cable-twisted yarns having 4.75 and 5.75 tpi (1.9 and 2.3 twists/cm), 
Superba heatset at 270.degree. C., and tufted into 1/8 in (0.32 cm) gauge, 
1/2 in (1.27 cm) pile height cut-pile carpets at 32 and 40 oz/sq yd (1.09 
and 1.36 kg/m.sup.2) and 1/8 in (0.32 cm) gauge, 5/8 in (1.6 cm) pile 
height cut-pile carpets at 50 oz/sq yd (1.70 kg/m.sup.2). The tufted 
carpets were then dyed in a continuous dye range, latexed and tip sheared 
in the same manner as in Examples 1-3 The finished carpets were tested for 
carpet bulk and newness retention. Yarn and carpet properties are 
summarized in Table 2. 
TABLE 2 
______________________________________ 
Yarn Twist Carpet Wt 
Carpet 
Item MR % BCE (tpi) (oz/sq yd) 
Bulk NR 
______________________________________ 
4 A 1.75 18 4.75 32 0.244 2.8 
4 B 1.75 18 5.75 32 0.185 3.2 
4 B' 1.75 18 5.75 40 0.239 3.7 
4 B" 1.75 18 5.75 50 0.265 3.7 
5 A 1.75 29 4.75 32 0.279 2.6 
5 B 1.75 29 5.75 32 0.221 3.6 
5 B' 1.75 29 5.75 40 0.280 3.8 
5 B" 1.75 29 5.75 50 0.313 4.1 
6 A 1.75 40 4.75 32 0.323 2.2 
6 B 1.75 40 5.75 32 0.261 3.5 
6 B' 1.75 40 5.75 40 0.320 3.0 
6 B" 1.75 40 5.75 50 0.375 3.2 
______________________________________ 
EXAMPLES 7-9 
Nylon 6,6 yarns were spun in a process similar to that used in Examples 4-6 
except that a 2.5 MR spinneret was used. For Example 7 the hot roll 
temperature was 170.degree. C., for Example 8 the hot roll temperature was 
190.degree. C., and for Example 9 the hot roll temperature was 210.degree. 
C. 
The yarns produced in Examples 7-9 were converted into two-ply 
cable-twisted yarns having 3.75, 4.75 or 5.75 tpi (1.5, 1.9, or 2.3 twists 
per cm), Superba heatset at 270.degree. C. and tufted into 1/8 in (0.32 
cm) gauge, 1/2 in (1.27 cm) pile height cut-pile carpets at 32 and 40 
oz/sq yd (1.09 and 1.36 kg/m.sup.2) and 1/8 in (0.32 cm) gauge, 5/8 in 
(1.6 cm) pile height cut-pile carpets at 50 oz/sq yd (1.7 kg/m.sup.2). The 
tufted carpets were then dyed in a continuous dyeing machine, latexed, and 
tip sheared in the same manner as in Examples 1-3. The finished carpets 
were tested for carpet bulk and newness retention. Yarn and carpet 
properties are summarized in Table 3. 
TABLE 3 
______________________________________ 
Yarn Twist Carpet Wt 
Carpet 
Item MR % BCE (tpi) (oz/sq yd) 
Bulk NR 
______________________________________ 
7 A 2.5 18 3.75 32 0.300 1.3 
7 B 2.5 18 5.75 32 0.242 2.9 
7 B' 2.5 18 5.75 40 0.297 3.2 
7 B" 2.5 18 5.75 50 0.349 3.3 
8 A 2.5 29 4.75 32 0.285 2.0 
8 B 2.5 29 5.75 32 0.262 2.8 
8 B' 2 5 29 5.75 40 0.334 2.7 
8 B" 2.5 29 5.75 50 0.401 3.3 
9 A 2.5 35 4.75 32 0.338 1.6 
9 B 2.5 35 5.75 32 0.305 2.5 
9 B' 2.5 35 5.75 40 0.376 2.6 
9 B" 2.5 35 5.75 50 0.442 3.3 
______________________________________ 
EXAMPLES 10-12 
Nylon 6,6 yarns were spun in a process similar to that used in Examples 7-9 
except that a 3.4 MR spinneret was used. For Example 10 the hot roll 
temperature was 170.degree. C., for Example 11 the hot roll temperature 
was 190.degree. C., and for Example 12 the hot roll temperature was 
210.degree. C. 
The yarns produced in Examples 10-12 were converted into two-ply, 
cable-twisted yarns having 4.75 and 5.75 tpi (1.87 and 2.26 twists/cm), 
Superba heatset at 270.degree. C. and tufted into 1/8 in (0.32 cm) gauge, 
1/2 in (1.27 cm) pile height cut-pile carpets at 32 and 40 oz/sq yd (1.09 
and 1.36 kg/m.sup.2) and 1/8 in (0.32 cm) gauge, 5/8 in (1.6 cm) pile 
height carpets at 50 oz/sq yd (1.70 kg/m.sup.2). The tufted carpets were 
then dyed in a continuous dyeing machine, latexed, and tip sheared in the 
same manner as in Examples 1-3. The finished carpets were tested for 
carpet bulk and newness retention. Yarn and carpet properties are 
summarized in Table 4. 
TABLE 4 
______________________________________ 
Yarn Twist Carpet Wt 
Carpet 
Item MR % BCE (tpi) (oz/sq yd) 
Bulk NR 
______________________________________ 
10 A 3.4 18 5.75 32 0.274 1.9 
10 A' 3.4 18 5.75 40 0.352 2.1 
10 A" 3.4 18 5.75 50 0.396 2.2 
11 A 3.4 25 4.75 32 0.324 1.2 
12 A 3.4 31 4.75 32 0.339 1.4 
12 B 3.4 31 5.75 32 0.307 2.0 
12 B' 3.4 31 5.75 40 0.392 2.2 
12 B" 3.4 31 5.75 50 0.451 2.3 
______________________________________ 
FIGS. 5-7 compare Examples 4-12 in three different carpet constructions 
using the data from Tables 2-4. In all three constructions it is observed 
that the control examples 4, 7, and 10 show either bulk or newness 
retention, or a balance of bulk and newness retention inferior to Examples 
5-6, 8-9, and 11-12. 
The carpet data from Examples 4-12 are plotted as newness retention versus 
carpet bulk in FIGS. 5-7. FIG. 5 shows data for 32 oz/sq yd (1.09 
kg/m.sup.2), 0.5 in (1.27 cm) pile height carpets. Each point corresponds 
to data for yarns processed under identical conditions and twisted to the 
same twist level, the points being connected to indicate a grouping at the 
same twist level. Each point on a line corresponds to a different MR yarn. 
FIGS. 6 and 7 show similar plots for 40 oz/sq yd (1.36 kg/m.sup.2), 0.5 in 
(1.27 cm) pile height and 50 oz/sq yd (1.70 kg/m.sup.2), 5/8 in (1.6 cm) 
pile height carpets, respectively. From each figure it can be seen that 
when high-bulk, high-twist yarns of the invention are used in tufting the 
carpet, the combination of carpet bulk and newness retention are superior 
to those carpets made from yarns not having high bulk and/or high twist 
levels. 
It will be noted that a "best-fit" straight line, labelled as lines X, Y 
and Z respectively, can be drawn through the data on FIGS. 5-7 as an 
approximation of the boundary between carpets having the desired balance 
of carpet bulk and newness retention from those which are deficient in one 
or both properties. As can readily be seen, by varying yarn bulk, twist 
and modification ratio, carpets having a desired balance of both carpet 
bulk and newness retention can be obtained. Alternatively, carpets having 
extraordinarily high levels of either bulk or newness retention can also 
be obtained, one property being sacrificed to increase the other. 
EXAMPLES 13-17 
The yarns of Examples 13-17 were produced in a process similar to that used 
in Examples 1-12. The filaments were spun and quenched as per the previous 
examples, except that after the quench chimney they passed through an 
inter-floor tube approximately 8 ft (2.6 m) long, where no additional 
cross-flow air was used. This extended the hold-up time during the quench 
process to provide further cooling. In addition, the pin 5 in FIG. 3 was 
removed, and the two pins 5' were instead a roll and a single stationary 
draw pin. The yarns were spun at 76 lb/hr (34.5 kg/hr), the feed roll 
speed was 875 ypm (795 mpm), the speed of the draw rolls was 2624 ypm 
(2385 mpm), and the draw ratio was 3.0. The yarn in caterpillar form was 
allowed to remain on the bulking drum for a longer period of time, a 
vacuum of 15 inches of water, and in some cases a mist quench (80 
ml/min/threadline) was used. The caterpillar take-off point was at the 5 
o'clock position versus the 1 o'clock position used in the previous 
Examples. The take-off point was adjusted by moving the pins 12 in FIG. 3 
from approximately the 5 o'clock position to approximately the 7-8 o'clock 
position. Table 5 summarizes the process conditions used and yarn bulk 
properties. 
TABLE 5 
______________________________________ 
Roll Temp Jet Temp 
Example 
(.degree.C.) 
(.degree.C.) 
Mist Quench 
Yarn Bulk 
______________________________________ 
13 220 200 No 48 
14 210 220 No 48 
15 220 220 No 43 
16 210 220 Yes 47 
17 220 220 Yes 49 
______________________________________ 
Yarn properties reported in the Examples above are plotted as yarn bulk (% 
BCE) versus MR in lines B and C of FIG. 1. Data for yarns produced using a 
draw roll temperature of 210.degree. C. are plotted on line C (Examples 3, 
6, 9 and 12). Data for yarns produced using a draw roll temperature of 
190.degree. C. are plotted on line B (Examples 5 and 11). Point D on FIG. 
1 corresponds to the yarn of Example 17.