Effects of filament fineness and disc type of drawn textured polyester yarns on carpet resilience and appearance retention performance

Abstract

The deformation on the carpet texture is generally caused by foot traffic, furniture loading and soiling. The resistance of the carpet to texture distortion depends on the pile yarn characteristic and morphology. In this study, the resilience and appearance retention of carpet samples produced with drawn textured polyester pile yarns which are widely used in the carpet industry, were investigated. In this context, 6 pile yarns were produced with 3 different filament finenesses (3.13, 2.08 and 1.56 dpf) and 2 different disc types (polyurethane and ceramic). The carpet specimens were applied to compression/recovery, dynamic loading, hexapod appearance retention and soiling tests. According to the results, the carpet sample with 2.08 dpf filament fineness and produced by polyurethane disc type showed less thickness loss and better compression recovery results. Hexapod test results showed that the carpet samples with the finest filament had the lowest appearance retention levels. For soiling performance, it was observed that carpet samples with coarser filaments had slightly less staining and disc type had a no significance effect.

Keywords

Carpet filament fineness disc type compressibility appearance retention

Introduction

The fibers commonly used as pile yarn in machine-made carpets are acrylic, polypropylene, polyamide, wool, polyester fibers. Wool fiber is known as the most prestigious material due to its high quality, but its high price led the manufacturers to use acrylic fiber as an alternative in machine-made carpets.^1,2 On the other hand, since the staple acrylic yarns cause to fuzz and loose fibers on the carpet surface, the polypropylene became widespread due to its low cost, low density and high durability. For this reasons, acrylic and polypropylene are the most widely used pile materials among all textile fibers, in the machine woven carpet industry.^2,3 Polyester fiber which is commonly used for tufted carpet production has a rising popularity in wilton face-to-face carpet production in the last years due to its high strength, soft touch and brilliancy features. Different forms of polyester fiber such as textured and bulked continuous filament (BCF) yarn are used as pile yarns.^1,4

The synthetic yarns are exposed to some mechanical and thermal processes to increase its elasticity, softness, bulkiness and crimp. These processes are called as texturing. The texture parameters affect the yarn characteristics and so the fabric performance. The increase in the number of filaments in the yarn cross-section is an important parameter that leads to improvement of yarn properties. The disc type for drawn texturing and false-twist texturing is another significant factor which affects the filament yarn and fabric features. In the production of textured yarn, the most preferred disc types are polyurethane and ceramic. Polyurethane friction discs provide some real advantages over hard friction disc systems. Softer material used for the disc ensures higher surface-to-yarn friction and higher yarn transport component. Polyurethane discs have no distorting effect on the yarn surface. Nevertheless, for high number of filament and high yarn count texturing process, their structure may be damaged and deteriorated by the high working tension. For this reason, polyurethane discs have short lifetime. Polyurethane disc type provides high bulkiness to the yarn and soft touch to the fabric whereas an opposite effect is obtained with ceramic disc type. Due to their higher-hardness characteristic, ceramic discs can damage the filament yarn and by the way cause decrease in yarn strength and breaking elongation.^5–8

In the literature, there are several researches which investigated the relationship between texturing parameters and filament yarn properties. Çirkin studied the effect of the texturing parameters such as production speed, draw ratio (D/R), disc combination etc. on the yarn properties.⁶ Özkan and Babaarslan investigated the effect of number of filaments in yarn cross-section on the textured yarns properties. In the study, it was stated that increasing number of filaments in the yarn cross-section had a statistically significant effect on the yarn strength, elongation, crimp contraction and shrinkage properties.⁹ Özkan conducted a study on the effect of filament cross-section shape, number of filaments and filament linear density on POY (Partially Oriented Yarn) and textured yarn properties.¹⁰ Stojanovic et al. studied the effect of false-twist texturing parameters on polyester yarn structure. In the study, texturing speed and temperature were found as the most significant parameters affecting the yarn structure and crimp properties.¹¹ Varshney et al. searched the yarn characteristic as a result of change in cross-sectional shape and fineness of polyester fiber. Polyester fibers with different cross-sections and fineness were spun in different twisting levels in the ring frame. It was deduced that bending rigidity of yarn increases with the increase in fibre linear density.¹² In literature, there are also some studies focused on the effects of texturing parameters on the mechanical behaviours of carpets. Javidpanah et al. studied the thickness loss of carpets samples after static loading. The carpet samples were produced with air-jet textured polyester yarns modified by different heat processes. It was concluded that the recovery of carpets after loading enhanced as the temperature in setting of pile yarns twist at the autoclave process increased. On the other hand, the friezing and heat-setting processes of pile yarns did not have a significant effect on the static compression recovery.¹³ Javidpanah et al. examined the thickness loss of carpet samples that were produced with the same modified air-jet textured polyester pile yarns after dynamic loading. It was determined that friezing and heat setting processes did not have a significant effect on dynamic compression recovery similar to static compression recovery in the previous study.¹³ Besides, decreasing temperature of twist heat setting did not change the thickness loss of the carpet samples.¹⁴ Many researchers have examined the effect of fiber types such as wool, acrylic, polypropylene and also structural parameters of carpets such as pile height and pile density on carpet compression and recovery properties.^3,15–22 Sarioglu et al.²³ analysed the effect of pile height and pile density on the compressibility and soiling properties of the carpets. They concluded that higher pile density provided lower thickness loss. It was also claimed that the pile height had a preventing effect for texture deformation after compression recovery and static loading tests. It was determined that there was no difference between the soiling performances of the carpet samples.²³ Since the textile floor coverings are also used for the purpose of sound insulation, some of the researchers investigated the effects of pile density, pile height and filament fineness on carpet sound absorption.^24–26 In order to explain the mechanical behaviour of the pile yarn under traffic exposure, a simulation model was submitted by Jafari and Ghane.²⁷ Compression and recovery performance of the carpet piles under the effect of traffic exposure was analysed with viscoelastic models. The carpet samples were applied hexapod wear test. The least square method was used to find the best fit for experimental data and the theoretical model. It was concluded that the generated viscoelastic model fits with the experimental results with an acceptable level.

When the scope of the previous studies were investigated, it can be highlighted that most of the studies on carpet performance are related to effect of pile density, pile height and filament fineness parameters. The most important distinctive aim of this study from the previous studies was to investigate the effects of filament fineness and disc type on carpet performance. Moreover, polyester fiber was selected as pile material in this study, because polyester fiber has an increasing usage as pile yarn in the carpet industry whereas most of the research in the literature has been carried out with acrylic and polypropylene pile yarns.

Material and methods

Material

In this study, drawn textured polyester filament yarns (DTY) were used as pile yarn. The DTY pile yarns were produced by plying 4 POY polyester filament yarns. With the aim of determining the effect of filament fineness, POY filament yarns were produced with 96, 144 and 192 number of filaments and 300 denier yarn linear density. Thus, DTY pile yarns were obtained with 384, 576 and 768 number of filaments and 1200 denier final yarn linear density. The parameters of textured polyester pile yarns are given in Table 1. The texturing process was carried out in 1-6-1 disc configuration using polyurethane and ceramic disc types, while the other machine parameters were kept constant. Polyester yarns were produced in KORTEKS Mensucat Sanayi ve Tic. A.Ş. (KORTEKS) in Turkey.

Table 1.

Texturing parameters of polyester yarn.

Sample code	POY linear density (denier)	POY number of filaments	DTY linear density (denier)	DTY number of filaments	DTY filament fineness (dpf)	Disc type
PU-313	300	96	1200	384	3.13	Polyurethane
CE-313	300	96	1200	384	3.13	Ceramic
PU-208	300	144	1200	576	2.08	Polyurethane
CE-208	300	144	1200	576	2.08	Ceramic
PU-156	300	192	1200	768	1.56	Polyurethane
CE-156	300	192	1200	768	1.56	Ceramic

Tenacity, breaking elongation, crimp contraction and shrinkage in dry-hot air (at 190°C) tests of the yarn samples were carried out according to the relevant standards^28–30 and the results are given in Table 2.

Table 2.

Tenacity, breaking elongation, crimp and shrinkage in dry-hot air test results of the yarn samples.

Sample code	Disc type	Tenacity		Breaking elongation		Crimp contraction		Shrinkage in dry-hot air
Sample code	Disc type	Mean (cN/dtex)	CV (%)	Mean (%)	CV (%)	Mean (%)	CV (%)	Mean (%)	CV (%)
PU-313	Polyurethane	3.33	1.94	28.05	3.50	39.97	0.34	7.3	0.00
CE-313	Ceramic	3.01	2.39	21.57	4.82	36.23	0.04	7.5	0.00
PU-208	Polyurethane	3.28	2.23	24.53	7.05	35.47	4.82	7.5	0.95
CE-208	Ceramic	2.93	1.27	19.06	2.40	27.78	0.23	7.3	2.93
PU-156	Polyurethane	3.42	4.36	17.92	9.30	30.22	5.85	8.3	0.00
CE-156	Ceramic	2.93	3.03	13.12	8.10	23.74	1.31	8.1	0.00

According to the yarn test results, yarn samples produced by polyurethane disc type have higher tenacity, breaking elongation and crimp contraction values than those of ceramic disc type. This was a probable result of damaging effect of ceramic disc to the yarn surface.⁵ Tenacity results were evaluated according to filament fineness and it was determined that there was no significant difference. However, a significant decrease in breaking elongation and crimp contraction values were observed in finer filaments. This situation was attributed to the fact that as the number of filaments in the yarn cross section (that means finer filaments) increases, the filaments are exposed to more frictional forces.⁹ Microscopic view of the yarn cross sections clearly demonstrates this situation (Figure 1). For both disc types, there was a decreasing trend with finer filaments in crimp contraction. This indicated that coarser filaments have bulkier structure. Although the shrinkage values of the pile yarn samples were similar, an increment was observed on 1.56 dpf filament fineness samples.

Figure 1.

Microscopic view (×10) of yarn samples with different filament fineness.

All six carpet samples were woven by Van de Wiele RCI02 model Wilton type face to face carpet weaving machine with 1/1 V ground weave. Properties of the carpet samples are shown in Table 3. All weaving parameters and carpet structural properties were kept constant. After weaving process, the carpet back was covered by latex at 115^oC.

Table 3.

Properties of carpet samples.

Ground weave	Pile density (piles/m²)	Weft sett (picks/10 cm)	Weft yarn (Nm)	Pile yarn linear density (denier)	Warp sett (ends/10 cm)	Stuffer warp yarn linear density (denier)	Chain warp yarn linear density (denier)	Pile height (mm)
1/1 V	915,200	143	1.3 JUTE	1200	32	1600 PET	800 PET	12

Method

Carpet samples were conditioned for 24 hours at standard atmospheric conditions (20 ± 2° C and 65% ± 4% relative humidity) according to ISO 139:2005 standard, before the performance tests were conducted.³¹

The resilience performance of carpet samples was investigated by compression/recovery and dynamic loading tests. Besides, the appearance retention of carpet samples was determined with hexapod tumbler test. The effects of filament fineness and texturing disc type on carpet resistance to soiling were determined with soiling test.

Two-way ANOVA and Duncan tests were applied to reveal the statistical significance of yarn properties on carpet performance. The statistical software package SPSS 21.0 was used to interpret the experimental data. All test results were assessed at 95% confidence interval.

Compression and recovery test

SDL Atlas Digital Thickness Gauge was used for compression and recovery test in accordance with the standard of BS 4098.³² According to the standard, 5 specimens were prepared from each sample (PU-313, CE-313, PU-208, CE-208, PU-156, CE-156). After compression and recovery test, assessments were carried out depending on the average value of 5 experimental results for each sample. With the purpose of determining the compression behaviours of carpet samples, weights were loaded from 2 kPa to 200 kPa pressures; then the weights were removed from 200 kPa to 2 kPa pressures, in order to determine the resilience behaviour. In Figure 2, compression and recovery curve which shows the carpet thickness values obtained at the corresponding loading and unloading pressures at intervals of 30 s is shown.

Figure 2.

The compression and recovery graphic of PU-313.

According to the graph (Figure 2), $t_{2}$ is the initial thickness under 2 kPa pressure (point A), $t_{200}$ is the compressed thickness under 200 kPa pressure (point B) and $t_{r}$ is the recovered thickness under 2 kPa pressure after unloading of weights (point C). The percentage of compression recovery of the specimens were calculated with equation (1).

Compression recovery (%) = \frac{t_{r} - t ₂ ₀ ₀}{t ₂ - t ₂ ₀ ₀} \times 100

(1)

Work of compression and recovery in j/m² was determined by calculating the area under the loading and unloading curves. The work of compression in j/m² estimated as the area under the loading curve (area ABD in Figure 2) and the work of recovery in j/m² estimated as the area under the unloading curve (area BCE in Figure 2). The percentage of work recovery was calculated by the ratio of work recovery to work compression as seen on the equation (2).

Work recovery (%) = \frac{{A r e a}_{B C E}}{{A r e a}_{A B D}} \times 100

(2)

Dynamic loading test

Dynamic loading test was carried out for determining the thickness loss of the carpet under dynamic forces. The WIRA dynamic loading machine gives information of the pile thickness loss by stimulating two of the main actions of walking, compression and the shearing effect at the edge of the shoe.³³ The thickness measurements were taken under 2 kPa pressure from A and B regions (Figure 3) of each specimen in accordance with TS 3374 ISO 1765 standard.³⁴ Periodic loading was made by dropping freely from 63 mm, every 4.3 seconds with a 1279 ± 13 g weight on the carpet sample. During the impact application, the sample moves front and backwards in horizontal axis alternately and the view of the carpet sample turns into as seen in Figure 3. Two samples prepared from each carpet set were applied to 50, 100, 200 and 1000 impacts in accordance with TS 3375 ISO 2094 standard.³⁵

Figure 3.

Carpet sample after dynamic loading test.

The percentage of thickness loss was calculated by using equation (3), where $h_{0}$ is the initial thickness and $h_{i}$ is the thickness values after 50, 100, 200 and 1000 impacts. $h_{0}$ and $h_{i}$ thickness values were obtained by calculating the average of 4 thickness values for each sample.

Thickness Loss (%) = \frac{h_{0} - h_{i}}{h_{0}} \times 100

(3)

Hexapod appearance retention test

For the hexapod appearance retention test, the carpet sample was placed into a tumbler and was exposed to hexapod rotation. The carpet surface was cleaned with vacuum cleaner after every 2000 revolution. Each carpet sample was applied in total 12,000 revolutions by using WIRA Hexapod Tumbler Carpet Tester device in accordance with TS ISO 10361 standard.³⁶ Hexapod test was used to determine the change in appearance on the carpet surface against mechanical effects in terms of crushing, pilling, yarn and loop loss, colour change, change in pattern clarity and visibility of carpet back. According to reference scales, the visual grading changes between 1 (the most distorted) and 5 (the least distorted) were evaluated by 3 people.³⁷

Soiling Test

With the aim of investigating the soiling properties of carpet samples, 3 g artificial dirt was added into 1000 g polyamide chips and the soiling material was prepared by rotating for 20 minutes in WIRA Hexapod test device. For each carpet sample, 2 specimens were prepared in compliance with TS 11378-2 standard.³⁸ The test was carried out by rotating the hexapod drum for 30 minutes in which the carpet samples, 250 g of soiling material and 1 kg of metal balls were placed. After the rotation completed, the specimens were cleaned by vacuum cleaner in order to remove excessive soiling material from the surface. Soiling degrees of the carpet samples were graded between 1 (the most stained) and 5 (the least stained) by 3 people in accordance with the standard of ISO 105-A02.³⁹

Results and discussion

Compression and recovery test results

Compression recovery is measure of tendency of pile yarns to return their initial shape after loading and unloading. Compression recovery results of carpet samples are illustrated in Figure 4. According to the figure, the best recovery results were observed in polyurethane disc type with 2.08 dpf filament fineness and ceramic disc type with 3.13 dpf filament fineness. The lowest recovery percentage was obtained in 3.13 dpf fineness with polyurethane disc. Sample CE-313, had higher recovery value than the others. As a general trend (except PU-313), the recovery performance decreased with increase in fiber fineness. The finer filaments had lower rigidity or in other words lower bending resistance due to the finer fiber diameter.¹² As seen from the results, coarser filaments showed better recovery performance. This was expected result since the coarser filaments had higher crimp contraction (see Table 2) and so higher bulkiness ensures higher recovery after compression. This result was in good correlation with Çelik’s findings, coarser fibers in staple acrylic pile yarns, provide better compression recovery percentage.³

Figure 4.

Compression recovery of carpet samples.

Two-way ANOVA results of compression recovery percentage are given in Table 4. According to the ANOVA table, filament fineness and disc types did not have statistically significant effect (p > .05) on compression recovery. When the factors were examined together, filament fineness*disc type (p = .009 < 0.05) had a statistically significant effect on compression recovery at a 95% confidence interval.

Table 4.

Two-way ANOVA results for compression recovery percentage.

Source	F	Sig.
Corrected model	3.732	0.012
Intercept	8975.730	0.000
Filament fineness	2.085	0.146
Disc type	2.898	0.102
Filament fineness * disc type	5.796	0.009

Work recovery percentage can be defined as the resistance of carpet pile yarns to compression. As seen in Figure 5, which show the work recovery percentage results of carpet samples, a similar trend was obtained with that of compression recovery, except 3.13 dpf filament fineness sample group. The samples with 2.08 dpf filament fineness performed higher work recovery than the other samples. In other respect, the samples produced by different disc types with same filament fineness had similar values. There wasn’t any significant difference in 3.13 dpf and 1.56 dpf filament fineness in terms of work recovery percentage results.

Figure 5.

Work recovery of carpet samples.

Two-way ANOVA results of work recovery percentage are given in Table 5. According to ANOVA table while filament fineness had a statistically significant effect (p = .001 < 0.05), disc type did not have any statistically significant effect (p > .05) on work recovery. When the factors were considered together, filament fineness*disc type (p > .05) did not have a significant effect on work recovery at 95% confidence interval.

Table 5.

Two-way ANOVA results for work recovery percentage.

Source	F	Sig.
Corrected model	5.126	0.002
Intercept	21,850.601	0.000
Filament fineness	10.317	0.001
Disc type	0.220	0.644
Filament fineness * disc type	2.387	0.113

Duncan test results, which were carried out to determine the similarities in terms of work recovery percentage of carpet samples produced with different filament fineness’s are shown in Table 6. According to the results, there was no statistically significant difference between carpet samples produced with 1.56 dpf and 3.13 dpf filament fineness. However, a statistically significant difference was observed between the carpet samples produced with 2.08 dpf filament fineness and the other carpet samples. In addition, the highest average work recovery values were obtained in the samples produced with 2.08 dpf filament fineness.

Table 6.

Duncan test results for work recovery percentage.

Filament fineness (dpf)	Subset
Filament fineness (dpf)	1	2
3.13	35.4050
1.56	36.2690
2.08		38.1020
Significance	0.167	1.000

Dynamic loading test results

Carpet samples were exposed to different impact cycles in accordance with the relevant standard. Thickness loss of carpet samples under dynamic loading after 50, 100, 200 and 1000 impacts are shown in Figure 6. As seen from the figure, thickness loss of carpet samples increased as the number of impact increased. CE-156 had the highest thickness loss after all impacts among all carpet samples. When the samples with same filament fineness were considered, the samples produced by polyurethane disc type had generally lower thickness loss than that of ceramic disc type. Hard surface of ceramic discs may have damaged the filament yarn structure. As a result a reduction trend occurred on yarn tenacity and yarn breaking elongation [8]. In coincide with the literature, DTY polyester samples produced by polyurethane disc types had higher tenacity, breaking elongation and crimp contraction results (see Table 2) than samples produced by ceramic disc types. According to the results, samples produced with polyurethane discs had a bulkier yarn structure and lower thickness loss after dynamic loading.

Figure 6.

Thickness loss of carpet samples after 50, 100, 200 and 1000 impacts.

Carpet surface is exposed to heavy foot traffic during usage. Therefore, the thickness loss values obtained as a result of high impact (1000 impacts) would give more accurate results expressing heavy foot traffic. The lowest thickness loss in the dynamic loading test was measured in 2.08 dpf filament fineness sample produced with polyurethane discs. This result coincides with work recovery percentage (Figure 5). As it was stated in Çelik’s study, the thickness loss after dynamic loading was higher in carpet samples produced with finer filaments.³ Besides, another study in the literature also showed that carpet samples produced with finer fibers have worse thickness loss than those of coarser fibers.²² In this study, it was observed that the tendency of the pile yarns to return to their initial position was lower with the carpet samples produced by finer filaments (which have lower crimp values) such as CE-156 and PU-156.

Two-way ANOVA results for thickness loss of carpet samples under dynamic loading after 1000 impacts are given in Table 7. According to ANOVA results, filament fineness was found to be statistically significant (p = .005 < 0.05), whereas disc type did not have significant effect (p = .410 > 0.05) on thickness loss after dynamic loading. It is also seen that there was no statistically significant effect (p = .603 > 0.05) between the parameters on thickness loss at a 95% confidence interval.

Table 7.

Two-way ANOVA results for thickness loss of carpet samples after 1000 impacts.

Source	F	Sig.
Corrected model	3.175	0.032
Intercept	2605.708	0.000
Filament fineness	7.061	0.005
Disc type	0.711	0.410
Filament fineness * disc type	0.520	0.603

Duncan test results for thickness loss of carpet samples after 1000 impacts are shown in Table 8. According to Duncan test results, there was no statistically significant difference between the carpet samples produced with 2.08 dpf and 3.13 dpf filament fineness’s in terms of thickness loss after 1000 impacts. However, there was a statistically significant difference between the carpet samples produced with 1.56 dpf filament fineness and the carpet samples produced with 2.08 dpf and 3.13 dpf filament fineness. Carpet samples produced with 1.56 dpf filament fineness had higher average thickness loss percentages than the other carpet samples. Consequently, carpet samples produced with finer filaments, which had lower crimp contraction and higher thickness loss after dynamic loading, similar to compression recovery results.

Table 8.

Duncan test results for thickness loss of carpet samples after 1000 impacts.

Filament fineness (dpf)	Subset
Filament fineness (dpf)	1	2
2.08	25.5988
3.13	27.2013
1.56		30.5088
Significance	0.245	1.000

Hexapod appearance retention test results

Hexapod test is carried out to determine the appearance retention of carpet texture as low abrasion by 4000 cycles and high abrasion by 12,000 cycles. In addition, unlike other performance tests, pile yarns are exposed to force not only a single axis, but also on multi axes in hexapod test. For that reason, hexapod test results are assumed to differ from other test results. In this study, since no significant abrasion was observed on carpet samples after 4000 cycles, the results of high abrasion with 12,000 cycles were evaluated. From Table 9, the samples with 3.13 dpf filament fineness produced by ceramic disc type and 2.08 dpf filament fineness produced by polyurethane disc type had performed better appearance retention compared to the other carpet samples. For all disc types, the worst appearance results were obtained from the carpet samples with 1.56 dpf filament fineness similar to compression recovery, work recovery and dynamic loading test results. Carpet samples with more filaments in the yarn cross section had worse appearance deterioration and abrasion. This result is ascribed as finer filaments lead the pile yarn to show lower bending rigidity and so lower resilience. In other words, it can also be stated that coarser filaments have more bulky structure due to higher crimp contraction, so this property results in better appearance results.

Table 9.

Hexapod appearance retention levels of carpet samples.

Sample code	Results^*
PU-313	4.0
CE-313	4.5
PU-208	4.5
CE-208	3.5
PU-156	3.0
CE-156	3.0

^*1 (the most distorted) - 5 (the least distorted).

Soiling test results

Soiling degree of the carpet samples are given in Table 10. Also photographic view and microscopic (×1000) view of carpet samples before and after soiling test are given in Figure 7. According to the results, there was no significant difference between the samples produced by different disc types. However, the samples with 3.13 dpf filament fineness had a slightly less staining tendency as seen in Figure 7, shown in the microscopic view. The reason for this situation can be explained by the number of filaments in the yarn cross section. Increasing the number of filaments in yarn cross section causes artificial dirt to spread over a larger contact area. Hence, the samples with 2.08 dpf and 1.56 dpf filament fineness’s had worse soiling degree.

Table 10.

Staining after soiling test.

Sample code	Soiling degree^*
PU-313	3
CE-313	2 - 3
PU-208	2
CE-208	2 - 3
PU-156	3
CE-156	2

^*1 (the most stained) and 5 (the least stained).

Figure 7.

Photographic view and microscopic (×1000) view of carpet samples before and after soiling test.

Conclusion

According to the results of carpet performance tests, it was determined that carpet samples with finer filaments (1.56 dpf filament fineness) performed the lowest resilience behaviour. This situation was attributed to the lower bending rigidity caused by lower diameter of finer filaments. Due to the higher crimp contraction and so bulkiness of yarns with coarser fibers (3.13 dpf and 2.08 dpf filament fineness) had better recovery performance.

In general, polyurethane disc type was detected to lead better recovery and lower thickness loss results than ceramic disc type. This situation was explained by the distorting effect of ceramic disc type on the yarns structure. Ceramic disc type damages the filament yarns and affects adversely the yarn crimp and elasticity. Higher bulkiness characteristics of the yarn samples produced with polyurethane discs caused to possess better recovery and thickness loss values of carpet samples produced from these yarns.

For these reasons, it was concluded in this study that the optimum carpet performance properties were obtained from the samples with 2.08 dpf filament fineness produced by polyurethane disc type.

In order to determine the appearance retention of carpet samples, the specimens were subjected to hexapod and soiling tests. According to hexapod test results, disc type was not composed a significant effect, nevertheless the lowest appearance retention levels were detected on the carpet samples with the finest filament. It was observed that higher number of filaments in the yarn cross section led lower bending rigidity. As mentioned before, due to the fact that the pile yarns with finer filaments had lower bending rigidity and so higher tendency to laying, the samples performed lower appearance retention. Depending on soiling test results, the samples with 3.13 dpf filament fineness were deduced to be less stained. Finer filaments were evaluated as having more contact area with artificial dirt due to the increased number of filaments in the yarn cross section. Besides, disc type did not have a significant effect on soiling.

Consequently, according to the findings of this study, it will be appropriate the usage of pile yarns produced with polyurethane disc type and coarser filaments for the outdoor carpets that will be exposed to heavy foot traffic and soiling.

Footnotes

Acknowledgements

The authors would like to thank for the company of KORTEKS A.Ş., Bursa, Turkey and Gizem İplik, Gaziantep, Turkey and their employees.

Declaration of conflicting interests

The author(s) declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.

Funding

The author(s) disclosed receipt of the following financial support for the research, authorship, and/or publication of this article: This study was supported by Kahramanmaras Sutcu Imam University, Division of Scientific Research Projects [grant number 2019/1-18 D [D6]].

ORCID iDs

Gülbin Fidan

Halil İbrahim ÇELİK

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20.

Ishtiaque

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21.

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22.

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