System and method for providing color enhanced yarns

Abstract

Systems and methods for producing BCF yarns include providing at least one color enhancement method for enhancing the color and / or shade of at least one of the N bundles of filaments. The color enhancement method includes securing one or more of the bundles of spun filaments prior to and / or during drawing, individually texturing one or more of the bundles of spun filaments from the other bundles of spun filaments, providing intermediate securing of at least one of the bundles of textured filaments, and feeding the secured and textured filaments into a mixing cam for positioning the secured and textured bundles relative to each other prior to reaching a final securing device, or a combination thereof.

Description

BACKGROUND

[0001] Bulk continuous filament (BCF) yarns are known for use in tufted carpets. Yarns having different colors along the length are desired to provide some type of fairly random colored carpet surface.

[0002] Typically, such yarns suitable for this purpose are made by space dyeing white or pigmented yarns after the yarns are produced. Space dyeing is a post-production process that adds time and cost to the overall process, and the dye can not penetrate through the entire cross-section of the filament, which can negatively affect the appearance of the cut ends of the filament and can result in color fading over time.

[0003] Accordingly, there is a need in the art for improved BCF yarns and other yarns for use in tufted carpets. SUMMARY

[0004] It is an object of the present invention to provide yarns having different colors along the length with more pronounced (or visible) color in localized areas.

[0005] Depending on the location of the filaments along the surface of the yarn, the yarn can have a gradient of color, shade, and / or dyeability properties along its axial length. One advantage of various embodiments is having more pronounced color and / or shade variations along the axial length of the yarn. The yarn can be a bulk continuous filament (BCF) yarn, which can be (1) extruded and drawn in a continuous operation, (2) extruded, drawn, and textured in a continuous operation, (3) extruded and take-up in one step and then opened, drawn, and textured in another step, or (4) extruded, drawn, and textured in one or more operations.

[0006] Further, for example, the BCF yarns or multi-step produced yarns can be used as yarns in carpets (e.g., tufted carpets) or garments.

[0007] The above objects are achieved by the methods and systems according to various embodiments of the present invention.

[0008] According to a first aspect, a method of producing a BCF yarn includes: A. providing N bundles of spun filaments, N being an integer of 2 or more; B. drawing the N bundles of spun filaments; C. texturing the N bundles of drawn spun filaments; D. fixing the N bundles of textured spun filaments to provide a BCF yarn, wherein at least a first bundle of the N bundles of spun filaments is fixed individually before or during step B.

[0009] According to some embodiments, all of the N bundles of spun filaments are fixed individually.

[0010] According to some embodiments, each of the N bundles of spun filaments is partially drawn before being fixed, and the N bundles are drawn to a final denier after being fixed.

[0011] According to some implementations, the length between consecutive fixations on each bundle is 5 to 50 mm.

[0012] According to some implementations, at least one bundle of N-bundled spun filaments has different color, hue, and / or dyeability characteristics compared to the color, hue, and / or dyeability characteristics of another bundle of N-bundled spun filaments.

[0013] According to some implementations, each bundle in an N-bundle spun filament has a different color, hue, and / or dyeability characteristics compared to the color, hue, and / or dyeability characteristics of other N-bundle spun filaments.

[0014] According to some embodiments, BCF yarn is produced according to the method of the first aspect.

[0015] According to some embodiments, the carpet includes a pile, and the pile is made of BCF yarn produced according to the method of the first aspect.

[0016] According to a second aspect, a method for producing BCF yarn includes: A. providing N bundles of spun filaments, where N is an integer of 2 or greater; B. stretching the N bundles of spun filaments; C. texturing the N bundles of stretched spun filaments; and D. fixing the N bundles of textured spun filaments to provide BCF yarn, wherein in step C, at least a first bundle of the N bundles of stretched spun filaments is texturized separately from the other bundles of the N bundles of stretched spun filaments.

[0017] According to some implementations, in step C, all N bundles of stretched spun filaments are individually textured.

[0018] According to some implementations, before or during step B, at least the first bundle is fixed separately from the other N bundles of spun filaments.

[0019] According to some implementations, all N bundles of spun filaments are individually secured before or during step B.

[0020] According to some implementations, at least one bundle of N-bundled spun filaments has different color, hue, and / or dyeability characteristics compared to the color and / or hue of another bundle of N-bundled spun filaments.

[0021] According to some implementations, each bundle of N-bundled spun filaments has different color, hue, and / or dyeability characteristics compared to the color, tint, and / or dyeability characteristics of the other N-bundled spun filaments.

[0022] According to some implementation methods, BCF yarn is produced according to the method of the second aspect.

[0023] According to some embodiments, the carpet comprises a pile, and the pile is made of a BCF yarn produced according to the method of the second aspect.

[0024] According to a third aspect, a method of producing a BCF yarn, comprising: A. providing N bundles of spun filaments, N being an integer of 2 or more; B. stretching the N bundles of spun filaments; C. texturing the N bundles of stretched spun filaments; and D. fixing the N bundles of textured spun filaments to provide a BCF yarn, wherein between steps C and D, the filaments of at least one of the N bundles of textured spun filaments are fixed individually.

[0025] According to some embodiments, prior to the final fixing in step D, the fixed bundles of textured spun filaments and the N bundles of textured spun filaments are guided on a mixing cam to position the bundles relative to each other.

[0026] According to some embodiments, while guiding the textured spun filaments on the mixing cam, the mixing cam is rotated, changing the position of the bundles relative to each other prior to the final fixing step in step D.

[0027] According to some embodiments, while guiding the textured spun filaments on the mixing cam, the mixing cam is stationary.

[0028] According to some embodiments, at least one of the N bundles of spun filaments is fixed individually prior to and / or during step B.

[0029] According to some embodiments, each of the N bundles of spun filaments is fixed individually prior to and / or during step B.

[0030] According to some embodiments, in step C, at least a first bundle of the N bundles of stretched spun filaments is textured separately from the other bundles of the N bundles of stretched spun filaments.

[0031] According to some embodiments, in step C, all of the N bundles of stretched spun filaments are textured individually.

[0032] According to some embodiments, the filaments of at least one of the N bundles of spun filaments have different color, shade and / or dyeability properties compared to the color, shade and / or dyeability properties of another of the N bundles of spun filaments.

[0033] According to some embodiments, the filaments of each of the N bundles of spun filaments have different color, shade and / or dyeability properties compared to the color, shade and / or dyeability properties of the other N bundles of spun filaments.

[0034] According to some embodiments, the yarn is produced according to the method of the third aspect. In some embodiments, the yarn is a BCF yarn.

[0035] According to some embodiments, the carpet comprises pile, and the pile is made using the yarn according to the third aspect.

[0036] According to some embodiments, the yarn is produced according to the method of the first aspect in combination with the method of the third aspect. And, according to some embodiments, the carpet comprises pile, and the pile is made using the yarn produced according to the method of the first aspect in combination with the method of the third aspect.

[0037] According to some embodiments, the yarn is produced according to the method of the first aspect in combination with the method of the third aspect. And, according to some embodiments, the carpet comprises pile, and the pile is made using the yarn produced according to the method of the first aspect in combination with the method of the third aspect.

[0038] According to some embodiments, the yarn is produced according to the method of the second aspect in combination with the method of the third aspect. And, according to some embodiments, the carpet comprises pile, and the pile is made using the yarn produced according to the method of the second aspect in combination with the method of the third aspect.

[0039] According to some embodiments, the yarn is produced according to the method of the first aspect in combination with the method of the second aspect and the method of the third aspect. And, according to some embodiments, the carpet comprises pile, and the pile is made using the yarn produced according to the method of the first aspect in combination with the method of the second aspect and the method of the third aspect.

[0040] According to the fourth aspect, a yarn spinning system comprises: A. a spinning plate for spinning N bundles of spun filaments, N being an integer of 2 or more; B. at least one stretching device for stretching the N bundles of spun filaments; C. at least one texturizer for texturizing the N bundles of stretched spun filaments; and D. a final fixing device for fixing the N bundles of texturized spun filaments to provide a yarn, wherein the system further comprises an initial fixing device, which is located upstream of or integrated within at least the stretching device, to fix at least one bundle of the N bundles of spun filaments before or during the stretching of the N bundles of spun filaments.

[0041] According to some embodiments, the at least one texturizer comprises at least a first texturizer and a second texturizer, and at least one bundle of the N bundles of spun filaments is texturized separately from the other N bundles of spun filaments by the first texturizer.

[0042] According to some embodiments, the at least one texturizer comprises N texturizers, and each bundle of the N bundles of spun filaments is texturized independently from each other by the respective N texturizers.

[0043] According to some embodiments, the system further comprises an intermediate fixation device disposed between the at least one texturizer and the final fixation device, the intermediate fixation device for fixing at least one of the N bundles of textured spun filaments.

[0044] According to some embodiments, the system further comprises a mixing cam disposed between the at least one texturizer and the final fixation device, the mixing cam for positioning the fixed and textured bundles relative to each other prior to reaching the final fixation device.

[0045] According to some embodiments, the mixing cam is rotated while the textured spun filaments are guided over the mixing cam to change the position of the bundles relative to each other prior to the final fixation step in step D.

[0046] According to some embodiments, the mixing cam is stationary while the textured spun filaments are guided over the mixing cam.

[0047] According to some embodiments, the filaments of at least one of the N bundles of spun filaments have different color, shade and / or dyeability properties compared to the color, shade and / or dyeability properties of another of the N bundles of spun filaments.

[0048] According to some embodiments, the filaments of each of the N bundles of spun filaments have different color, shade and / or dyeability properties compared to the color, shade and / or dyeability properties of the other N bundles of spun filaments.

[0049] According to a fifth aspect, a BCF yarn spinning system comprises: A. a spinning plate for spinning N bundles of spun filaments, N being equal to or greater than 2; B. at least one drawing device for drawing the N bundles of spun filaments; C. at least a first texturizer and a second texturizer, wherein at least one of the N bundles of drawn spun filaments is individually texturized by the first texturizer independently of the other N bundles of drawn spun filaments; and D. a final fixation device for fixing the N bundles of textured spun filaments to provide a BCF yarn.

[0050] According to some embodiments, the system further comprises N texturizers, wherein the N texturizers comprise the first texturizer and the second texturizer, and each of the N bundles of drawn spun filaments is individually texturized from the other N bundles of drawn spun filaments by the respective N texturizers.

[0051] According to some embodiments, the system further comprises a second fixation device disposed between the texturizer and the final fixation device, the second fixation device for fixing at least one of the N bundles of textured spun filaments.

[0052] According to some embodiments, the system further comprises a mixing cam disposed between the texturizer and the final tacking device, the mixing cam for positioning the tacked and textured bundles relative to each other prior to reaching the final tacking device.

[0053] According to some embodiments, the mixing cam is rotated while the textured spun filaments are guided thereon, changing the position of the bundles relative to each other upon reaching the final tacking device.

[0054] According to some embodiments, the mixing cam is stationary while the textured spun filaments are guided thereon.

[0055] According to some embodiments, the filaments of at least one of the N bundles of spun filaments have different color, shade, and / or dyeability characteristics compared to the color, shade, and / or dyeability characteristics of another one of the N bundles of spun filaments.

[0056] According to some embodiments, the filaments of each of the N bundles of spun filaments have different color, shade, and / or dyeability characteristics compared to the color, shade, and / or dyeability characteristics of the other N bundles of spun filaments.

[0057] According to a sixth aspect, a BCF yarn spinning system comprises: A. a spinning plate for spinning N bundles of spun filaments, N being an integer of 2 or more; B. at least one drawing device for drawing the N bundles of spun filaments; C. at least one texturizer for texturizing the N bundles of drawn spun filaments; D. a second tacking device disposed between the texturizer and a final tacking device, the second tacking device for tacking at least one of the N bundles of textured spun filaments; and E. a final tacking device for tacking the N bundles of textured spun filaments to provide a BCF yarn.

[0058] According to some embodiments, the system further comprises a mixing cam disposed between the second tacking device and the final tacking device, the mixing cam for positioning the tacked and textured bundles relative to each other prior to reaching the final tacking device.

[0059] According to some embodiments, the mixing cam is rotated while the textured spun filaments are guided thereon, changing the position of the bundles relative to each other upon reaching the final tacking device.

[0060] According to some embodiments, the mixing cam is stationary while the textured spun filaments are guided thereon.

[0061] According to some embodiments, the filaments of at least one of the N bundles of spun filaments have different color, shade, and / or dyeability characteristics compared to the color, shade, and / or dyeability characteristics of another one of the N bundles of spun filaments.

[0062] According to some embodiments, the filaments of each bundle of N spun filaments have different color, shade and / or dyeability characteristics compared to the color, shade and / or dyeability characteristics of the other bundles of spun filaments.

[0063] According to a sixth aspect, a BCF yarn spinning system comprises: A. a spinning plate for spinning N bundles of spun filaments, N being an integer of 2 or more; B. at least one drawing device for drawing the N bundles of spun filaments; C. at least one texturizer for texturizing the N bundles of drawn spun filaments; D. a second fixing device disposed between the texturizer and the final fixing device, the second fixing device for fixing at least one bundle of the N bundles of texturized spun filaments; and E. a final fixing device for fixing the N bundles of texturized spun filaments to provide a BCF yarn.

[0064] According to a seventh independent aspect, there is provided a yarn comprising two or more bundles of spun filaments, wherein the bundles comprise individual fixing points at which the filaments of the respective bundle are fixed together. In some embodiments, the yarn is a BCF yarn. In some embodiments, the bundles of filaments can further comprise a common fixing point at which the filaments of all bundles are fixed together. In some embodiments, the position of the bundles relative to each other varies at successive common fixing points. In some embodiments, the two or more bundles comprise one or more individual fixings between two common fixings along their length. In some embodiments, the spun filaments of the two or more bundles can comprise individual textures, for example, the bundles can be texturized individually. In some embodiments, the filaments of at least one bundle of spun filaments have different color, shade and / or dyeability characteristics compared to the color, shade and / or dyeability characteristics of another bundle of spun filaments. It will be clear that the yarn of the seventh aspect can or can not have been obtained by the method according to the first, second and / or third aspects and / or by using a spinning system according to the fourth, fifth or sixth aspects as above. The yarn of the seventh aspect can exhibit similar or equal preferred properties to yarns obtained by these methods or spinning systems, without necessarily having been obtained in that way.

[0065] The yarn of the seventh aspect can have a color or shade that varies along the length of the yarn. The claimed individual and common fixing points improve the reproducibility or richness of color.

[0066] In some embodiments, the filaments of the two or more yarns of the seventh aspect are solid dyed (also referred to as mass dyed) filaments. Such filaments comprise their respective colour throughout their entire cross-section and have better abrasion resistance while providing better colour reproduction when cut into pile. Thus, in some embodiments, the filaments or bundles are spun from a coloured polymer such as PET (polyethylene terephthalate), PTT (polytrimethylene terephthalate), PP (polypropylene) or PA (polyamide). In some embodiments, the yarn comprises at least two differently coloured filaments or bundles, wherein the difference in colour or shade is such that it can be expressed using a delta E value of greater than 1.0. For example, in some embodiments, the delta E value is at least 5.0 or at least 10.0. In some embodiments, the individual filaments or bundles are uniformly coloured over their length. The variation in colour and / or shade is obtained by providing separate and / or common fixation between the differently coloured bundles provided by the seventh aspect, as well as by separate texturing.

[0067] According to an eighth independent aspect, there is provided a carpet, rug or tile (herein collectively referred to as a "carpet") comprising pile formed from the yarn according to the seventh independent aspect.

[0068] The independent claims and the dependent claims each set out particular and preferred features of the application. Features from a dependent claim can be combined with features of the independent claim or of other dependent claims, and / or with features set out in the above and / or below description, as appropriate and expedient.

[0069] The above and other characteristics, features and advantages of the present application will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the application. This description is given for the sake of example only, without limiting the scope of the application. The reference figures cited refer to the attached drawings. BRIEF DESCRIPTION OF DRAWINGS

[0070] The example features and implementations are disclosed in the drawings. However, the present disclosure is not limited to the precise arrangements shown, and the drawings are not necessarily drawn to scale.

[0071] Figure 1 A schematic diagram of a system according to an implementation is shown.

[0072] Figure 2 A schematic diagram of a system according to a second implementation is shown.

[0073] Figure 3 A schematic diagram of a system according to a third implementation is shown.

[0074] Figure 4 A schematic diagram of a system according to a fourth implementation is shown.

[0075] Figure 5A schematic diagram of a system according to a fifth implementation is shown.

[0076] Figure 6 A schematic diagram of a system according to a sixth implementation is shown.

[0077] Figure 7 A schematic diagram of a system according to a seventh implementation is shown.

[0078] Figure 8 A schematic diagram of a system according to an eighth implementation is shown.

[0079] Figure 9 An example computing device that can be used in accordance with implementations herein is shown. DETAILED DESCRIPTION

[0080] Various implementations are described in the context of particular implementations. It should be noted that the term "comprising" as used in the claims is not to be construed as limiting the manner in which features, steps or components are presented; it does not exclude additional features, steps, components, or groups thereof. Thus, it should be construed that the term "comprising" as used in the claims is to be interpreted as specifying the presence of the stated features, steps or components as referred to, but does not preclude the presence or addition of one or more other features, steps, components, or groups thereof.

[0081] Throughout this specification, reference has been made to "one embodiment" or "an embodiment" (or "one implementation" or "an implementation"). Such references mean that a particular feature under review can be included in at least one embodiment of the application disclosed herein. Accordingly, appearances of the phrases "in one embodiment" or "in an embodiment" (or "in one implementation" or "in an implementation") at various places in the specification are not necessarily all referring to the same embodiment, though they can.

[0082] Also, as will be apparent to those of ordinary skill in the art, many of the specific features or characteristics described above can be combined with one another in any suitable manner in one or more embodiments.

[0083] According to a first aspect, a method of producing a BCF yarn includes: A. providing N bundles of spun filaments, N being an integer of 2 or more; B. drawing the N bundles of spun filaments; C. texturing the N bundles of drawn spun filaments; and D. consolidating the N bundles of textured spun filaments to provide a BCF yarn, wherein at least a first bundle of the N bundles of spun filaments is individually consolidated prior to or during step B.

[0084] According to a second aspect, a method of producing a BCF yarn, comprising: A. providing N bundles of spun filaments, N being an integer of 2 or greater; B. stretching the N bundles of spun filaments; C. texturing the N bundles of stretched spun filaments; and D. fixing the N bundles of textured spun filaments to provide a BCF yarn, wherein in step C, at least a first bundle of the N bundles of stretched spun filaments is texturized separately from other bundles of the N bundles of stretched spun filaments.

[0085] According to a third aspect, a method of producing a BCF yarn, comprising: A. providing N bundles of spun filaments, N being an integer of 2 or greater; B. stretching the N bundles of spun filaments; C. texturing the N bundles of stretched spun filaments; and D. fixing the N bundles of textured spun filaments to provide a BCF yarn, wherein between steps C and D, filaments of at least a bundle of the N bundles of textured spun filaments are fixed separately.

[0086] According to a fourth aspect, a BCF yarn spinning system, comprising: A. a spinning plate for spinning N bundles of spun filaments, N being an integer of 2 or greater; B. at least one stretching device for stretching the N bundles of spun filaments; C. at least one texturizer for texturing the N bundles of stretched spun filaments; and D. a final fixing device for fixing the N bundles of textured spun filaments to provide a BCF yarn, wherein the system further comprises an initial fixing device, upstream of at least the stretching device or integrated within at least the stretching device, for fixing at least a bundle of the N bundles of spun filaments before or during stretching of the N bundles of spun filaments.

[0087] According to a fifth aspect, a BCF yarn spinning system, comprising: A. a spinning plate for spinning N bundles of spun filaments, N being equal to or greater than 2; B. at least one stretching device for stretching the N bundles of spun filaments; C. at least a first texturizer and a second texturizer, wherein at least a bundle of the N bundles of stretched spun filaments is texturized by the first texturizer separately from other N bundles of stretched spun filaments; and D. a final fixing device for fixing the N bundles of textured spun filaments to provide a BCF yarn.

[0088] According to a sixth aspect, a BCF yarn spinning system, comprising: A. a spinning plate for spinning N bundles of spun filaments, N being an integer of 2 or greater; B. at least one stretching device for stretching the N bundles of spun filaments; C. at least one texturizer for texturing the N bundles of stretched spun filaments; D. a second fixing device disposed between the texturizer and the final fixing device, the second fixing device for fixing at least a bundle of the N bundles of textured spun filaments; and E. a final fixing device for fixing the N bundles of textured spun filaments to provide a BCF yarn.

[0089] According to a seventh independent aspect, there is provided a yarn comprising two or more bundles of spun filaments, wherein the bundles comprise individual fixing points at which the filaments of the respective bundle are fixed together.

[0090] According to an eighth independent aspect, there is provided a carpet, rug or tile (collectively referred to herein as "carpet") comprising piles formed from the yarn according to the seventh independent aspect.

[0091] Figure 1 A schematic diagram of a system for producing a BCF yarn according to one embodiment is shown. Series 100 includes three extruders 110, 120 and 130, three spinning stations (each comprising a spinneret 112, 122 and 132 and pumps 101, 102, 103), a processor 109, a quencher 150, fixing devices 115, 125, 135, a drawing device 160, a texturizer 170, and a final fixing device 180. Although not shown, the spinnerets 112, 122, 132 and pumps 101, 102, 103 can be included in one or more spinning stations.

[0092] Each spinneret 112, 122 and 132 can be, for example, a spinneret. Each spinneret defines a plurality of openings through which a stream of molten polymer is spun. The radial cross-sectional shape of each opening at least partially defines the radial cross-sectional shape of each filament. At least a portion of the opening radial cross-sectional shape in each spinneret can be the same or different.

[0093] In general, with respect to each aspect of the present invention, it should be noted that each filament has a given radial cross-sectional shape, such as circular, oval, fox, trilobal or other suitable radial cross-sectional shape. In some embodiments, the radial cross-sectional shape of the filaments in each bundle is the same, and in other embodiments, the shape of the filaments in each bundle can be different. Also, the radial cross-sectional shape of the filaments in one bundle can be the same or different than the radial cross-sectional shape of the filaments in another bundle. For example, a bundle of filaments or yarn can include filaments having different cross-sectional shapes to provide a desired texture. Further, the filaments can be solid or define at least one hollow void. Similarly, the size of the spinneret openings can be the same or different, depending on the desired denier / filament of each filament.

[0094] Each pump 101, 102, 103 is in fluid communication with a respective extruder 110, 120, 130 for pushing molten polymer from each extruder 110, 120, 130 through a respective spinneret 112, 122, 132. The processor 109 is in electrical communication with the spin pumps 101, 102, 103 and is configured to execute computer readable instructions that cause the processor to adjust the volumetric flow rate of thermoplastic polymer pumped by each spin pump to achieve the proportion of thermoplastic polymer to be included in the yarn. The volumetric flow rate extruded by each spin pump is greater than 0 and varies within ±40% or less of a baseline volumetric flow rate, where the baseline volumetric flow rate is equal to the total volumetric flow rate through the pumps divided by the number of pumps.

[0095] By increasing the denier per filament of the filaments in one or more bundles of filaments of the yarn, the color from that set of filaments is significantly more prevalent in the yarn. If other process controls are the same, increasing the speed of a spin pump increases the volumetric flow rate of molten thermoplastic polymer through the spinneret in fluid communication with the spin pump, and the increased volumetric flow rate through the spinneret increases the average denier per filament of the filaments spun through the spinneret. Conversely, decreasing the speed of a spin pump decreases the volumetric flow rate of molten thermoplastic polymer through the spinneret in fluid communication with the spin pump, and the decreased volumetric flow rate through the spinneret decreases the average denier per filament of the filaments spun through the spinneret. Thus, by varying the speed (and thus the volumetric flow rate) of the individual pumps in communication with the spinnerets through which the filaments of each bundle are spun, the average denier per filament of the filaments in each bundle of filaments can be increased or decreased. Increasing and decreasing the speed of at least one or more pumps can also vary according to a particular frequency and amplitude, in some implementations, resulting in portions of the length of the bundle having a higher DPF than other portions of the length.

[0096] Although not shown, the system 100 can be scaled to include another set of spin stations paired with each extruder (or one or more additional spin stations having a pump and a spinneret paired with each extruder) for producing a second yarn having a second proportion of thermoplastic polymer to be included in the second yarn. In such implementations, the sum of the volumetric flow rates extruded by each extruder through the spin pumps paired with the respective extruder varies within 0 to ±5%. Thus, the sum of the radial cross-sectional areas of all of the filaments in the radial cross-section of the yarn varies by ±5% or less. However, the average denier of the yarn from the first set of spin stations can be different than the average denier of the yarn from the second set of spin stations.

[0097] In other implementations, the volumetric flow rate expelled by each pump paired with a particular extruder is not limited relative to the volumetric flow rate expelled by the other pumps, unless it is desired to maintain a constant throughput of the extruder with which the pump is paired.

[0098] The volume flow rate of the thermoplastic polymers discharged by each extruder 110, 120, 130 is adjusted by the spin pumps 101, 102, 103, and the proportions of the thermoplastic polymers included in the yarn 190 are adjusted, which changes the overall color, shade, and / or dyeability characteristics of the yarn. The proportions of the thermoplastic polymers to be included in the yarn 190 relate to the proportions of the color, shade, and / or dyeability characteristics from each extruder 110, 120, 130 to be included in the yarn 190. The yarn 190 includes a first bundle of filaments 114 having the color, shade, and / or dyeability characteristics of the polymer in the first extruder 110, a second bundle of filaments 124 having the color, shade, and / or dyeability characteristics of the polymer in the second extruder 120, and a second bundle of filaments 134 having the color, shade, and / or dyeability characteristics of the polymer in the third extruder 130. When the bundles of filaments 114, 124, 134 are brought together to combine into the yarn 190, the bundles of filaments 114, 124, 134 in the yarn 190 provide a color and / or shade appearance that depends on the relative linear density, or denier per filament (e.g., also referred to as "denier per filament," "denier per fiber," or "DPF"), of the individual filaments in each bundle 114, 124, 134.

[0099] Thus, by changing the relative denier per filament of the filaments from each extruder 110, 120, 130 along the length of the filaments, the overall color, shade, and / or dyeability characteristics of the yarn 190 can be changed. The desired denier per filament of the filaments in each bundle 114, 124, 134 depends on the volume flow rate through each pump 101, 102, 103. For example, if the desired overall color of the yarn 190 is the color of the polymer in the extruder 110, the processor 109 adjusts the volume flow rates of the pumps 101, 102, 103 so that the denier per filament of the filaments in the bundle 114 is greater than the denier per filament of the filaments in the bundles 124, 134. This combination results in an appearance in which the yarn 190 has the color of the polymer in the extruder 110 because the filaments with the smaller denier do not stand out. As another example, if the desired overall color of the yarn 190 is a mixture of the colors of the polymers in the extruders 110, 120, the processor 109 adjusts the volume flow rates of the pumps 101, 102, 103 so that the denier per filament of the filaments in the bundles 114, 124 is greater than the denier per filament of the filaments in the bundle 134. This combination results in an appearance in which the color of the yarn is a mixture of the colors of the polymers in the extruders 110 and 120 because the filaments with the smaller denier do not stand out. As a third example, if the desired overall color of the first yarn is a uniform mixture of the colors from all three extruders 110, 120, 130, the processor 109 adjusts the volume flow rates of the pumps 101, 102, 103 to the baseline volume flow rates so that the denier per filament of the filaments in the bundles 114, 124, 134 is substantially the same.

[0100] The system 100 allows the manufactured filaments to have more colors and / or hues than the number of extruders providing each color or hue. For example, if extruders 110, 120, and 130 each have thermoplastic polymers pre-dyed in red, blue, and yellow, then different proportions of these thermoplastic polymers produce filaments with these colors and combinations thereof, such as purple, orange, and green.

[0101] For example, in some embodiments, the speed of each spinning pump 101, 102, 103 is at least 2 RPM. And in some embodiments, the maximum speed of each spinning pump 101, 102, 103 is 30 RPM. However, in other embodiments, the maximum speed of each spinning pump can be higher.

[0102] In some implementations, the instructions also cause processor 109 to determine the volumetric flow rate of each thermoplastic polymer to be pumped by each spinning pump 101, 102, 103 to achieve a desired proportion and to generate instructions to spinning pumps 101, 102, 103 based on this volumetric flow rate determination. However, in other implementations, the volumetric flow rate of each spinning pump 101, 102, 103 may be determined by another processor or otherwise input into system 100. Furthermore, in other embodiments, the instructions to spinning pumps 101, 102, 103 may be generated by another processor or otherwise input into system 100.

[0103] In various implementations, the volumetric flow rate extruded by each spinning pump is greater than zero and varies within ±40% or less of the baseline volumetric flow rate, which is calculated by dividing the total volumetric flow rate of the pumps by the number of pumps. The volumetric flow rate can be varied such that the flow of polymer through the spinneret is continuous and supports continuous filament formation. Variations in the volumetric flow rate of the thermoplastic polymer can be based on, but are not limited to, the type of polymer, the size and / or shape of the spinneret capillary, the temperature of the polymer, and the denier / filament ratio of the filament spun from that spinneret.

[0104] In some embodiments, computer-readable instructions are stored in computer memory that is electrically in communication with processor 109 and located near the processor (e.g., on the same circuit board and / or in the same housing). In other embodiments, computer-readable instructions are stored in computer memory that is electrically in communication with the processor but located away from the processor. In some cases, processor 109 and memory form a structure such as... Figure 9 The computer device shown will be described below. Figure 9 An example computing system including a processor is shown, which may include processor 109. For example, Figure 9 The system in the middle can be used by system 100.

[0105] Return to referenceFigure 1 In other embodiments, the fixation devices include, for example, heated air entanglers (e.g., air temperature higher than room temperature) or steam entanglers. Air entanglement is used for fixation every 6 to 155 mm (e.g., 20 to 50 mm). The fixation devices 115, 125, 135 can use a pressure of 2 to 6 bar, but the pressure can be increased with increased number of filaments, increased denier per filament, and / or increased filament production speed.

[0106] The stretching device is, for example, at least one or more godets, but in other implementations it can also include a stretch point positioner.

[0107] The texturizer 170 applies air, steam, heat, mechanical force, or a combination of one or more of the above to the stretched filaments passing through it.

[0108] The final fixation device 180 can be similar to the fixation devices 115, 125, 135 described above or alternative implementations described in connection therewith.

[0109] To produce a BCF yarn using the system 100, three streams of molten polymer 111, 121, and 131 having different colors from one another are provided by respective pumps to respective spinning stations. In other embodiments, at least one stream of molten polymer can have different color, shade, and / or dyeability characteristics from the other streams. For example, the streams of molten polymer can have different colors, shades, and / or dyeability characteristics from one another.

[0110] Examples of thermoplastic polymers that can be used in aspects include polyamides, polyesters, and polyolefins. For example, the polymer can be an aromatic or aliphatic polyamide, such as PA6, PA66, PA6T, PA10, PA12, PA56, PA610, PA612, PA510. The polyamide can be a polyamide blend (copolymer) or homopolymer or partially recycled polyamide or fully recycled-based polyamide.

[0111] In other embodiments of each aspect, the polymer can be a polyester, such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or polytrimethylene terephthalate (PTT). The PET can be virgin PET or partially or fully recycled-based PET, such as the PET described in U.S. Patent No. 8,597,553.

[0112] In yet another embodiment of each aspect, the polymer can be a polyolefin, such as polyethylene (PE) or polypropylene (PP). In certain embodiments, the polymer is PET, PTT, PP, PA6, PA66, or PES.

[0113] In some implementations of various aspects, the bundles are made of the same polymer. However, in other implementations, the bundles can be made of different polymers.

[0114] In some implementations according to various aspects, the polymer of the filaments can be a pre- spun-dyed polymer. In other implementations, the filaments are post-processed piece dyed or regular dyed.

[0115] Dyeability characteristics refer to the ability of a polymer to absorb dyes. For example, non-pre-spun-dyed filaments can appear white after spinning due to the absence of dye molecules, pigments, or other molecules that would provide a different color than the material base. When a dyeing process is performed, for example, PET with a deep dye, the melt stream formed with the PET will have a darker color saturation than the melt stream produced with conventional PET.

[0116] Three bundles of filaments 114, 124, and 134 are spun from each spinning plate 112, 122, and 132, respectively, and quenched by quenchers 150. Each bundle 114, 124, and 134 includes an average of 8-120 filaments.

[0117] Figure 1 The number of bundles of filaments shown in FIG. 1 is three, but in other implementations, there can be more than three bundles.

[0118] Each of these bundles 114, 124, and 134 of spun filaments is then individually fixed by respective fixing devices 115, 125, and 135. In other words, each bundle 114, 124, 134 is physically separated from the other bundles, and only the filaments belonging to the respective bundle are fixed together.

[0119] The fixed bundles of filaments 116, 126, and 136 are then drawn on a drawing device 160 including a plurality of godets. According to some implementations, each godet is rotated at a different speed. The draw ratio is typically 1.5 to 4.5. Each filament is drawn to a denier (weight per length) of 2 to 40, which is also referred to as denier per filament ("DPF"). After drawing, three bundles of drawn spun filaments 117, 127, and 137 are provided.

[0120] In alternative implementations (not shown in FIG. 1), air entanglement can be applied to one or more bundles by closing or opening air to 115, 125, and / or 135. Further, in other implementations, air can be applied constantly or in an on / off sequence to achieve a desired end result.

[0121] Additionally, in yet another implementation (not shown in FIG. 1), the bundles of spun filaments are first partially drawn before being individually fixed. After the fixing step, the fixed bundles of spun filaments are further drawn to the final denier. Figure 1 Additionally, in yet another implementation (not shown in FIG. 1), the bundles of spun filaments are first partially drawn before being individually fixed. After the fixing step, the fixed bundles of spun filaments are further drawn to the final denier.​

[0122] In some embodiments of various aspects, the DPF of the filaments in each bundle is equal. However, in some embodiments, at least some of the filaments in one bundle can have a different DPF than the other filaments in the bundle. Alternatively, in some embodiments, the filaments in one bundle can have the same DPF as the other filaments in the bundle, but those filaments can have a different DPF than the filaments in another bundle. Also, in some embodiments, the number of filaments in the bundles is equal. Also, in other embodiments, the number of filaments in each bundle can be different. The denier per filament of the spun filaments in one or more bundles can be increased by increasing the speed of the corresponding pump providing the polymer flow to the spinning station from which the filaments are extruded, or decreased by decreasing the speed of the corresponding pump. By increasing the denier per filament of a bundle, the color of that bundle is more prevalent in the yarn. For example, the speed of the pump providing the molten polymer flow to the spinning station can be increased, while the speed of the pumps providing the other molten polymer flows to the other spinning stations can be kept the same or decreased, resulting in a yarn having more of the color of the flow that was pumped at a higher speed than the other flows. Also, increasing and decreasing the speed of at least one or more pumps can also vary according to a particular frequency and amplitude, in some implementations, resulting in length portions of the bundle having a higher DPF than other portions of the length.

[0123] After the stretching step, bundle 117 has a first color, bundle 127 has a second color, and bundle 137 has a third color, where the first, second, and third colors are different. For example, the first color can be red, the second color can be blue, and the third color can be yellow. In other embodiments, the first, second, and third colors are different shades of the same color or different shades and / or combinations of colors.

[0124] Bundles 117, 127, and 137 are provided to texturizer 170. Bundles 117, 127, 137 are textured to have a bulk (or crimp or contraction) of 5-20%.

[0125] The bundles of textured spun filaments 118, 128, and 138 are then directed to fixture 180. For example, if fixture 180 is an air entangler, the air entangler can use 2 bar to 6 bar pressure, but the pressure can be increased with increased number of filaments, increased denier per filament, and increased speed of filament production. Bundles 118, 128, and 138 are fixed and thus provide BCF yarn 190 that includes an average of 24-360 filaments of 2 to 40 DPF per filament. Fixing is done using air entangling once every 12 to 80 mm. Fixing can be done more frequently for a desired particular appearance. For example, with more frequent fixing, the yarn looks less bulky and the color separation is reduced, which results in the colors looking more blended.

[0126] The location of the filaments originating from the bundles 114, 124 and 134 in the yarn 190 is more pronounced when viewed along the axial length of the yarn 190 than if the bundles of filaments 114, 124, 134 were not individually secured with the fixtures 115, 125 and 135.

[0127] The individual securing of each bundle of filaments 114, 124, 134 prevents each secured bundle of filaments from mixing with the other bundles of filaments during further drawing, texturing and securing. Thus, if each bundle includes filaments of the same color and the color of the filaments differs between the bundles, the individually secured bundle of filaments in each bundle provides a more pronounced group of filaments in the final BCF yarn, making the color of each individually secured bundle more pronounced. If more than one bundle (e.g., all bundles) are individually secured during and / or prior to the drawing process, the color of all the individually secured bundles is more pronounced in the final BCF yarn.

[0128] In Figure 2 , an alternative system and method for providing a BCF yarn 190 is shown. The system 200 is similar to the system 100 through the drawing step of the drawing device 160, but Figure 2 The system 200 in provides two additional color enhancement processes for securing and drawing the filaments 117, 127 and 137. In particular, instead of texturing these filaments 117, 127, 137 together in the texturizer 170, each secured and drawn bundle of filaments 117, 127, 137 is individually textured through the texturizers 171, 172, 173, respectively. Thereafter, the textured bundles of filaments 118, 128 and 138 are provided. The texturizing devices 171, 172 and 173 are similar to the texturizing device 170 described above or the alternative embodiments described in relation thereto, and the bundles are textured to have a loft of 5-20%.

[0129] When using bundles that have different colors and / or different shades of one color from each other, the individual texturing of the individual bundles of filaments provides a more pronounced color or color shade along the axial length of the BCF yarn. The individually textured filaments tend to stay more gathered together during the remaining production steps of making the BCF yarn, which results in the color or color shade of this bundle of spun filaments being more pronounced along the length of the BCF.

[0130] The individual texturing of one or more bundles of spun filaments makes the individually textured bundle more pronounced in the final yarn. When the bundle has a different color from the other bundles, or if all the bundles have different colors from each other, the color of the individually textured bundle is more pronounced in the final BCF yarn.

[0131] In addition to individually texturing the stationary and stretched filaments 117, 127, 137, the filaments 117, 127, 137 are subjected to an individual color entanglement process prior to final fixation at the fixation device 180. In this individual color entanglement process, the textured filament bundles 118, 128, and 138 are fed into individual fixation devices 119, 129, and 139 to individually fix each bundle of textured spun filaments. The fixation devices 119, 129, 139 are similar to the fixation devices 115, 125, 135 and 180 described with reference to Figure 1 For example, if the fixation devices 119, 129, 139 are air entanglers, the air entanglers can entangle every 15 to 155 mm and can use 2 bar to 6 bar pressure, but the pressure can increase with increased number of filaments, increased denier per filament, and / or increased filament production speed. The individual fixation devices 119, 129, 139 are disposed between the individual texturizers 171, 172, 173 and the final fixation device 180. Fixation can be performed more frequently for a desired particular appearance. For example, with more frequent fixation, the yarns appear less fluffy and the color separation is reduced, which results in the colors appearing more blended.

[0132] After being individually fixed using the fixation devices 119, 129, and 139, the bundles 118, 128, and 138 are directed to a mixing cam 300, which is disposed between the fixation devices 119, 129, 139 and the final fixation device 180. The mixing cam 300 positions the bundles fixed by the fixation devices 119, 129, 139 relative to each other prior to being fixed together in the final fixation device 180. The mixing cam 300 is cylindrical and has an outer surface defining a plurality of grooves for receiving and guiding the textured and fixed bundles.

[0133] The mixing cam 300 can rotate about its central axis or can be stationary. If rotating, the mixing cam 300 changes which side of the bundle is presented into the fixed jet of the fixture 180, which affects how the bundles (and filaments therein) are layered relative to each other. In some embodiments, the position is randomly varied. The speed of rotation can be varied to provide different appearances in the yarn 190. For example, one or more of the bundles 118, 128, 138 can have a first color on one side of the bundle 118, 128, 138 and a second color on the other side of the bundle 118, 128, 138, with the sides of the bundle spaced apart on the circumference but intersected by the same radial plane. It can be desirable to have a first color on the outward facing surface of the loop in the carpet in one area of the carpet, and a second color on the outward facing surface of the loop in the carpet in another area of the carpet. The rotating cam 300 can "flip" one or more of the bundles 118, 128, 138 so that the desired color is oriented on the portion of the outer surface of the yarn 190 so that the desired color is on the outer surface of the loop. The undesired color of that portion of the carpet is hidden on the inward facing surface of the loop. The rotation of the cam 300 ensures that the filaments running on the outside of the loop are changed due to the specific mechanical means, and not necessarily naturally in the downstream process.

[0134] When stationary, the position of the bundles 118, 128, 138 is guided by the mixing cam 300, but their relative position does not change. In alternative embodiments, the bundles 118, 128, 138 are fed directly to the fixture 180, or they are fed through a stationary guide set between the intermediate fixture 119, 129, 139 and the fixture 180.

[0135] The fixed, textured bundles 118, 128, and 138, positioned by the mixing cam 300, are thereafter fixed together into the BCF yarn 190 by the fixture 180. This fixing is done by air entanglement every 12 to 80 mm. For a particular appearance desired, the fixing can be done more frequently. For example, with more frequent fixing, the yarn appears less fluffy and the color separation is reduced, which results in the colors appearing more mixed.

[0136] This separate fixing and guiding effect by the mixing cam makes the colors in the yarn more structured and positioned. For example, when using such yarn, tufted yarn in a tufted carpet, the positioning of the colored bundles in the yarn results in the bundles being more prominent on the final carpet surface. The positioning of the colors in the BCF yarn has the effect that the color can be more present locally on the tuft top side facing upwards, away from the carpet backing, or hidden on the tuft low side facing towards the carpet backing. The effect is to provide very vivid and pronounced color areas on the carpet.

[0137] In other embodiments, one or more of the spun filament bundles can be stretched prior to fixation, such as Figures 3-8 illustrated in FIG. 3. Also, in some other embodiments (not illustrated), two or more bundles can be fixed together prior to stretching.

[0138] Figure 3 Another embodiment of a system for producing a BCF yarn is schematically illustrated. The system 300 includes three extruders 310, 320, and 330, three spinning stations 312, 322, 332, a quencher 350, a stretching device 360, two texturizers 371, 375, and a final fixation device 380. Each spinning station 312, 322, 332 is similar to the spinning stations 112, 122, 132 and the quencher 350 is similar to the quencher 150 described above with respect to Figure 1 the system 100. The stretching device 360 is similar to the stretching device 160 described above with respect to Figure 1 the system 100 or the alternative embodiments described in relation thereto. The texturizers 371, 375 are similar to the texturizers 170 described above with respect to Figure 1 the system 100 or the alternative embodiments described in relation thereto. Also, the final fixation device 380 is similar to the final fixation device 180 described above with respect to Figure 1 the system 100 or the alternative embodiments described in relation thereto.

[0139] Each spinning station 312, 322, 332 includes a pump and a spinneret through which the respective molten polymer stream 311, 321, 331 is pumped from the respective extruder 310, 320, 330. In this embodiment, the molten polymer streams 311, 321, and 331 have mutually different colors. However, as noted above with respect to Figure 1 the system 100, the molten polymer streams can have one or more different colors, shades, and / or dyeability characteristics. Although not illustrated, the system 300 can also include a processor in electrical communication with each pump, as illustrated and described above with respect to Figure 1 the system 100.

[0140] Three bundles of filaments 314, 324, and 334 are spun from each spinning station 312, 322, 332, respectively, quenched by the quencher 350, and stretched by the stretching device 360 to a final denier by a plurality of godets. After stretching, each bundle includes an average of 8-120 filaments, each filament having a denier of 2 to 40 denier per filament (DPF).

[0141] The spun filaments are preferably melt spun filaments. The polymer used to make each integral spun filament can be a polyester (PES) such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), a polyamide (PA) such as PA6, PA6.6, PA6.10, PA6T, PA10, a polyolefin (such as polypropylene (PP) or polyethylene (PE), or any combination of these. In some implementations, the bundles are made of the same polymer. However, in other implementations, the bundles can be made of different polymers.

[0142] After stretching, bundle 314 has a first color, bundle 324 has a second color, and bundle 334 has a third color. Bundles 324 and 334 can also have the same color. Bundle 314 has a different color than bundles 324 and 334. For example, the first color can be red, the second color can be blue, and the third color can be yellow. In other implementations, the first, second, and third colors are different shades of the same color or different shades and / or combinations of colors.

[0143] As described above, in other implementations, at least one of the streams of molten polymer can have a different color, shade, and / or dyeability characteristic than the other streams. For example, the streams of molten polymer can have different colors, shades, and / or dyeability color characteristics from one another. Dyeability characteristic refers to the adsorptive affinity of the filaments to dyes. Further, according to some implementations, the polymer of the filaments can be a pre-dyed polymer. In other implementations, the filaments are post-processed dyed or regularly dyed.

[0144] The first bundle 314 is provided to texturizer 371 and textured to have a loft of 5-20%. This first bundle 314 is textured separately from the other bundles 324, 334. The second and third bundles 324 and 334 are provided to texturizer 375 and co-textured to have a loft of 5-20%.

[0145] The two textured bundles 316 and 376 are directed to the fixing device 380. For example, if the fixing device 380 is an air entangler, the air entangler can use a pressure of 2 bar to 6 bar, but the pressure can increase with increased number of filaments, increased denier per filament, and / or increased speed of filament production. The bundles 316 and 376 are fixed and thus provide a BCF yarn 390 that includes 24-360 filaments of 2 to 40 DPF. The fixing is performed using air entangling once every 12 to 80 mm. For a particular look desired, the fixing can be performed more frequently. For example, with more frequent fixing, the yarn looks less fluffy and the color separation is reduced, which results in the colors looking more mixed.

[0146] The position of the filaments originating from beam 314 is more pronounced compared to the filaments originating from beams 324 and 334 when viewed along the axial length of the yarn 190. The latter are more intimately mixed and the unique color of the polymer streams 321 and 231 appears to have merged or mixed.

[0147] Figure 4 A schematic diagram showing another embodiment of a system 400 for producing a BCF yarn is shown. The system 400 includes three extruders 410, 420, and 430, three spinning stations 412, 422, 432, a quencher 450, a draw device 460, three texturizers 471, 472, 473, and a final fixturing device 480. Each spinning station 412, 422, 432 is similar to the spinning stations 112, 122, 132, and the quencher 450 is similar to the quencher 150 described above with respect to Figure 1 The draw device 460 is similar to the draw device 160 described above with respect to Figure 1 The texturizers 471, 472, 473 are similar to the texturizer 170 described above with respect to Figure 1 The final fixturing device 480 is similar to the final fixturing device 180 described above with respect to Figure 1 The final fixturing device 480 is similar to the final fixturing device 180 described above with respect to

[0148] Each spinning station 412, 422, 432 includes a pump and a spin plate through which a respective stream of molten polymer 411, 421, 431 is pumped from a respective extruder 410, 420, 430. Although not shown, the system 400 can also include a processor in electrical communication with each pump, as described above with respect to Figure 1 The draw device 460 is similar to the draw device 160 described above with respect to Figure 1 The final fixturing device 480 is similar to the final fixturing device 180 described above with respect to

[0149] Three beams 414, 424, and 434 are spun from the spinning stations 412, 422, 432, quenched by the quencher 450, and drawn to a final denier by the draw device 460, which is a plurality of godets. Each beam 414, 424, and 434 includes an average of 8-120 filaments. And, after drawing, each filament in each beam has a denier per filament (or denier per filament (DPF)) of 2 to 40 denier per filament.

[0150] The spun filaments are preferably melt spun filaments. The polymer used to make each bundle of spun filaments can be polyester (PES), such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyamide (PA), such as PA6, PA6.6, PA6.10, PA6T, PA10, polyolefin (such as polypropylene (PP) or polyethylene (PE), or any combination thereof. In some implementations, the bundles are made of the same polymer. However, in other implementations, the bundles can be made of different polymers.

[0151] After the stretching step, bundle 414 has a first color, bundle 424 has a second color, and bundle 434 has a third color, where the first, second, and third colors are different. For example, the first color can be red, the second color can be blue, and the third color can be yellow. In other implementations, the first, second, and third colors are different shades of the same color or different shades and / or combinations of colors.

[0152] As described above, in other implementations, at least one of the streams of molten polymer can have different color, shade, and / or dyeability characteristics than the other streams. For example, the streams of molten polymer can have different color, shade, and / or dyeability characteristics from each other. Dyeability characteristics refer to the adsorptive affinity of the filaments to dyes. Further, according to some implementations, the polymer of the filaments can be a pre-dyed polymer. In other implementations, the filaments are post-processed dyed or regularly dyed.

[0153] The first bundle 414 is provided to texturizer 471 and textured to 5-20% loft. This first bundle 414 is textured separately from the other bundles 424, 434. The second bundle 424 is provided to texturizer 472 and textured to 5-20% loft. The third bundle 434 is provided to texturizer 473 and textured to 5-20% loft. Thus, all of the bundles are individually textured.

[0154] The three textured bundles 416, 426, and 436 are then directed to the fixing device 480. For example, if the fixing device 480 is an air entangler, the air entangler can use a pressure of 2 bar to 6 bar, but the pressure can increase with increased number of filaments, increased denier per filament, and / or increased speed of filament production. The bundles are fixed and thus provide a BCF yarn 493 comprising 24-360 filaments of 2 to 40 DPF. The fixing is done with air entangling once every 12 to 80 mm. The fixing can be done more frequently for a desired specific appearance. For example, with more frequent fixing, the yarn looks less fluffy and the color separation is reduced, which results in the colors looking more mixed.

[0155] When viewed along the axial length of yarn 493, the positions of the filaments originating from bundles 414, 424, and 434 are very clear, depending on the position of the bundles within yarn 493.

[0156] Figure 5 The alternative system 500 is shown. This system 500 is similar to... Figure 3 The difference in the system 300 shown is that... Figure 5 In system 500, the stretched and textured filaments 316 and 376 are provided to separate fastening devices 510 and 570, respectively. Fastening is performed every 25 to 155 mm using air entanglement. Then, via fastening device 580, the fastened textured bundles 517 and 577—which can be understood as two intermediate single yarns—are fastened together to form BCF yarn 594. This fastening is performed every 12 to 80 mm using air entanglement. Fastening can be performed more frequently for a desired specific appearance. For example, with more frequent fastening, the yarn appears less fluffy and color separation is reduced, resulting in a more blended color appearance. Fastening devices 510, 570, and 580 can be similar to those described above. Figure 1 The described fasteners 115, 125, 135, or alternative embodiments described therein. For example, if the fasteners 510, 570, and 580 are air entanglers, the air entanglers can use pressures from 2 bar to 6 bar, but this pressure can be increased with increasing filament quantity, increasing denier / filament, and / or increasing filament production speed.

[0157] Figure 6 Another alternative system 600 is shown in the figure. Figure 6 The system 600 in the middle is similar to Figure 5 The difference in System 500 is that... Figure 6 In system 600, stretched, textured, and fixed filaments 517, 577 are guided to a hybrid cam 610, which is similar to the above. Figure 2 The hybrid cam 300 described herein, or alternative embodiments described therein, are described. The hybrid cam 610 positions the bundles secured by the fixing devices 510, 570 relative to each other before they are secured together in the final fixing device 680. The hybrid cam 610 is cylindrical and has an outer surface defining a plurality of grooves for receiving and guiding the textured and fixed bundles.

[0158] The mixing cam 610 can rotate about its central axis or remain stationary. If rotated, the mixing cam 610 changes which side of the bundle is presented to the fixed nozzle in the fixing device 680, which affects how the bundle (and the filaments therein) are layered relative to each other. In some embodiments, the positions are randomly varied. The rotational speed can be varied to provide different appearances in the yarn 695. For example, one or more of the bundles 517, 577 may have a first color on one side of the bundles 517, 577 and a second color on the other side of the bundles 517, 577, wherein the sides of the bundles are circumferentially spaced but intersected by the same radial plane. It may be desirable to have the first color on the arcuate outward surface of the carpet loop in one area of ​​the carpet and the second color on the arcuate outward surface of the carpet loop in another area of ​​the carpet. The rotating cam 610 can “flip” one or more of the bundles 517, 577 such that the desired color is located on the arcuate outward surface of the carpet loop. The undesirable color in that part of the carpet is hidden on the inward surface of the loop. The rotation of cam 610 ensures that the filaments running on the outside of the ring are altered by a specific mechanical means, rather than necessarily occurring naturally in the downstream process.

[0159] When stationary, the positions of the two bundles 517 and 577 are fed through the mixing cam 610, but their relative positions remain unchanged. The fixed, textured bundles 517 and 577, positioned by the cam 610, are then secured together by the fixing device 680 to form BCF yarn 695. The fixing device 680 uses air entanglement to fix one bundle 517 and 577 every 12 to 80 mm. In an alternative embodiment, the bundles 517 and 577 are supplied directly to the fixing device 680, or they are supplied via a fixing guide disposed between the intermediate fixing devices 510 and 570 and the final fixing device 680.

[0160] Fixture 680 is similar to the above regarding Figure 1 The described fixing devices 115, 125, 135, or alternative embodiments described therein. For example, if the fixing device 680 is an air entangler, the air entangler can use a pressure of 2 bar to 6 bar, but the pressure can be increased with the increase in the number of filaments, the increase in denier / filament, and / or the increase in the filament growth rate.

[0161] Figure 7 Another alternative system 700 is shown in the figure. Figure 7 The system 700 in the middle is similar to Figure 4 The difference in System 400 is that... Figure 7In system 700, textured bundles 416, 426, and 436 are individually secured by securing devices 719, 729, and 739, respectively. Securement is performed every 25 to 155 mm using air entanglement. The secured textured bundles 717, 727, and 737 are then fed to securing device 780, and BCF yarn 796 is produced. Securement is performed every 12 to 80 mm via securing device 780 using air entanglement. For a specific desired appearance, securing can be performed more frequently. For example, with more frequent securing, the yarn appears less fluffy and color separation is reduced, resulting in a more blended color appearance. Securing devices 719, 729, 739, and 780 can be similar to those described above. Figure 1 The described fasteners 115, 125, 135 or alternative embodiments described therein. For example, if the fasteners 719, 729, 739 and 780 are air entanglers, the air entanglers can use pressures from 2 bar to 6 bar, but the pressure can be increased with increasing filament quantity, increasing denier / filament and / or increasing filament production speed.

[0162] Figure 8 Another alternative system 800 is shown in the figure. Figure 8 The system 800 is similar to Figure 7 The system 700 differs in that it guides bundles 717, 727, and 737 to the hybrid cam 800, which is similar to the above-mentioned systems. Figure 2 The hybrid cam 300 described herein, or alternative embodiments described therein, positions the bundles 717, 727, 737 secured by the fixing devices 719, 729, 739 relative to each other before being fixed together in the final fixing device 880. The hybrid cam 800 is cylindrical and has an outer surface defining a plurality of grooves for receiving and guiding the textured and fixed bundles.

[0163] The mixing cam 800 can rotate about its central axis or can remain stationary. If rotating, the mixing cam 800 changes which side of the bundles 717, 727, 737 is presented to the stationary jet in the fixture 880, which affects how the bundles (and filaments therein) are layered relative to one another. In some embodiments, the position is randomly varied. The speed of rotation can be varied to provide different appearances in the yarn 897. For example, one or more of the bundles 717, 727, 737 can have a first color on one side of the bundle 717, 727, 737 and a second color on the other side of the bundle 717, 727, 737, with the sides of the bundles spaced apart circumferentially but intersected by the same radial plane. It can be desirable to have a first color on the outward facing surface of the arc in the carpet loop in one area of the carpet and a second color on the outward facing surface of the arc in the carpet loop in another area of the carpet. The rotating cam 800 can “flip” one or more of the bundles 717, 727, 737 so that the desired color is oriented on the portion of the outer surface of the yarn 897 so that the desired color is on the outward facing surface of the yarn in the carpet loop. The undesired color of the carpet portion is hidden on the inward facing side surface of the loop. Rotation of the cam 800 ensures that the filaments running on the outside of the loop are changed due to the specific mechanical means, rather than necessarily occurring naturally in the downstream process.

[0164] When stationary, the position of the bundles 717, 727, 737 is fed through the mixing cam 800, but their relative position does not change. The stationary, textured bundles 717, 727, 737 positioned by the cam 800 are thereafter fixed together into the BCF yarn 897 by the fixture 880. The fixture 880 fixes the bundles 717, 727, 737 once every 12 to 80 mm using air entanglement. The fixing can be done more frequently for a particular appearance desired. For example, as the fixing is done more frequently, the yarn appears less fluffy and the color separation is reduced, which results in the colors appearing more mixed. In alternative embodiments, the bundles 717, 727, 737 are fed directly to the fixture 680, or they are fed through a stationary guide set between the intermediate bundle device 719, 729, 739 and the final fixture 880.

[0165] The fixture 880 can be similar to the fixture 115, 125, 135 described above with respect to Figure 1 or alternative embodiments described in relation thereto. For example, if the fixture 880 is an air entangler, the air entangler can use a pressure of 2 bar to 6 bar, but the pressure can be increased with an increased number of filaments, an increased denier per filament, and / or an increased speed of filament production.

[0166] There is a need to provide yarns, particularly BCF yarns, that have more pronounced color variation or color hue variation along the axial length. When used to provide a tufted surface of a tufted carpet, such yarns provide the tufted surface with a multi-colored aspect that has very localized color variations.

[0167] Figure 9 An example computing device that can be used to control the pumps of system 100 is illustrated. As used herein, a "computing device" or "computer" can include multiple computers. The computer can include one or more hardware components such as, for example, a processor 1021, a random access memory (RAM) module 1022, a read only memory (ROM) module 1023, storage 1024, a database 1025, one or more input / output (I / O) devices 1026, and an interface 1027. Not all of the above-listed hardware components can be necessary to practice the methods herein. Alternatively and / or additionally, the computer can include one or more software components such as, for example, a computer readable medium that includes computer executable instructions for performing the methods associated with the example embodiments. It is contemplated that one or more of the above-listed hardware components can be implemented using software. For example, storage 1024 can include a software partition associated with one or more other hardware components. It is understood that the above-listed components are examples and are not intended to be limiting.

[0168] Processor 1021 can include one or more processors each configured to execute instructions and process data to perform one or more functions associated with the computer for producing at least one filament and / or at least one yarn. Processor 1021 can be communicatively coupled to RAM 1022, ROM 1023, storage 1024, database 1025, I / O devices 1026, and interface 1027. Processor 1021 can be configured to execute computer program instruction sequences to perform various processes. The computer program instructions can be loaded into RAM 1022 for execution by processor 1021.

[0169] RAM 1022 and ROM 1023 can each include one or more devices for storing information associated with the operation of processor 1021. For example, ROM 1023 can include a memory device configured to access and store information associated with the computer including information for identifying, initializing, and monitoring the operation of one or more components and subsystems. RAM 1022 can include a memory device for storing data associated with one or more operations of processor 1021. For example, ROM 1023 can load instructions into RAM 1022 for execution by processor 1021.

[0170] Storage 1024 can include any type of mass storage device configured to store information that the processor 1021 can need to execute processes consistent with the disclosed embodiments. For example, storage 1024 can include one or more disk and / or optical devices, such as hard drives, CD-ROMs, DVD-ROMs, or any other type of mass media devices.

[0171] Database 1025 can include one or more software and / or hardware components that cooperate to store, organize, sort, filter, and / or arrange data used by the computer and / or processor 1021. For example, database 1025 can store computer readable instructions that cause the processor 1021 to adjust the volumetric flow rate of thermoplastic polymer pumped by each spin pump to achieve a proportion of thermoplastic polymer to be included in the yarn. It is contemplated that database 1025 can store additional information and / or information different from that listed above.

[0172] I / O devices 1026 can include one or more components configured to communicate information with a user associated with the computer. For example, I / O devices can include a console having an integrated keyboard and mouse to allow a user to maintain a database of digital images, results of analysis of digital images, metrics, and the like. I / O devices 1026 can also include a display including a graphical user interface (GUI) for outputting information on a monitor. I / O devices 1026 can also include peripheral devices such as, for example, a printer for printing information associated with the computer, a disk drive (e.g., USB port, floppy disk, CD-ROM or DVD ROM drive, etc.) accessible by a user to allow the user to input data stored on a portable media device, a microphone, a speaker system, or any other suitable type of interface device.

[0173] Interface 1027 can include one or more components configured to send and receive data over a communication network such as the Internet, a local area network, a network of workstations peer-to-peer, a direct link network, a wireless network, or any other suitable communication platform. For example, interface 1027 can include one or more modulators, demodulators, multiplexers, demultiplexers, network communication devices, wireless devices, antennas, modems, and any other type of device configured to enable data communication over a communication network.

[0174] Various implementations have been described. However, it is to be understood that various modifications can be made without departing from the spirit and scope of this description. Accordingly, other implementations are within the scope of the following claims.

[0175] Disclosed are materials, systems, devices, methods, compositions, and assemblies that can be used in, used in conjunction with, used to make, or are products of, systems and devices of the disclosed methods. These and other assemblies are disclosed herein, and it should be understood that when combinations, subsets, interactions, groups, etc. of assemblies are disclosed, while specific reference of each various individual and collective combinations and permutation of these assemblies can not be explicitly disclosed, each is specifically contemplated and described herein. For example, if a system is disclosed and discussed, then each individual and collective combinations and permutation of that system, and possible modifications, are also specifically contemplated and discussed herein, unless specifically stated otherwise. Likewise, any subset or combination of these are also specifically contemplated and disclosed. This concept applies to all aspects of this disclosure including, but not limited to, steps in methods using the disclosed systems or devices. Thus, if there are a variety of additional steps that can be performed, it is understood that each of these additional steps can be performed with any specific method step or combination of method steps of the disclosed methods, and each such combination or subset of combinations is specifically contemplated and should be considered disclosed.

[0176] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, when a numerical range is given in "between" a first and second number, the range includes the first and second number.

Claims

1. A yarn comprising two or more bundles of spun filaments, wherein each bundle includes a separate fixing point at which the filaments of each bundle are fixed together, wherein the sum of the radial cross-sectional areas of all the filaments in the radial cross-section of the yarn varies by ±5% or less.

2. The yarn of claim 1, wherein the filament bundles further include a common fixing point at which the two or more filament bundles are fixed together.

3. The yarn of claim 2, wherein the two or more bundles include one or more separate fixing points along their length between the common fixing point.

4. The yarn of claim 3, wherein the two or more bundles of spun filaments comprise separate textures, i.e., have been individually textured.

5. The yarn according to claim 1, wherein the filaments of at least one bundle of the spun filament bundle have different color, hue, and / or dyeability characteristics compared to the color, tint, and / or dyeability characteristics of another bundle of the spun filament bundle.

6. The yarn according to claim 1, wherein the yarn is obtained by the following steps: A. Provide N bundles of spun filaments, where N is an integer of 2 or greater; B. Partially stretch the N bundles of spun filaments; C. Separately fix at least the first bundle of N partially stretched spun filaments; D. Stretch N bundles of fixed and partially stretched spun filaments to the final denier / filament; E. Texture the N bundles; and F. Perform final fixation of the N bundles of spun filaments to provide yarn.

7. The yarn according to claim 1, wherein the yarn is a BCF type yarn.

8. The yarn according to claim 1, wherein at least one filament of the spun filament bundle has different color, hue, and / or dyeability characteristics compared to the color, hue, and / or dyeability characteristics of another bundle of the spun filament bundle.

9. The yarn of claim 2, wherein, The position of the bundles relative to each other is changed at consecutive common fixed points.

10. A carpet, rug, or carpet tile comprising pile formed from yarn according to any one of claims 1 to 9.

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