Abstract:
A spin finish composition for nylon feeder yarn to be processed at high temperature into carpet yarn, such as by steam jet texturing, comprising tridecyl stearate with a specific emulsifier and an antistatic agent results in improved processing and better quality yarn, and yarn packages.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a yarn finish. More specifically, this invention relates to a spin finish for polyamide feeder yarn to be processed at high temperature into carpet yarn such as by steam jet texturing. 
     Various finishes for synthetic filaments are disclosed in the prior art for high temperature processing. However, none of the prior art teach a specific combination of ingredients to achieve the specific beneficial results of the composition of this invention. The critical amounts and ingredients are shown in the discussion below. Many of the prior art finishes flash off in high temperature processing such as steam jet texturing for yarn. Others fail to have emulsion stability or have insufficient yarn lubrication. Still others require numerous, costly components, and do not provide good package formation during take-up of the yarn, or good package unwinding properties. 
     The yarn finish of this invention is an improvement over the finish disclosed in U.S. Pat. No. 3,781,202 which is hereby specifically incorporated by reference in toto. The esters resulting from the reaction of a long chain fatty acid with a monohydric long chain aliphatic alcohol are known as textile yarn lubricants in U.S. Pat. No. 3,306,850 and U.S. Pat. No. 3,649,535. However, for high temperatures, diesters are taught, or other lubricants must be added. 
     SUMMARY OF THE INVENTION 
     The composition of the oil portion of yarn spin finish of this invention is 
     
                       I______________________________________Component            Percent by Weight______________________________________a)  tridecyl stearate    40 to 60b)  corn oil glyceride   20 to 30    ethoxylated with 10 mols    ethylene oxidec)  sulfated glycerol trioleate                    20 to 30orII______________________________________a)  tridecyl stearate    40 to 60b)  polyethylene glycol (10)                    20 to 30    oleatec)  sulfonated petroleum product                    20 to 30______________________________________ 
    
     The compound labeled b) is an emulsifier. The compound labeled c) is an antistatic compound. 
     The yarn finish composition has all the advantages of the finish disclosed in U.S. Pat. No. 3,781,202 in addition to the following advantages over the prior (including that in U.S. Pat. No. 3,781,202) high temperature spin finishes for textile yarn. 
     Lower yarn to metal friction 
     Higher yarn to yarn friction 
     Low number of components 
     Low cost 
     Better yarn package formation 
     Better yarn package unwind properties The combination of low yarn to metal and high yarn to yarn friction is particularly important and can be achieved only by the particular combination and ratio of components listed above, without losing other equally important benefits. The better yarn package formation during take-up of the yarn from spinning is also important. Of course, the low number of components and cost is always important. Higher yarn to yarn friction is conducive to better cohesion in the package as it is taken up and in the yarn as it is processed. For example, this improved cohesion improves tuftability when the yarn is tufted into a carpet. 
     The friction characteristics are also influenced by the emulsifier. Other compounds than those listed adversely affect the unique lubrication properties of this finish. 
     The amount of finish used on the yarn is set forth in U.S. Pat. No. 3,781,202. 
     By tridecyl stearate is meant the pure compound or the compound prepared by reacting tridecyl alcohol with commercial stearic acid, which may also contain some palmitic acid. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The oil portion of the oil in water emulsion, 4 to 20 percent by weight oil, of this improved spin finish for textured carpet yarn is preferably 
     
                       I______________________________________Component            Percent by Weight______________________________________tridecyl stearate    55corn oil ethoxylated with 10 mols                22ethyleneoxidesulfated glycerol trioleate                23orII______________________________________tridecyl stearate    50polyethylene glycol (10) oleate                23sulfonated petroleum product                27______________________________________ 
    
     By polyethylene glycol (10) oleate is meant 10 mols of polyethylene glycol was reacted with 1 mol oleic acid. 
     TABLE A 
     Comparison of Friction and Package Formation 
     Yarn finish I is labeled I above. 
     Yarn finish II is labeled II above. 
     Yarn finish III is shown in Table I of U.S. Pat. No. 3,781,202 and represents the prior art finish and control for these runs. 
     
         ______________________________________Run  Yarn    Package       Yarn to                             Yarn toNo.  Finish  Formation Rating                      Metal  Yarn                 Slip  Stick______________________________________1    I       2.2           390    370   5501    II      1.5           340    380   8001    III     0.5           410    380   4902    I                     75     440   6102    II                    65     530   11302    III                   90     430   6403    I                     48     540   7903    II                    49     520   10103    III                   60     480   690______________________________________ 
    
     Run No. 1 was spinning of a 2600 denier, continuous filament yarn which was draw wound and then textured. 
     Run 2 was spinning of a 1300 denier, continuous filament yarn which was draw-textured in one operation. 
     Run No. 3 was spinning of a 2600 denier continuous filament yarn, also draw-textured in one operation. 
     The yarn to metal friction test is described in ASTMD 3108-72T, with results reported here in grams rather than coefficient of friction. The yarn to yarn friction tests were made by simply modifying the yarn to metal test by removing the metal pin and twisting the yarn upon itself 360° in the same location. While running this test, friction builds up as the yarn &#34;sticks&#34; then breaks loose as the yarn &#34;slips.&#34; The values reported herein as &#34;stick&#34; and &#34;slip&#34; are the maximum and minimum values obtained for the &#34;stick&#34; and &#34;slip&#34; portions of the test. 
     The package formation rating is an objective visual rating by experts of the package formed - higher number means better package. 
     Each rating is an average from 20 packages. The ratings are as follows: 
     0 -- sluffing off end 
     1 -- severe bulge on sides 
     2 -- slight bulge on sides 
     3 -- straight sides, no bulge 
     These results clearly show the highly improved package formation and friction properties of the improved finish of this invention. 
     The following table shows the criticality of the particular emulsifier-antistatic agent combinations of this invention to the improved friction, static and other properties of the finish of this invention. 
     
                       TABLE B______________________________________          Finish                Finish  Finish  Finish          A     II      B       CIngredient       Percent by Weight______________________________________tridecyl stearate            50      50      50    50sulfonated petroleum            30      27      30    35productcorn oil glyceride            20ethoxylated with 10 molsethylene oxidepolyethylene glycol (10) 23oleateoleic acid ethoxylated           20    15with 5 mols e. o.static, millivolts            55      25      48    70yarn to metal friction,            420     390     360   390gramsyarn to yarn friction,gramsslip             643     635     705   785stick            953     1133    1195  1310oil on yarn, % by            1.0     0.9     0.9   0.9weight, based on yarnweight______________________________________ 
    
     The static property of the yarn finishes is measured by using a Valchem Friction Analyzer which is similar to the apparatus of the yarn to metal test described in ASTM 3108-72T. In place of the strain gages an eye through a pair of copper electrodes utilizes the Farraday cage principle to detect the amount of static generated across a metal pin. The Farraday &#34;eye&#34; is located just downstream from the pin over which the yarn coated with finish passes traveling at 200 feet per minute. The static is measured with an electrometer, amplified and recorded in millivolts. 
     As can be seen above, tridecyl stearate with the emulsifier and antistatic agents switched from Finish I and Finish II, i.e., Finish A above, has high yarn to metal friction and poorer static property. Using other emulsifiers gave poorer static properties, also. 
     Table C, below, shows the processing results of the finishes of this invention, I and II, compared with other finishes; note, that only finishes I and II combine retention of finish after jet texturing, low yarn to metal friction, good package formation, good tufting (into carpet) performance and excellent texturing performance. Each of the other finishes is deficient in one or more of these properties, even though the componenets are similar. 
     Sulfonated petroleum product is define in U.S. Pat. No. 3,781,202. 
     
                                           TABLE C__________________________________________________________________________               Finish Compositions               I  II D  E  F  III.sup.1__________________________________________________________________________Refined coconut oil       63       59  Lubricanttridecyl stearate   55 50              Lubricantisodecyl stearate            63        Lubricantbutyl stearate                  50     Lubricantpolyethylene glycol (10) oleate                  23              Emulsifierpolyethylene glycol (10) corn oil               20                 Emulsifiersulfated petroleum product                  27 12 12    10  Antistatsulfated glycerol triolate               25                 Antistatsorbitol oleate + 40 ethylene oxide                     25           Emulsifierpolyethylene glycol oleate   25        Emulsifiersorbitan oleate                 25     Emulsifiertallow amine + 20 ethylene oxide                           25     Antistat__________________________________________________________________________       Finish CompositionsFiber ProcessingData        I     II   D    E     F    III__________________________________________________________________________% finish on .80   .85  .85   .80  .95  .78undrawn yarn% finish after       .75   .81  .85  .50   .44  .77jet draw-texturePackage formation.sup.4       2.2   2.0  1.5  1.3   2.4  .5Yarn to Metal       75    65   90   50    60   90friction texturedyarn in gramsTexturizing E     E    F    P     P    Gperformance.sup.2Tufting     G     G    F    F     P    Gperformance.sup.3__________________________________________________________________________ .sup.1 III is spin finish described in U.S. Pat. No. 3,781,202, Table I. .sup.2 draw-steam jet textured at 5000 fpm 3tufting performance per 50 yards carpet, 180 ends on 30&#34; slat type tufting machine 5/32&#34; gauge  G = good -- less than 25 pull backs &amp; 15 snags  F = fair -- less than 50 pull backs &amp; 30 snags  P = poor -- more than 50 pull backs &amp; 30 snags .sup.4 package formation -- average rating 20 packages  0 = sluffing off end  1 = severe bulge on sides  2 = slight bulge on sides  3 = straight sides -- no bulge