Thesis Details

Thesis Title: The Effects of Finish Lubricant Viscosity and Fiber Crimp on Nylon 6,6 Carpet Yam Processing and Bulk Properties
Thesis Author: Todd Scheerer
Abstract: Fiber cohesion is defined as the energy necessary to separate fibers from an assembly and is a characteristic comprised of two primary components: fiber friction and the entanglement of coiled, crimped, or hooked fibers. Optimization of cohesion for several short staple fibers has improved yarn quality and processing efficiency. However, limited published research exists on the cohesion of nylon 6,6 long staple fiber, a principal fiber used in carpet pile yarns. Two key fiber properties that have been shown to influence the cohesion of nylon 6,6 fiber are crimp frequency and the viscosity of the lubricant in the spin finish. To study the effects of these two properties on nylon 6,6 carpet yarn processing and bulk properties, fiber variants were converted into plied yarn, heat-set by two methods, and processed into finished carpet. Friction and cohesion properties were determined in fiber, sliver, and yarn forms by several test methods. These measurements were then correlated with sliver, yarn, and carpet quality data. The selection of a finish lubricant was found to significantly influence yarn bulk and carpet body. However, the viscosity of the lubricant did not explain all significant results. Fiber crimp level influenced card mat openness and sliver evenness. Finally, the Monsanto-Mill Heat-set Yarn Bulkometer was proven as a new test method for determining heat-set yarn bulk.