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WO1999050483A1 - Etirement de filaments de polyester - Google Patents

Etirement de filaments de polyester Download PDF

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Publication number
WO1999050483A1
WO1999050483A1 PCT/US1998/006154 US9806154W WO9950483A1 WO 1999050483 A1 WO1999050483 A1 WO 1999050483A1 US 9806154 W US9806154 W US 9806154W WO 9950483 A1 WO9950483 A1 WO 9950483A1
Authority
WO
WIPO (PCT)
Prior art keywords
filaments
round
tow
cross
dpf
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1998/006154
Other languages
English (en)
Inventor
Arun Pal Aneja
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Priority to AU67838/98A priority Critical patent/AU6783898A/en
Priority to PT98913243T priority patent/PT1068378E/pt
Priority to JP2000541366A priority patent/JP2002509995A/ja
Priority to EP98913243A priority patent/EP1068378B1/fr
Priority to PCT/US1998/006154 priority patent/WO1999050483A1/fr
Priority to DE69827045T priority patent/DE69827045T2/de
Priority to ES98913243T priority patent/ES2230684T3/es
Priority to TW087105274A priority patent/TW567255B/zh
Publication of WO1999050483A1 publication Critical patent/WO1999050483A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/082—Melt spinning methods of mixed yarn
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters

Definitions

  • This invention concerns improved drawing of polyester filaments, and more particularly a process for drawing mixed polyester filaments in the same bundle, especially drawing a tow of such mixed filaments, and the resulting drawn filaments and bundles and downstream processes therefor and products thereof .
  • Polyesters have been produced commercially on a large scale for processing into shaped articles such as fibers, primarily from poly (ethylene terephthalate) .
  • Synthetic polyester yarns have been known and used commercially for several decades, having been first suggested by . H. Carothers, U.S. Patent No. 2,071,251, and then hinfield and Dickson suggested poly (ethylene terephthalate) in U.S. Patent No. 2,465,319.
  • polyester polymers including copolymers
  • poly (ethylene terephthalate) which is often referred to as homopolymer PET.
  • homopolymer PET has generally been preferred over copolymers because of its lower cost, and also because its properties have been entirely adequate, or even preferred, for most end-uses. It is known, however, that homopolymer PET requires special dyeing conditions (high temperature requiring super-atmospheric pressure) not required for nylon fibers, for example, so copolyesters have been suggested and used commercially for some purposes .
  • Homopolymer PET is often referred to as 2G-T
  • poly (trimethylene terephthalate) is referred to as 3G-T (although some have started calling this PTT)
  • poly (tetramethylene terephthalate) is referred to as 4G-T, and so on.
  • Polyester fibers are either (1) continuous filaments or (2) fibers that are discontinuous, which latter are often referred to as staple fiber or cut fibers, and are made by first being formed by extrusion into continuous polyester filaments, which are processed in the form of a tow of continuous polyester filaments before being converted into staple.
  • An important stage in the processing of such continuous polyester filaments has been "drawing" to increase the orientation of the long chain polyester molecules, and thereby improve the properties of the filaments .
  • the present invention relates to improvements in this drawing stage and to the improved products resulting therefrom.
  • the present invention has been made in the course of that work, so is described with particular reference to its value in drawing polyester filaments in tows for further processing in such systems, but is not confined to drawing such tows and is believed to have potential for use more broadly when drawing other bundles of polyester filaments.
  • a process of drawing a mixture of polyester filaments in the same bundle of polyester filaments wherein said mixture is a mixture of different cross- sections and/or of different deniers per filament, and wherein said polyester is chain-branched with about 0.1 to about 0.8 mole % of chain-brancher; such mole % is calculated conventionally as the molecular weight of the chain-brancher unit divided by the molecular weight of the polymer repeat unit times 100, the repeat unit for 2G-T being ethylene terephthalate by way of example .
  • a mixture of polyester filaments wherein said mixture is a mixture of different cross- sections and/or of different deniers per filament, wherein said polyester is chain-branched with about 0.1 to about 0.8 mole % of chain-brancher, and wherein the shrinkage is about 0.5 to about 3%.
  • Such mixtures may be in the form of continuous filamentary drawn tows and drawn yarns, and downstream products of mixtures of polyester filaments resulting therefrom, including mixtures of staple (cut) fiber in various forms, including yarns, and fabrics and garments as well as the yarns themselves, and it will be understood that the resulting mixtures of polyester fibers may also be mixed with other fibers, such as of other synthetic polymers, including polyamides (nylons of various types) and polyolefins, for example, and/or natural fibers, such as cotton and wool.
  • other synthetic polymers including polyamides (nylons of various types) and polyolefins, for example, and/or natural fibers, such as cotton and wool.
  • filament and fiber are used inclusively herein, and are not generally intended to be mutually exclusive; sometimes, however, these general terms are modified, as in terms such as “continuous filament” and “staple fiber”.
  • Figure 1 is a magnified photograph of mixed filament cross-sections according to the invention as explained hereinafter in greater detail.
  • Figures 2 to 6 are average stress-strain curves of single filaments for use in mixtures according to the invention, as described more specifically hereinafter.
  • the essence of the invention is the use of chain-branched polyester polymer to make the polyester filaments that are drawn according to the process of the invention to provide the mixtures of filaments according to the invention.
  • chain-branchers i.e., multi-functional, polyester- forming intermediates having more than the requisite two functional groups that are required for polymerization, such as a glycol and a dibasic acid, both of which are difunctional
  • MacLean et al U.S. Patent Nos. 4,092,299 and 4,113,704
  • IX a lower dpf, or larger differences, such as at least 1.2X, 1.3X or 1.5X or more.
  • the average stress-strain curves were obtained as follows as an average of 10 individual filaments of each type taken from the tow bundle. Ten samples of each type of filament were separated from the tow bundle using a magnifying glass (LUXO Illuminated Magnifier) . The denier per filament (DPF) of each sample filament was measured on a VIBROSCOPE
  • Crimp Frequency was measured as the number of crimps per inch (CPI) after the crimping of the tow.
  • the crimp is exhibited by numerous peaks and valleys in the fiber.
  • Ten filaments are removed from the tow bundle at random and positioned (one at a time) in a relaxed state in clamps of a fiber-length measuring device. The clamps are manually operated and initially moved close enough together to prevent stretching of the fiber while placing it in the clamp. One end of a fiber is placed in the left clamp and the other end in the right clamp of the measuring device . The left clamp is rotated to remove any twist in the fiber.
  • the right clamp support is moved slowly and gently to the right (extending the fiber) until all the slack has been removed from the fiber but without removing any crimp. Using a lighted magnifier, the number of peaks on top and bottom side of the fiber are counted. The right clamp support is then moved slowly and gently to the right until all the crimp has just disappeared. Care is taken not to stretch the fiber. This length of the fiber is recorded.
  • the crimp frequency for each filament is calculated as :
  • CTU Chip Take Up
  • Relative Viscosity is the viscosity of polymer dissolved in HFIP solvent (hexafluoro- isopropanol) containing 100 ppm of 98% reagent grade sulfuric acid.
  • the viscosity measuring apparatus is a capillary viscometer obtainable from a number of commercial vendors (Design Scientific, Cannon, etc.).
  • the relative viscosity in centistokes is measured on a 4.75 wt. % solution of polymer in the solvent at 25°C.
  • the H 2 S0 4 used for measuring LRV destroys cross-links, specifically silicon in the case of tetraethyl ortho silicate chain-brancher.
  • Non-Acid Relative Viscosity is the viscosity of polymer similarly dissolved, measured and compared in hexafluoro-isopropanol solvent but without any sulfuric acid. Since the acid is not present, the cross-links are left intact when the NRV is measured.
  • Delta RV ( ⁇ RV) is the expression we have used herein to define the difference between the NRV and the LRV measured as described above, and express the amount of cross-linking destroyed by the acid when measuring LRV.
  • the first two defects are fibers and clumps of fibers that dye darker than normal fibers .
  • DDDs have a diameter less than 4X the normal (drawn) fiber diameter.
  • EFDs have a diameter 4X the normal fiber diameter or greater. Both defects must be longer than 0.25 inch (6.35 mm) .
  • Samples are processed through a roller top type card. The sliver is dyed
  • Mixed filaments were melt spun at 282°C from chain-branched ethylene terephthalate polymer, such mixed filaments being a mixture of light filaments (finer denier) of scalloped-oval (SO) cross-section and of heavy filaments (heavier denier) of round cross- section.
  • the different filaments were melt-spun simultaneously through different capillaries in the same spinneret, each containing 1000 capillaries, from polymer containing 0.24% (0.22 mole %) tetraethyl silicate (TES, essentially as described in Mead et al . , U.S. Patent No.
  • the spinnerets had 516 round capillaries, each of flow area 0.0003079 sq. in. (0.199 mm 2 ) to make heavy filaments (round cross-section) , and 484 non-round capillaries each of flow area 0.0002224 sq. in (0.143 mm 2 ), to make light filaments (scalloped- oval cross-section) .
  • the smaller non-round capillaries were located on the inner five (of 9) rings while the larger round capillaries were located on the outer four rings of the spinneret .
  • a conventional finish was applied to provide a finish level (on fiber) of 0.15%.
  • the nominal denier per filament i.e., the denier of the total tow bundle divided by the number of filaments
  • the nominal denier per filament i.e., the denier of the total tow bundle divided by the number of filaments
  • the round filaments were extruded at a rate of 85.2 lbs/hr (38.7 Kg/hr) from a 520 capillary spinneret.
  • the hollow filaments were extruded at a rate of 80.4 lbs./hr (36.5 Kg/hr) from a 490 capillary spinneret, using an orifice shape essentially as described in Figure 5B of U.S. Patent No. 5,356,582.
  • the scalloped- oval filaments were extruded at a rate of 73.8 lbs/hr (33.5 Kg/hr) from a 450 capillary spinneret.
  • Example 2 Conventional finish was applied as in Example 1, and the tow was processed and scrutinized for Product Defects. It was surprising, in view of previous attempts with conventional filaments, that the sliver resulting from this Example of an intimate blend of three different cross-sections (round, hollow, and scalloped-oval) , did not show any Product Defects of
  • the drawn tow (8.3 CPI, 3.3 CPcm, 19.9 CTU) of 2.85 nominal dpf (3.2 dtex) was processed and showed zero Product Defects (EFD, DDD, SPL) .
  • Round filaments were extruded at a rate of 70.4 lbs/hr (32 Kg/hr) from a 286 capillary spinneret; trilobal filaments were extruded at a rate of 44 lbs/hr (20 Kg/hr) from a 160-capillary spinneret, using an orifice shape essentially as described in Figure XI of U.S.
  • Patent No. 2,945,739; scalloped-oval (4 grooves) filaments were extruded at a rate of 110 lbs/hr (50
  • Twenty bobbins of round filaments (66,924 denier, 74,360 dtex), thirty-five bobbins of trilobal filaments (64,400 denier, 71,555 dtex), four bobbins of scalloped-oval filaments (20,520 denier, 22,800 dtex), and five bobbins of hollow filaments (21,054 denier, 23,393 dtex) were combined to form a tow having nominal blend ratio of 39% round, 37% trilobal, 12% scalloped- oval and 12% hollow filaments with a total denier of 172,898 (192,108 dtex).
  • the tow was drawn, crimped and relaxed essentially as described in Example 2 to give a drawn tow of approximately 64,490 denier (71,655 dtex) of an intimate blend containing these four differently- shaped crimped (8.9 CPI, 3.5 CPcm, 20 CTU) filaments - round, trilobal, scalloped-oval, and hollow - with a nominal 4.3 dpf (4.8 dtex). Filament properties are listed in Table 4B. The drawn dpfs were significantly different although the spun dpfs were very similar, which shows the difficulty of predicting beforehand what will happen when mixed filaments are drawn together.
  • Example 20 Conventional finish was applied as in Example 1.
  • the drawn tow was processed to show zero Product Defects (EFD, DDD, SPL) .
  • EXAMPLE 5 In Table 5, drawn filament properties are summarized similarly for filaments of only two differently-shaped drawn filaments from a drawn tow prepared essentially as described in Example 4 except that only two different cross-sections - round and trilobal - were combined similarly, in proportions of round fibers - 51%, and trilobal fibers - 49%.
  • the crimp was measured as 8.9 CPI , 3.5 CPcm and 22.5 CTU.
  • the tow was processed to show zero Product Defects (EFD, DDD, SPL) , despite the drawn dpfs and filament properties being significantly different from those in Table 4B. This confirms the difficulty of predicting behavior of filaments during drawing.
  • Another portion of the same tow was processed through another route, using in addition an annealer at 145°C, before the stuffer box crimper, and then relaxed at 145°C to give a drawn tow (11.6 CPI, 3.0 CPcm, 10.7 CTU) of filaments whose properties are listed in the lower part of Table 6B .
  • Example 1 Conventional finish was applied as in Example 1. Both drawn tows were processed and showed zero Product Defects (EFD, DDD, SPL) , again despite the filaments having significantly different properties from those drawn in other Examples .
  • ESD Product Defects
  • Example 7 is similar to Example 1 of U.S. Patent No. 5,591,523 in that filaments of scalloped-oval cross- section of differing deniers were simultaneously drawn

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Artificial Filaments (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Abstract

L'invention concerne l'amélioration de l'étirement simultané des filaments de polyester mélangé en utilisant un polyester à chaîne ramifiée pour le polymère à partir duquel les filaments de polyester sont filés.
PCT/US1998/006154 1998-03-31 1998-03-31 Etirement de filaments de polyester Ceased WO1999050483A1 (fr)

Priority Applications (8)

Application Number Priority Date Filing Date Title
AU67838/98A AU6783898A (en) 1998-03-31 1998-03-31 Drawing of polyester filaments
PT98913243T PT1068378E (pt) 1998-03-31 1998-03-31 Desenho de filamentos de poliester
JP2000541366A JP2002509995A (ja) 1998-03-31 1998-03-31 ポリエステルフィラメントの延伸
EP98913243A EP1068378B1 (fr) 1998-03-31 1998-03-31 Etirement de filaments de polyester
PCT/US1998/006154 WO1999050483A1 (fr) 1998-03-31 1998-03-31 Etirement de filaments de polyester
DE69827045T DE69827045T2 (de) 1998-03-31 1998-03-31 Verstreckung von polyesterfilamenten
ES98913243T ES2230684T3 (es) 1998-03-31 1998-03-31 Estirado de filamentos de poliester.
TW087105274A TW567255B (en) 1998-03-31 1998-04-08 Improved drawing of polyester filaments

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1998/006154 WO1999050483A1 (fr) 1998-03-31 1998-03-31 Etirement de filaments de polyester

Publications (1)

Publication Number Publication Date
WO1999050483A1 true WO1999050483A1 (fr) 1999-10-07

Family

ID=22266706

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1998/006154 Ceased WO1999050483A1 (fr) 1998-03-31 1998-03-31 Etirement de filaments de polyester

Country Status (8)

Country Link
EP (1) EP1068378B1 (fr)
JP (1) JP2002509995A (fr)
AU (1) AU6783898A (fr)
DE (1) DE69827045T2 (fr)
ES (1) ES2230684T3 (fr)
PT (1) PT1068378E (fr)
TW (1) TW567255B (fr)
WO (1) WO1999050483A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6458455B1 (en) 2000-09-12 2002-10-01 E. I. Du Pont De Nemours And Company Poly(trimethylene terephthalate) tetrachannel cross-section staple fiber
US6752945B2 (en) 2000-09-12 2004-06-22 E. I. Du Pont De Nemours And Company Process for making poly(trimethylene terephthalate) staple fibers

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5188892A (en) * 1986-10-31 1993-02-23 E. I. Du Pont De Nemours And Company Spun textile yarns
WO1997002372A1 (fr) * 1995-06-30 1997-01-23 E.I. Du Pont De Nemours And Company Nouveau cable polyester

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5188892A (en) * 1986-10-31 1993-02-23 E. I. Du Pont De Nemours And Company Spun textile yarns
WO1997002372A1 (fr) * 1995-06-30 1997-01-23 E.I. Du Pont De Nemours And Company Nouveau cable polyester

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6458455B1 (en) 2000-09-12 2002-10-01 E. I. Du Pont De Nemours And Company Poly(trimethylene terephthalate) tetrachannel cross-section staple fiber
US6752945B2 (en) 2000-09-12 2004-06-22 E. I. Du Pont De Nemours And Company Process for making poly(trimethylene terephthalate) staple fibers
US6835339B2 (en) 2000-09-12 2004-12-28 E. I. Du Pont De Nemours And Company Process for preparing poly(trimethylene terephthalate) tetrachannel cross-section staple fiber
US6872352B2 (en) 2000-09-12 2005-03-29 E. I. Du Pont De Nemours And Company Process of making web or fiberfill from polytrimethylene terephthalate staple fibers

Also Published As

Publication number Publication date
AU6783898A (en) 1999-10-18
EP1068378A1 (fr) 2001-01-17
DE69827045T2 (de) 2005-09-08
JP2002509995A (ja) 2002-04-02
ES2230684T3 (es) 2005-05-01
PT1068378E (pt) 2005-02-28
EP1068378B1 (fr) 2004-10-13
TW567255B (en) 2003-12-21
DE69827045D1 (de) 2004-11-18

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