Process for making soil and stain resistant carpet fiber

Abstract

A method for producing carpet yarn produces yarn having substantial soil hiding, soil repelling and resistance to staining with acid dye characteristics. The yarn is made by forming at least one hollow trilobal fiber from a molten nylon polymer having an amine end group level below about 25 meq/kg, the fiber having a modification ratio of about 2 and a void volume of at least 3%; quenching the formed fiber sufficiently to solidify the molten nylon; immediately after quenching, at a yarn speed of at least 300 mpm, finishing the fiber with spin finish containing fluorochemical; fully drawing the finished fiber; texturing the finished yarn by a hot fluid texturing process; and subsequently, applying to the textured yarn a sulfonated stainblocker, the stainblocker being heated to at least 50.degree. C. and applied while the fiber temperature is at least about 100.degree. C. in the stainblocker application step. The yarn travels at a rate sufficient to permit fixation of the stainblocker while minimizing penetration of stainblocker into the yarn.