High luster fiber materials, methods of manufacture and uses thereof

Abstract

A plied carpet fiber material is disclosed herein that includes at least one nontextured fiber component plied with at least one additional fiber component to form the plied carpet fiber material, wherein each nontextured fiber component comprises a luster component. Plied carpet fiber materials are also disclosed herein that include: a) at least one nontextured fiber component, wherein each nontextured fiber component comprises a luster component, and b) at least one textured fiber component, wherein each textured fiber component comprises a luster component, wherein the at least one nontextured fiber component and the at least one textured fiber component are plied with one another to produce the plied carpet fiber material. Plied carpet fiber materials are also disclosed herein that include: a) at least two nontextured fiber components, wherein each nontextured fiber component comprises a luster component, and wherein the at least two nontextured fiber components are plied together to form the plied carpet fiber material. Methods are also provided for producing a plied carpet fiber material that include: a) providing at least one nontextured fiber component, wherein each nontextured fiber component comprises a luster component; b) providing at least one textured fiber component, wherein each textured fiber component comprises a luster component; and c) combining the at least one nontextured fiber component and the at least one textured fiber component to form the plied fiber material.

Description

FIELD OF THE SUBJECT MATTER

The field of the subject matter herein is fiber materials, yarn products and carpet products, methods of manufacture and uses thereof, and more specifically, high luster plied fiber materials and yarns, methods of manufacture and uses thereof.

BACKGROUND

Fibers for consumer use, especially fibers that are incorporated into carpet products and fabrics/textiles, are constantly being evaluated for improvements with respect to the consumer's sensory perception. These improvements may relate to texture, quality, softness and luster.

Carpet fibers, which are used in the production of carpet products, such as wall-to-wall carpet, rugs and mats, are modified and in some instances improved to provide a certain fiber texture, overall texture when the fibers are incorporated into a carpet product and to provide a desired “look” for the space where the carpet product is being used. Additional issues that arise in the design of carpet fiber material and carpet products are daily and long-term durability.

One method that is being used to modify the texture and look of fabrics is to incorporate fibers that have been “textured” into the fabric product. Texturing is a general process that crimps synthetic fibers, thus providing a bulkier product that simulates a more natural fiber. Texturing processes are heavily implemented in the production of carpet fibers to increase the bulk of the yarn, which adds value to the carpet product. (see U.S. Pat. Nos. 3949041; 3979496; 5653010; 5802832; 6041586; 6209302 and 6725639) However, utilizing the texturing process for carpet fibers does have tradeoffs, in that the texturing process decreases the luster of the fibers and/or yarns, and thus the overall appearance of the yarns and/or carpet products suffer.

Luster is another characteristic of a fiber and/or yarn. Luster can be defined as follows: “brightness or reflectivity of fibers, yarns, carpets or fabrics. Synthetic fibers are produced in various luster classifications including bright, semi-bright, semi-dull and mid-dull. The luster of finished carpet could also be influenced by yarn heatsetting methods, dyeing and finishing. Luster is “shown” on the side of the yarn or fiber—meaning that it's the side or shaft of the fiber or yarn that shows the brightness of the yarn or reflects light to some degree to produce a luster effect. In high-traffic commercial areas, duller carpet yarns are often preferred for soil-hiding ability.” (see www.fabrica.com: Glossary of Fabric and Rug Terms) Luster levels are considered when producing fibers and yarn; however, generally fiber and yarn blends are conventionally put together using a single luster level to produce a desired effect on the look of the finished product. Also, given that the texturing process is a conventional process used to produce carpet fibers, yarns and products, it can be difficult to produce carpet yarns and products with increased luster.

U.S. Pat. Nos. 4,848,413 and 4,897,989 (“Gray patents”) teach a “three-ply” yarn, pile fabric and methods of making both the yarn and fabric, wherein the yarn includes nontextured filaments; however, upon review of the methods of producing the yarn, along with the Figures, it is clear that the yarn is not actually “plied” or cabled. The yarns disclosed in the Gray patents are actually “three filament” yarns consisting of two nontextured filaments and one textured filament, wherein the filaments are commingled using an air jet. The commingling of the three filaments leads to the “wool-like appearance” of the pile fabric, along with the minimization of “finger marks”. The goal of achieving a “wool-like appearance” in the pile fabric effectively negates any increased luster provided by the nontextured filaments.

U.S. Pat. No. 6,582,816 teaches textile effect yarns and methods of producing those yarns, wherein the yarns are utilized to produce carpets. Although nontextured yarns are utilized in the '816 patent, the nontextured yarns are not plied or cabled with the textured yarns. This point is important, because if the nontextured yarns and textured yarns are plied together and then heatset, the carpet product will show the influences of the nontextured fiber luster while maintaining the durability and “wearability” of the textured yarns. In the '816 patent, the nontextured yarns and the textured yarns are commingled using an air jet similar to that in the above-mentioned Gray patents.

Therefore, it would be desirable to produce a plied or cabled fiber material and/or yarn that comprises a significantly higher luster level than conventional carpet yarns, which can be incorporated into or utilized independently in the production of a new and unique carpet product that is not only durable but also wears well over the usable life of the product.

SUMMARY OF THE SUBJECT MATTER

A plied carpet fiber material is disclosed herein that includes at least one nontextured fiber component plied with at least one additional fiber component to form the plied carpet fiber material, wherein each nontextured fiber component comprises a luster component.

Plied carpet fiber materials are also disclosed herein that include: a) at least one nontextured fiber component, wherein each nontextured fiber component comprises a luster component, and b) at least one textured fiber component, wherein each textured fiber component comprises a luster component, wherein the at least one nontextured fiber component and the at least one textured fiber component are plied with one another to produce the plied carpet fiber material.

Plied carpet fiber materials are also disclosed herein that include: a) at least two nontextured fiber components, wherein each nontextured fiber component comprises a luster component, and wherein the at least two nontextured fiber components are plied together to form the plied carpet fiber material.

Methods are also provided for producing a plied carpet fiber material that include: a) providing at least one nontextured fiber component, wherein each nontextured fiber component comprises a luster component; b) providing at least one textured fiber component, wherein each textured fiber component comprises a luster component; and c) combining the at least one nontextured fiber component and the at least one textured fiber component to form the plied fiber material.

DETAILED DESCRIPTION

In order to produce a plied carpet fiber material and/or yarn that comprises a significantly higher luster level than conventional carpet yarns, which can be incorporated into or utilized independently in the production of a new and unique carpet product, a carpet yarn material has been developed that includes at least one nontextured fiber component plied with at least one additional fiber component, such as at least one end of an additional fiber component, to form the plied carpet fiber material, wherein each nontextured fiber component comprises a luster component.

In another embodiment, a plied carpet material has been developed that includes a) at least one nontextured fiber component, wherein each nontextured fiber component comprises a luster component, and b) at least one textured fiber component, wherein each textured fiber component comprises a luster component, wherein the at least one nontextured fiber component and the at least one textured fiber component are plied with one another to produce the plied carpet fiber material. It should be understood that carpet yarns disclosed herein may be used to produce carpet products, such as wall-to-wall carpet, area rugs, bathroom mats and the like.

In yet another embodiment, plied carpet fiber materials may also include: a) at least two nontextured fiber components, wherein each nontextured fiber component comprises a luster component, and wherein the at least two nontextured fiber components are plied together to form the plied carpet fiber material.

It has been discovered that by including at least one nontextured fiber component into a carpet yarn or carpet product that the differences in luster can be accentuated. Incorporating at least one nontextured fiber component into the plied carpet yarn or carpet product also addresses the shortcomings of the previously mentioned patents, wherein the nontextured filaments and yarns were commingled using an air jet in order to provide a “wool like appearance”. When the carpet yarn material comprises at least one nontextured fiber component, as described herein, wherein the nontextured fiber components are plied with similar fiber components, there is minimal heat shrinkage in heatsetting because of the lack of texture or crimp in the yarn. When the carpet yarn material comprises at least one plied nontextured fiber component, as described herein, wherein the plied nontextured fiber components are plied with textured fiber components and heatset, the nontextured fiber components take on the twist of the plied yarn while retaining the luster of a nontextured fiber.

The carpet yarn material, as mentioned, is a plied product. As used in the carpet industry, the term “ply” means the measure of the number of individual yarns twisted together to produce a finished carpet yarn. For example, a two-ply yarn means that each tuft consists of two yarns twisted or plied together. As used herein, the term “end” means one strand of a fiber.

As mentioned, in some embodiments, at least one nontextured fiber component may be plied with another nontextured fiber component to form a 2-ply plied nontextured yarn. In other embodiments, a nontextured fiber component may be plied with a textured fiber component to form a 2-ply plied yarn. Once the 2-ply plied yarn is formed, it can be plied with another textured fiber component to form a 3-ply plied yarn. Additional higher plied yarns (4-ply, 5-ply, etc) may also be formed. As used herein, the phrase “additional fiber component” means a textured fiber component, a nontextured fiber component or a combination thereof, if there are two or more plies of the additional fiber component.

Some embodiments of the plied carpet fiber materials comprise a plurality of binder fibers. Binder fibers are only useful in a finished product when they are activated, such as by heat activation. In some embodiments, activating the binder fibers comprises forming chemical, such as covalent, ionic or hydrogen and/or physical, such as adhesion, bonds between at least some of the plurality of binder fibers and at least one of the nontextured fiber component and/or the textured fiber component. However, it is not necessary to activate the binder fiber in the carpet yarn materials during the initial production of the carpet yarn materials. For example, if a contemplated carpet yarn material is produced with a plurality of binder fibers, the carpet yarn material may be shipped to a customer, who would then activate the binder fibers.

In embodiments where the nontextured fiber component is combined with conventional plied yarns, one ply of the nontextured fiber component is plied with one ply of a conventional yarn (textured), in order to form a two-ply plied yarn. This two-ply plied yarn is then plied or cabled with another one-ply conventional yarn. The three-ply yarn may then be heatset, if it is a cut pile carpet application. After heatsetting, the three-ply yarn has the bulked appearance of being textured, but has a higher luster component from the nontextured fiber component. The two-ply plied yarn may also be plied or cabled with conventional yarns that are greater than one-ply, such as two-ply, three-ply or greater. The nontextured fiber component may be dyed prior to or after any of the plying steps or heatsetting steps by any conventional dying process.

In some embodiments, plied yarns are heatset to prevent untwisting under traffic. In these embodiments, the plied yarns are “cut pile” yarns, as opposed to loop carpet yarns, wherein loop carpet yarns do not require heatsetting. These plied yarns may be heatset at any time after plying. Heatsetting or “twist setting” comprises a thermal energy that is applied to the materials and/or products. Heatsetting is considered a process that locks in the twist of the yarn by heating the yarn to a temperature that loosens the bonds between the molecules. New bonds are formed as the yarn cools.

The thermal energy may come from any suitable source, including extended/non-point sources, such as a UV-VIS source, an infra-red source, a heat source, both radiative and convective, or a microwave source; or electron sources, such as electron guns or plasma sources. Other suitable energy sources include electron beams, and radiative devices at non-IR wavelengths including x-ray, and gamma ray. Still other suitable energy sources include vibrational sources such as microwave transmitters. In preferred embodiments, the energy source is an extended source. In more preferred embodiments, the energy source is a heat source, such as an atmospheric pressure forced air machine, which can be followed by a steam purge, or a pressurized twist-setting machine. An example of an atmospheric pressure forced air machine is the Suessen® Twist-Setting Machine, which will activate at least some of the plurality of heat-activated binder fibers and/or twistset other fiber components at temperatures ranging from about 190° C. to about 200° C. Examples of pressurized twist-setting machines are those of the autoclave-type and those manufactured by Superba®, which will activate at least some of the plurality of heat-activated binder fibers at temperatures ranging from about 105° C. to about 138° C. If no binder fibers are present, the temperature range for twistsetting the fibers ranges from about 123° C. to about 138° C.

It should be understood that the thermal energy may be applied consistently or in short bursts. It is also contemplated that the thermal energy may be gradually and continuously applied over a temperature range until the thermal energy is at or above the melting point of the heat-active components. For example, the fiber material and/or yarn may be heated by an atmospheric pressure forced air machine at a temperature of about 195° C. for a residence time of about 60 seconds, before the treated fiber material and/or yarn product is tufted. The thermal energy may also be immediately applied at or above the melting point of the heat-active binder fiber components without any ramp time.

In a contemplated embodiment, the at least one nontextured fiber component, the at least one textured fiber component and/or the at least one additional fiber component may comprise any suitable fiber material that can be utilized in a carpet product, such as those described herein. It should be understood that in embodiments where there are at least two nontextured fiber components, that those fiber components may comprise similar chemical constituents or different chemical constituents, as long as the fiber components are nontextured. It should also be understood that in embodiments where there are at least two textured fiber components, that those fiber components may comprise similar chemical constituents or different chemical constituents, as long as the fiber components are textured. In other contemplated embodiments, the at least one nontextured fiber component and/or at least one textured fiber component comprise materials previously disclosed in European Patent No. 324,773 and U.S. Pat. No. 5,478,624, which are both commonly-owned and incorporated herein by reference in their entirety. As mentioned in those patents, the fiber components may comprise a polyamide-based compound, including nylon-6 and nylon-6,6 or a polyester-based compound.

The luster component of the at least one nontextured fiber component, the luster component of the at least one textured fiber component and the luster component of the at least one additional fiber component may comprise any suitable luster component depending on the needs of the product, the customer and/or the vendor, and it is contemplated that each of the luster components of the nontextured fiber components and the textured fiber components are different from one another. Each luster component may be determined by any suitable and conventional method, but luster components are referred to herein as by their percent TiO₂, % TiO₂ or their percent titanium dioxide content, which are each interchangeable and have the same meaning for the purposes of this work. In embodiments where there are at least two nontextured fiber components and/or at least two textured fiber components, the luster component for the nontextured fiber components and/or the textured fiber components is the average of the luster component for each of the nontextured fiber components or the textured fiber components. For example, if there is a nontextured fiber component having a 0.45% TiO₂ and a second nontextured fiber component having a 0.55 % TiO₂, the luster component of the complete nontextured fiber component is 0.50 % TiO₂. The same calculations apply to blends (at least two) textured fiber components.

In contemplated embodiments, the luster component of the nontextured fiber component is at least about 10% greater than the luster component of either the textured fiber component or of an identical fiber that is textured. In other contemplated embodiments, the luster component of the nontextured fiber component is at least about 25% greater than the luster component of either the textured fiber component or of an identical fiber that is textured. In yet other contemplated embodiments, the luster component of the nontextured fiber component is at least about 50% greater than the luster component of either the textured fiber component or of an identical fiber that is textured. And in additional embodiments, the luster component of the nontextured fiber component is at least about 75% greater than the luster component of either the textured fiber component or of an identical fiber that is textured. The percent difference of luster components may be measured by any suitable analytical method or apparatus, including reflective spectroscopic techniques.

The at least one textured, nontextured fiber components and additional fiber components may also comprise denier components. As mentioned earlier, denier (or fiber denier) is a physical property of a particular fiber and can be defined as: “A direct yarn numbering measurement, it is the weight in grams of 9,000 meters of yarn. Therefore, the higher the denier, the larger the yarn. Typical nylon carpet fiber has 15-18 denier. This thickness of a fiber can be regulated by the size of the openings of the spinneret.” (see www.fabrica.com: Glossary of Fabric and Rug Terms) In this definition, the term “denier” is used to mean “denier per filament”. However, in recent years, the denier per filament for soft fibers has approached 9 denier per filament. In some contemplated embodiments, the denier component (which may comprise either the denier or the denier per filament) of the at least one textured component and the at least one nontextured component is the same. In other embodiments, the denier component of the at least one textured component is different than the denier component of the at least one nontextured component. In yet other embodiments, where there are at least two nontextured components and/or at least two textured components, the denier component may be different for each component. For example, in an embodiment where there are at least two nontextured components, the denier per filament for one nontextured component may be 12 and the denier per filament of the second nontextured component may be 15. In some embodiments, the denier component that comprises a denier per filament may be a number comprising decimal places, such as 16.4 or 17.28. The denier components comprise any suitable denier or denier per filament for the needs of the product, the customer and/or the vendor.

Nontextured, additional and textured fiber components may comprise any suitable shape and/or have any suitable diameter, including a delta (triangle) shape, a “Y” shape, a circular shape, a square shape, a starflake-type of irregular shape, a ribbon shape or a combination thereof. When referring to shape, this generally means that if you slice the fiber width-wise, you will see the “shape” of the fiber at the flat site of the cut. In some contemplated embodiments, the nontextured and/or textured fiber components may also comprise an “O” shape meaning that the center of the fiber is hollow. A hollow core can also be present in the delta shape and the square shape.

Carpet yarns and/or carpet products described herein may also include a plurality of synthetic materials. As further contemplated, the synthetic material may comprise at least one heat-active material and also may comprise at least one polyamide compound or polyamide-based compound. As used herein, the term “compound” means a substance with constant composition that can be broken down into elements by chemical processes. Polyamides and polyamide-based compounds, as the name implies, are polymers that comprise amide monomers. Several contemplated polyamide-based compounds comprise nylon-6, nylon-6,6 and/or nylon-12.

Amides are an important group of nitrogenous compounds and monomers that are used as intermediates and/or building blocks in the production of polymers, textiles, plastics and adhesives. Amide monomers are generally represented by the following formula:
wherein R is an alkyl group, an aryl group, a cyclic alkyl group, an alkenyl group, an arylalkylene group, or any other appropriate group that can be utilized to be a part of an amide compound.

As used herein, the term “monomer” generally refers to any chemical compound that is capable of forming a covalent bond with itself or a chemically different compound in a repetitive manner. The repetitive bond formation between monomers may lead to a linear, branched, super-branched, or three-dimensional product. Furthermore, monomers may themselves comprise repetitive building blocks, and when polymerized the polymers formed from such monomers are then termed “blockpolymers”. The weight-average molecular weight of monomers may vary greatly between about 40 Dalton and 20000 Dalton. However, especially when monomers comprise repetitive building blocks, monomers may have even higher molecular weights. Monomers may also include additional groups, such as groups used for crosslinking, radiolabeling, and/or chemical or environmental protecting.

The term “alkyl” is used herein to mean a branched or a straight-chain saturated hydrocarbon group or substituent of 1 to 24 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, octyl, decyl, tetradecyl, hexadecyl, eicosyl, tetracosyl and the like. In some embodiments, contemplated alkyl groups contain 1 to 12 carbon atoms. The term “cyclic alkyl” means an alkyl compound whose structure is characterized by one or more closed rings. The cyclic alkyl may be mono-, bi-, tri- or polycyclic depending on the number of rings present in the compound. The term “aryl” is used herein to mean a monocyclic aromatic species of 5 to 7 carbon atoms or a compound that is built with monocyclic aromatic species of 5 to 7 carbon atoms and is typically phenyl, naphthalyl, phenanthryl, anthracyl etc. Optionally, these groups are substituted with one to four, more preferably one to two alkyl, alkoxy, hydroxy, and/or nitro substituents.

The term “alkenyl” is used herein to mean a branched or a straight-chain hydrocarbon chain containing from 2 to 24 carbon atoms and at least one double bond. Preferred alkenyl groups herein contain 1 to 12 carbon atoms. The term “alkoxy” is used herein to mean an alkyl group bound through a single, terminal ether linkage; that is, an alkoxy group may be defined as —OR wherein R is an alkyl group, as defined above. The term “arylalkylene” is used herein to mean moieties containing both alkylene and monocyclic aryl species, typically containing less than about 12 carbon atoms in the alkylene portion, and wherein the aryl substituent is bonded to the structure of interest through an alkylene linking group. Exemplary arylalkylene groups have the structure —(CH₂)_j—Ar wherein “j” is an integer in the range of 1 to 6 and wherein “Ar” is an aryl species.

ε-Caprolactam, also known as aminocaproic lactam and 2-oxohexamethyleneimine, is a compound that is produced in flake and molten forms and is used primarily in the manufacture of nylon-6, nylon-66 and nylon-12 products such as those products contemplated herein or other synthetic fibers, plastics, bristles, films, coatings, synthetic leathers, plasticizers and paint vehicles. Caprolactam can also be used as a cross-linking agent for polyurethanes and in the synthesis of the amino acid lysine.

Amides, such as caprolactam, are generally produced by reacting a ketone with hydroxylamine to make an oxime, and then using an acid catalyzed rearrangement of the oxime(s), conventionally called the Beckmann rearrangement, to form the amide. Merchant quality caprolactam can be produced by methods described in U.S. patent application Ser. No. 10/251335 filed on Sep. 21, 2002, which is commonly owned and herein incorporated in its entirety.

In addition, methods are provided herein that teach that a plied carpet fiber or carpet yarn material may be produced that includes: a) providing at least one nontextured fiber component, wherein each nontextured fiber component comprises a luster component and b) forming the plied carpet fiber or carpet yarn using the at least one nontextured fiber component. Other methods are provided herein that teach a plied carpet yarn or carpet fiber material that includes a) providing at least one nontextured fiber component, wherein each nontextured fiber component comprises a luster component, b) providing at least one textured fiber component, wherein each textured fiber component comprises a luster component; and c) combining the at least one nontextured fiber component with the at least one textured fiber component to produce a plied carpet fiber and/or carpet yarn.

The nontextured fiber components, textured fiber components and/or the plurality of binder fibers may be provided by any suitable method, including a) buying the nontextured fiber components, textured fiber components and/or the plurality of binder fibers from a supplier or textile mill; b) preparing or producing the nontextured fiber components, textured fiber components and/or the plurality of binder fibers in house using chemicals provided by another source and/or c) preparing or producing nontextured fiber components, textured fiber components and/or the plurality of binder fibers in house using chemicals also produced or provided in house or at the location. It is contemplated that nontextured fiber components, textured fiber components and/or the plurality of binder fibers are made of any suitable material, such as those materials already described herein.

The nontextured fiber components, textured fiber components, additional fiber components and/or the plurality of binder fibers can be combined once the components and, in some embodiments, the plurality of binder fibers are provided. Combining nontextured fiber components, textured fiber components and/or the plurality of binder fibers can be done using any suitable, conventional and/or readily available combining method. It is contemplated that nontextured fiber components, textured fiber components and/or the plurality of binder fibers can be combined together at the same time or can be combined sequentially—meaning that, in some contemplated embodiments, the nontextured fiber components and/or textured fiber components can be combined first before the at least some of the plurality of binder fibers is combined with both components or the at least some of the plurality of the binder fibers may be combined with each one of the nontextured fiber component and/or the textured fiber component before each is combined with one another. In contemplated embodiments, the nontextured fiber components are combined with other nontextured fiber components or textured fiber components by plying, cabling and/or folding the fiber components with one another. It is also contemplated that plying the nontextured fiber components with one another or with textured fiber components coupled with heatsetting the plied fiber components will significantly increase the luster component of the plied yarn.

The fiber materials contemplated and described herein may be used alone or in combination with other materials and/or products to form any suitable product, including yarn products and carpet products. It should be understood that the nontextured fiber components, the textured fiber components, the plied carpet yarn and/or the carpet product may be dyed—alone or in combination—using any conventional dyeing methods, such as carpet dyeing—exhaust or continuous dyeing, yarn skein dyeing and/or yarn package dyeing. Precolored yarns may also be utilized, such as those that are solution dyed during extrusion spinning or yarn space dyed. Fibers may also be used that are dyed by solution dyeing (extrusion melt dyeing)). Also, any conventional colorants may be used, such as those that are currently being used in the carpet and textile industries. It should also be understood that the nontextured fiber components, the textured fiber components, the plied carpet yarn and/or the carpet product may be produced in a “non-dyed” form in order to send to customers for dying treatments. In one example, the nontextured fiber components may be dyed and then plied with textured fiber components. The resulting 2 or 3-ply yarn may then be heatset and the entire yarn dyed. This second dying for the nontextured fiber components would produce unique styling effects that combine color and luster in the final carpet product.

EXAMPLES

The fiber materials, yarn products, carpet products and methods used to produce those materials and products, as described in the examples, are for illustrative purpose only and should not, in any way, limit the scope of this invention.

Example 1

Undrawn feeder yarn for 1124 Medium Dyeable Bright (MB) was obtained. The undrawn yarn or total bundle denier was 2786. This denier is at take up in extrusion, which in this Example is the first step in a two step operation. It should be understood, however, that the two step process described in this Example can be easily converted into a one step process that produces a similar product. In this Example, the second step is called “Sintex” and the yarn is drawn, thus reducing the total bundle denier to about 1037 denier. This drawn denier, which is about 1037, is divided by the number of filaments (or 60 in this case) resulting in a denier per filament (dpf) of 17.28. The Mod ratio, which is the ratio between the outside and inside circumference of the cross-section was calculated to be 2.33. The undrawn 2786 bundle denier fiber was spun according to the specifications shown in Table 1. The samples of 1024 MB produced an average 1037 drawn untextured total bundle denier (v. 1150-1175 total bundle denier for standard drawn textured 1124 MB) and commingling averaged 23 EPM. EPM stands for “entanglement per meter” and are the “tack” points put in the yarn to keep the individual filaments together during cabling. The 1024 MB drawn untextured process included pre-draw, mechanical draw, bypassing texturing going directly to driven Roll 4, then to commingling, and then relaxing 1% between driven Roll 4 and driven Roll 5, and then to winder. The Sintex machine specifications for this example are shown in Table 2.

TABLE 1
Spinning Specifications
	Product	1124 MB
	Spin Description	2780 MB
	Polymer Type	MBM-Chip
	Capillary	8.5 × 30 × 30
	Throughput (pph)	38.0
	Spinnerette	60Y Type 146
	Number of Filaments	60
	Spin Merge	7845
	Line	1
	Model	50
	Finish Type	N-149-16
	Drip Indicator Type	0.020 inches
	Winder Tensions (gms)	125 ± 15
	Oil on Yarn (%)	1.00 ± 0.3
	Lube Roll (RPM)	18.5 ± 0.5
	Quench Inlet (126 CFM)	1.40 ± 0.05
	Quench Exhaust (152 CFM)	1.55 ± 0.05
	Undrawn Denier (units)	2805 ± 83
	Mod Ratio	2.30 ± 0.3
	TiO2 (%)	N/A
	Monomer Exhaust (Inches)	8 ± 0.5
	ME Ring Temp (° C.)	N/A
	Sleeve Number	2020
	Inside Color	Red Bars
	Outside Color	Yellow/Red
	Filtration	25 micron metal felts
	Pot Life (Days Max)	60
	Max Pack Pressure (psig)	4000
	Schedule Wipes	As Needed
	Doff Cycle	50 min
		Target	Range
	Zone Temperature (° C.)	255	230-260
		250	230-260
		Adjustable	230-290
	EPT (° C.)		258 ± 7
	Block Temp (° C.)		258 ± 7
	QZT Range (° C.)		1 to 120
	Ind. QZT		120 Max

TABLE 2
Sintex Machine Specifications
Specification		1024 MB
		(w/N-149-16)
Finished Product		1024 MB
Description
Feeder Yarn	Description	2780 MB
(Supply Yarn)	Polymer Type	MBM-Chip
	Undrawn Sleeve	2020
	Inside	Red Bars
	Outside	Yellow/Red
Controllers	Superheater Temperature	390 ± 10° C.
	Impedence Temp., North	OFF
	Impedence Temp., South	OFF
	Commingling Air Pressure	90 ± 15 psi
	Temco Commingling Jets	LD 32.02
	Air Blast On	90 ± 15 psi
Inverters	Roll 1	36.50 ± 0.3
(Frequency (Hz))	Roll 2	24.07 ± 0.3
	Roll 3	61.27 ± 0.3
	Roll 4	130.56 ± 0.3
	Roll 5	129.25 ± 0.3
	Print Roll	109 ± 3
	Travel Guide	65 ± 3
Line Gauge Settings	Winder Air Pressure (P0)	65 ± 5 psi
	Anti-Burn Out Air	80 ± 2 psi
	Pressure
	Panel Temperature	45 ± 20° C.
		(Steady State)
	Nozzle	0.058 inches
		(Nominal)
Drawing Speed		6420 FPM
		(6.0 k)
Roll Ratios	2/1	1.1
	3/1	2.8
	4/3	1.0
	5/4	0.99
Roll Number/Wraps	Temperature ° C.	RPM
1/3	N/A	2191 ± 22
2 (Vapor)/6	120 ± 10	1444 ± 14
3 (Vapor)/6	155 ± 10	3676 ± 37
4/6	N/A	3917 ± 31
5/6	N/A	3878 ± 32
Doff Cycle		34 minutes/0 Seconds
Between Winders		15 Seconds
Nominal Package Size		10.3 inches
Tensions	After #4 Roll	150 ± 30 gms
	Before Comm.	50 ± 30 gms
	After Comm.	125 ± 30 gms
	Winder	100 ± 30 gms
Lab Samples Individual	Denier	1000 ± 50
Limits	EPM (eTYT)	25.0 (10-45)
	Crimp (eTYT)	N/A

Thus, specific embodiments and applications of high luster fiber materials and yarns, their manufacture and uses thereof have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure and the claims. Moreover, in interpreting the disclosure and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.

Claims

1. A plied carpet fiber material, comprising:

at least one nontextured fiber component plied with at least one additional fiber component to form the plied carpet fiber material, wherein each nontextured fiber component comprises a luster component.

2. The plied carpet fiber material of claim 1, wherein the at least one additional fiber component comprises at least one nontextured fiber component.

3. The plied carpet fiber material of claim 1, wherein the at least one additional fiber component comprises at least one textured fiber component.

4. The plied carpet fiber material of claim 1, wherein the at least one additional fiber component comprises at least two plies.

5. The plied carpet fiber material of claim 4, wherein the at least two plies comprises at least one nontextured fiber component, at least one textured fiber component or a combination thereof.

6. The plied carpet fiber material of claim 1, wherein the luster component of the nontextured fiber component is at least 10% higher than a luster component of an identical fiber component that is textured.

7. The plied carpet fiber material of claim 6, wherein the luster component of the nontextured fiber component is at least 25% higher than a luster component of an identical fiber component that is textured.

8. The plied carpet fiber material of claim 7, wherein the luster component of the nontextured fiber component is at least 50% higher than a luster component of an identical fiber component that is textured.

9. The plied carpet fiber material of claim 8, wherein the luster component of the nontextured fiber component is at least 75% higher than a luster component of an identical fiber component that is textured.

10. The plied carpet fiber material of claim 1, wherein the at least one nontextured fiber component or the at least one ply of an additional fiber component comprises a delta shape, a Y shape, a circular shape, a square shape, a starflake shape, a ribbon shape, or a combination thereof.

11. The plied carpet fiber material of claim 10, wherein the at least one nontextured fiber component or the at least one ply of an additional fiber component comprises a delta shape, a circular shape, a square shape, or a combination thereof.

12. The plied carpet fiber material of claim 11, wherein the delta shape fiber component, the circular shape fiber component or the square shape fiber component is hollow.

13. The plied carpet fiber material of claim 1, wherein the at least one nontextured fiber component, the at least one ply of an additional fiber component or a combination thereof are dyed.

14. A plied carpet fiber material, comprising:

at least one nontextured fiber component, wherein each nontextured fiber component comprises a luster component, and

at least one textured fiber component, wherein each textured fiber component comprises a luster component, wherein the at least one nontextured fiber component and the at least one textured fiber component are plied with one another to produce the plied carpet fiber material.

15. The plied carpet fiber material of claim 14, wherein the luster component of the nontextured fiber component is at least 10% higher than the luster component of the textured fiber component.

16. The plied carpet fiber material of claim 15, wherein the luster component in the nontextured fiber component is at least 25% higher than the luster component of the textured fiber component.

17. The plied carpet fiber material of claim 16, wherein the luster component in the nontextured fiber component is at least 50% higher than the luster component of the textured fiber component.

18. The plied carpet fiber material of claim 17, wherein the luster component in the nontextured fiber component is at least 75% higher than the luster component of the textured fiber component.

19. The plied carpet fiber material of claim 14, wherein the at least one nontextured fiber component or the at least one textured fiber component comprises a delta shape, a Y shape, a circular shape, a square shape, a starflake shape, a ribbon shape, or a combination thereof.

20. The plied carpet fiber material of claim 19, wherein the at least one nontextured fiber component or the at least one textured fiber component comprises a delta shape, a circular shape, a square shape, or a combination thereof.

21. The plied carpet fiber material of claim 20, wherein the delta shape fiber component, the circular shape fiber component or the square shape fiber component is hollow.

22. The plied carpet fiber material of claim 14, wherein the at least one nontextured fiber component, the at least one textured fiber component or a combination thereof are dyed.

23. A plied carpet fiber material, comprising:

at least two nontextured fiber components, wherein each nontextured fiber component comprises a luster component, and wherein the at least two nontextured fiber components are plied with one another to produce the plied carpet fiber material.

24. The plied carpet fiber material of claim 23, wherein the luster component of the nontextured fiber components is at least 10% higher than the luster component of an identical fiber component that is textured.

25. The plied carpet fiber material of claim 24, wherein the luster component in the nontextured fiber components is at least 25% higher than the luster component of an identical fiber component that is textured.

26. The plied carpet fiber material of claim 25, wherein the luster component in the nontextured fiber components is at least 50% higher than the luster component of an identical fiber component that is textured.

27. The plied carpet fiber material of claim 26, wherein the luster component in the nontextured fiber components is at least 75% higher than the luster component of an identical fiber component that is textured.

28. The plied carpet fiber material of claim 23, wherein the at least two nontextured fiber components comprise a delta shape, a Y shape, a circular shape, a square shape, a starflake shape, a ribbon shape, or a combination thereof.

29. The plied carpet fiber material of claim 28, wherein the at least two nontextured fiber components comprise a delta shape, a circular shape, a square shape, or a combination thereof.

30. The plied carpet fiber material of claim 29, wherein the delta shape fiber component, the circular shape fiber component or the square shape fiber component is hollow.

31. The plied carpet fiber material of claim 23, wherein at least one of the at least two nontextured fiber components are dyed.

32. A carpet yarn comprising the carpet fiber material of one of claims 1, 14 or 23.

33. A carpet product comprising the carpet yarn of claim 32.

34. A carpet yarn comprising the carpet fiber material of claim 1 and a plurality of binder fibers.

35. A carpet yarn comprising the carpet fiber material of claim 14 and a plurality of binder fibers.

36. A carpet yarn comprising the carpet fiber material of claim 23 and a plurality of binder fibers.

37. The carpet yarn of one of claims 34, 35 or 36, wherein at least some of the binder fibers comprises a synthetic material.

38. The carpet yarn of claim 37, wherein the synthetic material comprises a polyamide-based compound.

39. A method of producing a plied carpet fiber material, comprising:

providing at least one nontextured fiber component, wherein each nontextured fiber component comprises a luster component;

providing at least one textured fiber component, wherein each textured fiber component comprises a luster component; and

combining the at least one nontextured fiber component and the at least one textured fiber component to form the fiber material.

40. The method of claim 39, wherein combining comprises plying the at least one nontextured fiber component and the at least one textured fiber component to form the plied fiber material.

41. The method of claim 39, wherein the luster component of the nontextured fiber component is at least 10% higher than the luster component of the textured fiber component.

42. The method of claim 41, wherein the luster component in the nontextured fiber component is at least 25% higher than the luster component of the textured fiber component.

43. The method of claim 42, wherein the luster component in the nontextured fiber component is at least 50% higher than the luster component of the textured fiber component.

44. The method of claim 43, wherein the luster component in the nontextured fiber component is at least 75% higher than the luster component of the textured fiber component.

45. The method of claim 39, wherein the at least one nontextured fiber component or the at least one textured fiber component comprises a delta shape, a Y shape, a circular shape, a square shape, a starflake shape, a ribbon shape, or a combination thereof.

46. The plied carpet fiber material of claim 45, wherein the at least one nontextured fiber component or the at least one textured fiber component comprises a delta shape, a circular shape, a square shape, or a combination thereof.

47. The method of claim 46, wherein the delta shape fiber component, the circular shape fiber component or the square shape fiber component is hollow.

48. The method of claim 39, wherein the at least one nontextured fiber component, the at least one textured fiber component or a combination thereof are dyed.