Abstract: A multi-step process is disclosed for heat setting twisted, bulk continuous filament (BCF) yarn comprising the steps of developing crimp in the yarn under hot atmospheric air and heat setting the yarn by saturated steam treatment.

Abstract: Disclosed are processes for application of dyes and topical chemistries to single yarns during a yarn rewind process. The process foregoes the need for downstream environmentally unfavorable dyeing and low PH chemical treatment processes on the finished carpet. Further, neutral pH dye solutions can be used instead of the prior art low pH dye solutions. The single, treated yarn can then be twisted, weaved and tufted, twisted yarn under dry conditions, and the twisted yarn subsequently weaved or weaved and tufted, into a finished fabric or carpet. Also disclosed are systems, BCF yarns, and carpets made from the BCF yarn treated by the disclosed processes.

Abstract: Briefly described, embodiments of the present disclosure include trilobal bulked continuous filaments (BCFs) with a generally round central void, spinneret plates with a capillary design for producing the BCFs of the present disclosure, articles and carpets produced from the BCFs of the present disclosure, methods of producing the trilobal BCFs of the present disclosure, and the like.

Abstract: Synthetic fibers with enhanced stain resistance, yarns and carpets prepared from these fibers and compounds and methods for their production are provided.

Abstract: A multicolor carpet comprising a plurality of tufted yarns, wherein the yarns comprise solution-dyed bulked continuous filaments, wherein at least one of the yarns is of a different color than any of the other yarns, wherein the yarns have not been twisted, and wherein the yarns have not been heatset.

Abstract: Briefly described, embodiments of the present disclosure include trilobal bulked continuous filaments (BCFs) with a generally round central void, spinneret plates with a capillary design for producing the BCFs of the present disclosure, articles and carpets produced from the BCFs of the present disclosure, methods of producing the trilobal BCFs of the present disclosure, and the like.

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.

Abstract: Disclosed are processes for applying anti-soil compositions on BCF yams during cable or air twisting processes prior to weaving, knitting or tufting. The process foregoes the need for downstream environmentally unfavorable dyeing and low pH chemical treatment processes on the finished carpet. The anti-soil composition can be comprised of a high specific surface energy chemical or other material, for example a fluorochemical. Further, the anti-soil composition can further comprise an anti-stain component. Also disclosed are systems, BCF yarns, and carpets made from the BCF yarn treated by the disclosed process.

Abstract: Disclosed are processes for application of dyes and topical chemistries to single yarns during a yarn rewind process. The process foregoes the need for downstream environmentally unfavorable dyeing and low PH chemical treatment processes on the finished carpet. Further, neutral pH dye solutions can be used instead of the prior art low pH dye solutions. The single, treated yarn can then be twisted, weaved and tufted, twisted yarn under dry conditions, and the twisted yarn subsequently weaved or weaved and tufted, into a finished fabric or carpet. Also disclosed are systems, BCF yarns, and carpets made from the BCF yarn treated by the disclosed processes.

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.

Abstract: Intermittently colored yarns having an intermittent and random dye spacing pattern, and systems and methods of making the same, are disclosed. Such intermittently colored yarns exhibit higher quality and lower manufacturing costs over the known intermittently colored yarns. The intermittent coloring takes place while the yarn is in caterpillar form. Carpets made from such intermittently colored yarns exhibit enhanced aesthetics over carpets made from known intermittently colored yarns. Alternatively, a stain resist, colorless base dye, or bleaching agent can be applied in the same intermittent and random spacing pattern to the intermittently colored yarns prior to subsequent dyeing. This creates a mirror image like color effect to the resulting 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.

Abstract: Disclosed are processes for applying anti-soil compositions onto BCF yarns during cable or air twisting processes prior to weaving, knitting or tufting into finished carpet. The process foregoes the need for downstream environmentally unfavorable dyeing and low pH chemical treatment processes on the finished carpet. The anti-soil composition can be comprised of a high specific surface energy chemical or other material, for example a fluorochemical. Further, the anti-soil composition can further comprise an anti-stain component. Also disclosed are systems, BCF yarns, and carpets made from the BCF yarn treated by the disclosed process.

Abstract: Intermittently colored yarns having an intermittent and random dye spacing pattern, and systems and methods of making the same, are disclosed. Such intermittently colored yarns exhibit higher quality and lower manufacturing costs over the known intermittently colored yarns. The intermittent coloring takes place while the yarn is in caterpillar form. Carpets made from such intermittently colored yarns exhibit enhanced aesthetics over carpets made from known intermittently colored yarns. Alternatively, a stain resist, colorless base dye, or bleaching agent can be applied in the same intermittent and random spacing pattern to the intermittently colored yarns prior to subsequent dyeing. This creates a mirror image like color effect to the resulting yarn.

Abstract: Briefly described, embodiments of the present disclosure include trilobal bulked continuous filaments (BCFs) with a generally round central void, spinneret plates with a capillary design for producing the BCFs of the present disclosure, articles and carpets produced from the BCFs of the present disclosure, methods of producing the trilobal BCFs of the present disclosure, and the like.

Abstract: Briefly described, embodiments of this disclosure include hexalobal bulked continuous filaments with three axial voids, spinneret plates with a capillary design for producing the hexalobal, tri-void bulked continuous filaments (BCFs) of the present disclosure, articles made from the hexalobal filaments of the present disclosure, methods of making the hexalobal, tri-void filaments of the present disclosure, and the like.

Abstract: A filament comprising a synthetic polymer and characterized by a hexalobal cross-section having three major lobes and three minor lobes, and a major radius (R1) and a minor radius (R2). Each lobal cross-section having essentially straight side portions extending outwardly and tangent to a convex tip at each end. The ratio of the major radius (R1) to the minor radius (R2) defining an exterior modification ratio (R1/R2) of greater than 1.

Abstract: The invention provides a process for making permanent stain resistant polyamide carpets with light color. The process comprises dyeing a low amine end and cationic dyeable polyamide carpet with acid dyes, and imparting stain resist compositions onto the carpet. In addition to stain resist compositions, a fluoro-chemical is also applied to improve soil resistance. The resulted carpet displays a built-in permanent anti-stain and anti-soil resistance after many shampoo-washes.

Abstract: A bulked continuous filament with a three-sided exterior configuration is characterized in that each side has a smoothly curved contour extending between a first and a second rounded tip with an inwardly extending depressed region being disposed adjacent to each tip. Generally, the filament has an exterior modification ratio in the range from about 1.4 to about 2.5, and a tip ratio in the range from about 2.0 to about 10.0. The filament generally delta-shaped void with three major apices extending centrally and axially therethrough. Each side of the void is convexly shaped and formed from a pair of facets that meet to define minor apices. The void is oriented such that each major apex extends toward the approximate midpoint of one side of the exterior of the filament and each minor apex extends toward a tip of an exterior side.

Abstract: An apparatus and method for texture heat-setting bulk continuous filament (BCF) yarns in hot air heat-setting machines that includes a preheating device/step using a mixture of steam and atmospheric air to preheat a twisted BCF yarn bundle to develop crimp memory and provide cohesion to the twisted BCF yarn bundle. Yarn bundle cohesion during texture heat-setting helps to avoid frequent breaks at the winder of the hot air heat-setting machine. The addition of the preheating device/step significantly improves the ability of hot air heat-setting machines to maintain continuous operation during texture setting of BCF yarns and makes the hot air heat-setting method commercially viable for this application.