Learn about commercial carpet fiber types, fiber shapes, dyeing methods and their levels of stain resistance.

1. CARPET 101
Technical Session

2. AGENDA
 Fiber Types used in Commercial Carpets
 Solution Dye Vs Millitron Dye
 Milliken Performance Enhancements
Technical Session

3. Fiber
Types
Technical Session

4.  wool
traditional
expensive
higher weight for
performance
resistance to
cigarette burns
warm and natural
hand
Fiber Type
natural
Technical Session

5. Wool Fiber – surface scales

6. 80/20 Wool Nylon
Wool
Fiber
Nylon
Fiber

7.  olefin (polypropylene)
economical to manufacture
solution dyed
crushes easily
attracts oil
Fiber Type
man-made
Technical Session

8. melting point - olefin
OLEFIN
WOOL COTTON LINEN
30 sec 5 sec 3 sec
TYPE 6,6 NYLON
WOOL COTTON LINEN
30 min 15 min 10 min
OLEFIN M.P. = ~180C
NYLON 6 M.P. = ~215C
POLYESTER M.P. = ~249C
NYLON 6,6 M.P. = ~260C
Technical Session

9.  nylon
two types of nylon
 type 6
 type 6,6
resilient
resistant to abrasion
color retention (with
properly selected dyes)
Fiber Type
man-made
Technical Session

10. TYPE 6 NYLONTYPE 6,6 NYLON
hexamethylene diamineadipic acid caprolactam
Type 6,6 vs. Type 6 Nylon
molecular structure
Technical Session

11. TYPE 6,6 NYLON
(tighter molecular structure)
TYPE 6 NYLON
(more open molecular structure)
Stain Resistance
Type 6 vs. Type 6,6 nylon
Technical Session

12. Nylon Fiber
 Nylon 6
Softer hand
Easier to dye
Better color yield
Used in “Mill
Extruded”
Solution Dye
 Nylon 6.6
More resilient (20%
more than type 6)
Superior texture
retention
More resistant to soil
and stains
More resistant to
fading
Technical Session

13. ROUND
TRILOBAL
(SHORT)
TRILOBAL
(LONG)
HOLLOW
FILAMENT
4 fiber shapes
Technical Session

14. modification ratio
< 1.5 MR2.5 MR > 3.5 MR
Technical Session

15. Type 6 Trilobal Nylon

16. Type 6,6 Nylon, Mixed Denier

17. HIGHEST
Residential
LOWEST
Commercial
BRIGHT SEMI-DULL MID-DULL
diamond Chalk – TiO2
LUSTER
Technical Session

18. Solution Dye
Vs
Millitron Dye
Technical Session

19.  Properties
Color added at extrusion
Colors are typically resistant to
fading
Color offering is limited to about 125
colors
Solution dyed fiber CAN stain and
soil – “not bullet proof”
Mill extruded SDN is always Type 6
nylon
Solution dyed Nylon
Technical Session

20. Mill Extruded Type 6 Nylon
Technical Session

21. Types of Dyeing Methods
 Solution Dye
 Colorant is added to molten polymer
 Stock Dye
 Staple fiber is dyed before spinning
 Yarn Dye
 Yarn is dyed after it has been spun. Space dyeing is
a variation of yarn dyeing.
 Piece Dye
 Carpet is dyed after it has been formed
 Injection Dye - Millitron
 Pressurized dye solution is injected onto the face of
carpet with a series of small jets.
Technical Session

22. Millitron
Dyeing
Method
Technical Session

23. Millitron®
The Millitron®
is a proprietary, continuous dye injection machine which
injects color into the carpet pile through an electronically
controlled valve and jet system to create the design.
Technical Session

24. Undyed Nylon Fiber
neutral
Technical Session

25. T 6,6 Nylon Fiber
positive
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pH 4-6
Technical Session

26. T 6,6 Nylon Fiber
positive
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Heat and Moisture applied –
expands openings
Technical Session

27. neutral
T 6,6 Nylon Fiber
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Ionicly Bonded Color
Locked In Pre-metallized
Dye Particles
Technical Session
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negative
positive

28. Fiber Performance Measures
Type 6,6
Nylon
Type 6
Nylon
80 /20
Wool / Nylon
Solution
Dyed Nylon
Solution
Dyed Olefin
Light Fastness
Ozone Fastness
Staining Resistance
Soiling Resistance
Resilience
Cost
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Excellent
Good
Poor
Milliken
Technical Session

29. CARPET
PERFORMANCE
ENHANCEMENTS
Technical Session

30. Carpet Performance Enhancements
 AlphaSanTM
—Antimicrobial
Safe – silver based
Non-migrating
 StainSmartTM
Stain Resist
Repellancy
Release Technology – nano particle
application
 ColorsealTM
– Bleach Protection
Technical Session

31. • Alphasan is a SILVER based
Zirconium Phosphate ceramic
compound.
®
Antimicrobial
• SAFE - silver based chemistry
• Permanently bound in the
carpet backing
• Will not migrate
• Will reduce odors due to
microbial activity
Designed for Carpet:
Technical Session

32. Carpet Performance Enhancements
StainSmartTM
Resists – stains
Repels – liquid spills
Releases - soil
Technical Session

33. StainSmart Performance
Kool Aid Test after rinse
Soiling
No ChemistryF’ChemicalStainSmart
Technical Session

34. Color Seal
Functions to reduce the negative impact
of accidental spills/drips from bleach
containing solutions.
Does not allow for cleaning or sanitizing
carpet with bleach containing products

35. Color Seal Performance
Color Seal Applied
Control
(No Color Seal)

36. Questions &
Answers
Technical Session

37. THANK
YOU
Technical Session

38. THANK
YOU
Technical Session

41. Fiber Shape (cross-section)
 Fiber shape is a cross section of a
single fiber. It results from the shape
of the holes in the spinneret when the
fiber is extruded. Manufactures
modify the shape to enhance
performance characteristics.
Technical Session

42. Nylon Fiber
Processing
Technical Session

43. Color Seal and Stain Resist
Bleach Test Stain Resist Test Control
No Treatments