Process for improving stain resistance and lightfastness of carpet yarn
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[0009]Provided by the present invention is a method for dyeing carpet fibers that may be used in forming carpet that has the stain resistance and lightfastness of carpet made with solution dyed yarn while also allowing for the color variation of carpet made with space dyed yarn. According to an embodiment of the invention, the method comprises an initial step of providing two or more solution dyed bulk continuous filament (BCF) fibers. These BCF fibers are preferably formed from yarns formed from a cationic-based pigmented polymer, such as polyamide. For example, in some embodiments, a suitable fiber is nylon type 6 fiber. In other embodiments, a suitable fiber is nylon type 6.6 fiber. The BCF fibers are twisted or cabled to form a 2 or more ply strand of fiber. The twist level provided should be suitable for the wear performance and style of carpet. This twisting step is carried out on conventional twisting equipment. For example, in certain embodiments, the fibers are twisted usin...
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