|
Abstract:
|
Carpet fibers are manufactured by the fiber producer to
possess physical properties that affect the aesthetics and
performance of carpet. After the fibers have been
purchased by the yarn manufacturer, they are spun into yarn,
usually two or more ends twisted together, and heatset.
During the heatset process, the assembly of fibers are
bulked and set in the desired size or shape such that the
assembly resists change to a different size or shape. The
process can be carried out in the presence (Superba or
autoclave) or the absence (Suessen) of moisture.
Most previous research has concentrated on the
variation in yarn properties produced by varying machine
parameters. However, the exact combination of fiber
properties engineered by the fiber manufacturer that
increases final yarn is not known.
Nylon 6,6 fibers with two modification ratios, two draw
ratio, and three crimp levels were used to create 30 yarn
conditions. The thirty yarn conditions were spun into yarn
and heatset on a Superba TVP to determine the effects of the
fiber variants on yarn bulk.
Bulk was measured on the 30 yarn conditions using the
Textured Yarn Tester (T.Y.T.), Cylinder Bulk Test, and
Carpet Body Ranking. Sliver and yarn quality were
evaluated using Uster CV, RotorRing, Fiber Alignment Index,
Digimat Defects, and Zweigle Hairiness tests. other tests included diagnostic dyeing, X-ray analysis, Differential
Scanning Calorimetry, and the Monsanto 20K Contract Walk
wear tests.
Testing results indicated that the 2.75 modification
ratio, 3.75 draw ratio, and 11 c.p.i. fiber yielded the
highest level of yarn bulk after heatsetting. Dye uptake
was found to increase as the modification ratio increased.
The 2.10 modification ratio produced yarn with the best wear
characteristics in tufted carpet.
|