CA2058830A1 - Melt-colored thick and thin yarn - Google Patents
Melt-colored thick and thin yarnInfo
- Publication number
- CA2058830A1 CA2058830A1 CA 2058830 CA2058830A CA2058830A1 CA 2058830 A1 CA2058830 A1 CA 2058830A1 CA 2058830 CA2058830 CA 2058830 CA 2058830 A CA2058830 A CA 2058830A CA 2058830 A1 CA2058830 A1 CA 2058830A1
- Authority
- CA
- Canada
- Prior art keywords
- melt
- process according
- yarn
- colored
- poly
- 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.)
- Abandoned
Links
- 238000000034 method Methods 0.000 claims abstract description 29
- 238000009987 spinning Methods 0.000 claims abstract description 8
- 238000004043 dyeing Methods 0.000 claims abstract description 7
- 238000009826 distribution Methods 0.000 claims abstract description 5
- 229920002959 polymer blend Polymers 0.000 claims abstract 5
- 229920000728 polyester Polymers 0.000 claims description 25
- -1 poly(ethyleneterephthalate) Polymers 0.000 claims description 17
- 229920000642 polymer Polymers 0.000 claims description 9
- 229920001059 synthetic polymer Polymers 0.000 claims description 9
- 239000000049 pigment Substances 0.000 claims description 8
- 239000003086 colorant Substances 0.000 claims description 6
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 5
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 5
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 claims description 5
- LLLVZDVNHNWSDS-UHFFFAOYSA-N 4-methylidene-3,5-dioxabicyclo[5.2.2]undeca-1(9),7,10-triene-2,6-dione Chemical compound C1(C2=CC=C(C(=O)OC(=C)O1)C=C2)=O LLLVZDVNHNWSDS-UHFFFAOYSA-N 0.000 claims description 4
- 239000002253 acid Substances 0.000 claims description 4
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 claims description 4
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 claims description 4
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical compound OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 claims description 4
- 239000006229 carbon black Substances 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 3
- 235000011037 adipic acid Nutrition 0.000 claims description 2
- 239000001361 adipic acid Substances 0.000 claims description 2
- 239000001055 blue pigment Substances 0.000 claims description 2
- RBLSQHNMLLTHMH-UHFFFAOYSA-N dibenzofuran-2,8-dicarboxylic acid Chemical compound C1=C(C(O)=O)C=C2C3=CC(C(=O)O)=CC=C3OC2=C1 RBLSQHNMLLTHMH-UHFFFAOYSA-N 0.000 claims description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-L isophthalate(2-) Chemical compound [O-]C(=O)C1=CC=CC(C([O-])=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-L 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 2
- 150000001991 dicarboxylic acids Chemical class 0.000 claims 1
- 230000001747 exhibiting effect Effects 0.000 abstract description 3
- 239000004744 fabric Substances 0.000 description 12
- 239000000835 fiber Substances 0.000 description 9
- 239000000975 dye Substances 0.000 description 7
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 4
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 3
- 230000009477 glass transition Effects 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 2
- 229920006125 amorphous polymer Polymers 0.000 description 2
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- MMINFSMURORWKH-UHFFFAOYSA-N 3,6-dioxabicyclo[6.2.2]dodeca-1(10),8,11-triene-2,7-dione Chemical group O=C1OCCOC(=O)C2=CC=C1C=C2 MMINFSMURORWKH-UHFFFAOYSA-N 0.000 description 1
- XUKUURHRXDUEBC-KAYWLYCHSA-N Atorvastatin Chemical compound C=1C=CC=CC=1C1=C(C=2C=CC(F)=CC=2)N(CC[C@@H](O)C[C@@H](O)CC(O)=O)C(C(C)C)=C1C(=O)NC1=CC=CC=C1 XUKUURHRXDUEBC-KAYWLYCHSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 235000003403 Limnocharis flava Nutrition 0.000 description 1
- 244000278243 Limnocharis flava Species 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 150000002148 esters Chemical group 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000001023 inorganic pigment Substances 0.000 description 1
- 238000002074 melt spinning Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000012860 organic pigment Substances 0.000 description 1
- 125000000020 sulfo group Chemical group O=S(=O)([*])O[H] 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
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
- D01D5/20—Formation of filaments, threads, or the like with varying denier along their length
-
- 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
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/04—Pigments
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Artificial Filaments (AREA)
Abstract
MELT-COLORED THICK AND THIN YARN
Abstract The present invention provides a process for producing a variable denier melt-colored synthetic polymeric filamentous yarn, having a random distribution of light and dark sections, produced without dyeing and exhibiting improved dye light-fastness, which comprises creating a melt-colored polymer mixture, spinning a melt-colored yarn from said synthetic melt-colored polymer mixture, and subjecting said melt-colored synthetic yarn to a thick and thin drawing process to produce a filamentous yarn of variable denier.
Abstract The present invention provides a process for producing a variable denier melt-colored synthetic polymeric filamentous yarn, having a random distribution of light and dark sections, produced without dyeing and exhibiting improved dye light-fastness, which comprises creating a melt-colored polymer mixture, spinning a melt-colored yarn from said synthetic melt-colored polymer mixture, and subjecting said melt-colored synthetic yarn to a thick and thin drawing process to produce a filamentous yarn of variable denier.
Description
20~883~ 2782 MELT~COLORED THICK AND THIN YARN
Fi~l~ of the Lnve~tion The present invention relates to melt-colored synthetic polymer yarn colltaining fibers or filaments having a random distribution of light and dark sections.
More particularly, it relates to Sbers or filaments of this type which are produced without dyeing and which correspond to denier fluctuations or variations of random size in the direction of the axis of the fibers or ~laments. It also relates to yarns made therefrom, and a method of preparing such yarns.
I3ackground of the Invention Man-made fibers are generally produced by spinning and drawing. In most instances, the fibers produced by this procedure are substantially uniform in thickness.
However, in certain applications, it is important that yarns contain filaments having a variable denier. For instance, such yarns are useful in providing the means of producing variable texture in fabrics made thereErom and the fabrics containing such yarns have an attractive appearance, i.e., a "busy~ looking fabric, and a pleasing feel to the touch.
It is known in the art that these variable denier fabrics may be dyed, thus producing mottled or other novelty e~cts owing to the varying rates and extent to which the dyestuff is taken up by the portions of different denier. While these conventional~y dyed thick and thin yarns are currently in high demand, the added step of dyeing after the initial spinning and dravving of these variable denier yarns creates an extra step in the production process and an increased cost factor. Addidonally, the problem of dye lightfastness of the fabric becomes a concern when the dye is applied at a post spinning and drawing stage. While fabrics prepared in this manner 5 may be suitable for wearing appareL they are less suitable as automotive fabrics, upholstery, curtain fabrics and the like.
Therefore, a need exists in the art for a method to produce these variable denier synthetic polyrner fibers, ~laments, and fabrics made therefrom, exhibiting improved dye lightfastness without the need to be dyed.
~O
Summary of the Invention The present invention provides a process for producing a variable denier melt-colored synthetic polymeric filamentous yarrl, having a random distribution of light and dark sections, produced without dyeing and exhibiting improved dye lightfastness, 15 which comprises creating a melt-colored polymer mLxture, spinning a melt-colored yarn from said synthetic melt-colored polyrner mixture, and subjecting said melt-colored synthetic yarn to a tbick and thin drawing process so as to produce a filamentous yarn of variable denier.
Preferred synthetic polymers include linear terephthalate polyesters (PET), 20 those being polyesters of glycol containing from 2 to 20 carbon atoms and a dicarboxylic acid compound comprising at 1east about 75% terephtbalatic acid. The 20~8830 remainder, if any, of the dicarboxylic acid compound may be any suitable dicarboxylic acid. The preferred polyester is poly(ethyleneterephthalate). The feeder yarn utilized to prepare the yarn and filarnents of the present inveDtion will have a birefnngence in the range of about 0.01 to about 0.05. The preferred melt coloring agent is a colored 5 pigment in a polyethylene carrier. The most preferred melt coloring agent is a colored agent in a PET carner.
Definitio~
The term "fiber" as used herein includes fibers of extreme or indefinite leogth (i.e., filaments) and ~bers of short length (i.e., staple). The term "yarnN as used 10 herein means a continuous straod of fibers.
The term "fabric" as used oerein includes a textile structure composed of mechanically interlocked fibers or Slarnents. The structure can be nonwoven, woven or knitted.
The term "multifilament yarn" as used herein means a yarn comprised of a 15 plurality of individual filaments or strands.
The term "glass transition temperature~ (T~) means the temperature at which an amorphous polymer or the amorphous regions of a partially crystalline polymer changes to or from a hard and relatively brittle state to a more flexible or rubbery condition. At sufficiently low temperatures, all amorphous polymers or amorphous 20 regions of sernicrystalline polymers assume characteristics of glasses, such as hardness, stiffness, and brittleness. Polyrners in the glassy state are characterized by a low - 20~8830 volume coef~lcient of expansio4 when compared with that of the polymer in the ~uid state. In this respect, polymers in the glassy state resemble crystalline polymers which are also characterized by a low volume coefficient of expansion. The temperatureinterval at which thc volume coef~cient of expansion of the amorpbous polymer S changes f~om a high to a low value is the glass transition temperature range.
Bire&ingence ( a n) is obtained in the following manner:
Sodium D rays (wavelength 589 millimicrons) are used as a light source, and the filaments are disposed in a diagonal position. The bireringence (Q n) of the specimen is computed from the following equation:
a n = n ~ + r a when n is the ioterference fringe due to the degree of orientatio~ of the polymer molecular chaio; r is the relardation obtained by measuring the orientation not developing into the interference fringe by means of a Berek's compensator; a is the diameter of the filarnent; and ~1 is the wavelength of the sodium D rays.
Detailed Descri~tion of the Preferred Fmbodiments A number of procedures are known ;D the art for producing Slarnents having a variable denier. One such method, for example, is that of Stanko et al. U. S.
Patent No. 4,906,519. Fiber-forming synthetic polymers suitable for use in ~he 20~8830 present invention include synthetic polyrners having a glass transition temperature (T,) of at least 30C.
Preferred synthetic polymers include linear terephthalate polyesters (PET), i.e., polyesters of a glycol containing f~om 2 to 20 carbon ator~s and a dicarboxylic acid S component comprising at least about 75% terephthalic acid. The remainder, if any, of the dicarboxylic acid component may be any suitable dicarboylic acid such as sebacic acid, adipic acid, isophthalic acid, sulfonyl-4,4-dibenzoic acid, or 2,8-dibenzofurandicarboxylic acid.
Examples of linear terephthalate polyesters which may be employed include poly(ethyleneterephthalate), poly(butylene terephthalate), poly(elhyleneterephlhalate/s-chloroisophthalate)(85lls)~
poly(ethyleneterephthalate/S-[sodiurn sulfo] isophthalate)(97/3), or poly(cyclohexane-1,4dimethyleneterephthalate/hexahydroterephthalate) (75/25).
T~e preferred polyester is poly(ethylene terephthalate), which includes a linear 20 polyester in which at least about 85% of the recurring structural units are ethylene terephthalate units of the following formula:
OcHtcH2~
o o More preferably, the linear polyester contains at least ninety percent (90%) recurring structural units of ethylene terephthalate. In a particularly preferred S embodiment of the process, the polyester is substantially all poly(etbylene terephthalate). Up to lS mole percent of other copolymerizable ester units otherthan poly(ethylene terephthalate) can also be present.
The feeder yarn utilized to prepare the yarn and filaments of the present invention must have su~lcient molecular orientation (birefringence- n). The amount of birefringence in the feeder yarn will be an amouot in the range of from about 0.01 to about O.OS, and, more preferably, from about 0.015 to 0.031, and, most preferably, about Q018.
In order for the feeder yarn to have sufficient molecular orientation, the lake-up spèed will generally be in the range of from about 1,600 to about 4,000 meters/rn~nute, preferably, from about 1,800 to about 2,800 meters/minute, and most prcferably, about 2,000 meters/minute.
In order to achieve maximum contrast between the thick and thin sections of tbe yarn, the feeder yarn should be aged for a sufficient amount of time, typicaUy about 24 hours to about 7 days.
The variable denier filaments of the present invention are prepared by drawiDg, at ambient temperature, i.e., 15-30~C, the feeder yarn having thc abovc 20~8830 described molecular orientation (birefringence) at ~ draw ratio of from about 1.27 to about 2.07 and in a draw zone having a length of frsm about 15.2 to about 300 cmMore preferably, tho draw ratio is from about 1.69 to about 1.97 and the draw zone has a length of from about 30.5 to about 813 cr~ Most preferably, the draw ratio is about 1.97 and the length of the draw zone is 61 c~
The resulting thick and thin filarnents contain slubs which preferably have a length in the range of from about 1.4 inches to 30.9 inches, an average length of slub of from about 9.1 to about 16.2 inches, and occupy ~om about 16.4 to about 49.8 percent of the longitudinal axis of the filarnents. The above-recited percent ofoccupancy, length of slub, and average length of slub are obtained by measuring 50 feet of at least 10 filaments which have been selected at random.
Melt-coloring agents suitable for use in the present invention are inorganic and organic pigments in a thermoplastic carrier. This carrier can be PET, nylon,polyethylene or any other carrier suitable for pigment dispersion. Fxamples are carbon black pigment in a PET carrier and navy blue pigment in a PET carrier. The preferred melt coloring agent is a colored pigrnent in a polyethylene carrier. The most preferred melt coloring agent is a colored pigment in a PET carrier. The yarns comprising the variable denier filaments can be processed into fabrics which find particular use in draperies, upholstery fabrics, and automotive upholstery applications.
The following examples present illustrative but non-limiting embodiments of the present invention, 20~8830 A PET yarn was produced by melt spirming molten PET and winding up the yarn at different winding speeds ranging from 1600 to 2725 mp~ Carbon black pigment in a concentration range up to 0.25 wt. percent was added to the molten PET
S prior to spinning. The fecder yarns were then drawn at ambient temperature, using a draw ratio range of 1.69 to 2.07, and a draw zone of 24 inches.
Test Sampl~ Winding Speed (mpm~ Birefringence Pigment (wt. ~!
1600 0.014 0.10 2 2000 0.015 0.10 3 2400 0.023 0.10 4 2725 0.031 0.10 1600 0.014 0.17 6 2000 0.015 0.17 7 2400 0.023 0.17 8 2725 0.031 0.17 9 1600 0.014 0.25 2000 0.015 0.25 11 2400 0.0~3 0.25 12 2725 0.031 0.25 The yarns produced at these conditions had a random distribution of light and dark sections without the necessity of dyeing, and showed improved dye lightfastness.
20~8830 Example 2 A PET yarn was produced by melt spinning molten PET with 0.20 wt. percent navy pigment added to the molten PET prior to spinning. This yam was wound at 1600 mpm and drawn at ambient temperature at a draw ratio of 2.02 and a draw 5 zone of 24 inches.
Test Sample Windin~ Speed (mpm) Birefrin~ence Pi~ment (wt- ~!
1600 0.014 0.10 2 1600 0.014 0.20 3 1600 0.014 0.25 A yarn with random dark blue and light blue sections was produced, without dyeing, and showing improved dye lightfastness.
Fi~l~ of the Lnve~tion The present invention relates to melt-colored synthetic polymer yarn colltaining fibers or filaments having a random distribution of light and dark sections.
More particularly, it relates to Sbers or filaments of this type which are produced without dyeing and which correspond to denier fluctuations or variations of random size in the direction of the axis of the fibers or ~laments. It also relates to yarns made therefrom, and a method of preparing such yarns.
I3ackground of the Invention Man-made fibers are generally produced by spinning and drawing. In most instances, the fibers produced by this procedure are substantially uniform in thickness.
However, in certain applications, it is important that yarns contain filaments having a variable denier. For instance, such yarns are useful in providing the means of producing variable texture in fabrics made thereErom and the fabrics containing such yarns have an attractive appearance, i.e., a "busy~ looking fabric, and a pleasing feel to the touch.
It is known in the art that these variable denier fabrics may be dyed, thus producing mottled or other novelty e~cts owing to the varying rates and extent to which the dyestuff is taken up by the portions of different denier. While these conventional~y dyed thick and thin yarns are currently in high demand, the added step of dyeing after the initial spinning and dravving of these variable denier yarns creates an extra step in the production process and an increased cost factor. Addidonally, the problem of dye lightfastness of the fabric becomes a concern when the dye is applied at a post spinning and drawing stage. While fabrics prepared in this manner 5 may be suitable for wearing appareL they are less suitable as automotive fabrics, upholstery, curtain fabrics and the like.
Therefore, a need exists in the art for a method to produce these variable denier synthetic polyrner fibers, ~laments, and fabrics made therefrom, exhibiting improved dye lightfastness without the need to be dyed.
~O
Summary of the Invention The present invention provides a process for producing a variable denier melt-colored synthetic polymeric filamentous yarrl, having a random distribution of light and dark sections, produced without dyeing and exhibiting improved dye lightfastness, 15 which comprises creating a melt-colored polymer mLxture, spinning a melt-colored yarn from said synthetic melt-colored polyrner mixture, and subjecting said melt-colored synthetic yarn to a tbick and thin drawing process so as to produce a filamentous yarn of variable denier.
Preferred synthetic polymers include linear terephthalate polyesters (PET), 20 those being polyesters of glycol containing from 2 to 20 carbon atoms and a dicarboxylic acid compound comprising at 1east about 75% terephtbalatic acid. The 20~8830 remainder, if any, of the dicarboxylic acid compound may be any suitable dicarboxylic acid. The preferred polyester is poly(ethyleneterephthalate). The feeder yarn utilized to prepare the yarn and filarnents of the present inveDtion will have a birefnngence in the range of about 0.01 to about 0.05. The preferred melt coloring agent is a colored 5 pigment in a polyethylene carrier. The most preferred melt coloring agent is a colored agent in a PET carner.
Definitio~
The term "fiber" as used herein includes fibers of extreme or indefinite leogth (i.e., filaments) and ~bers of short length (i.e., staple). The term "yarnN as used 10 herein means a continuous straod of fibers.
The term "fabric" as used oerein includes a textile structure composed of mechanically interlocked fibers or Slarnents. The structure can be nonwoven, woven or knitted.
The term "multifilament yarn" as used herein means a yarn comprised of a 15 plurality of individual filaments or strands.
The term "glass transition temperature~ (T~) means the temperature at which an amorphous polymer or the amorphous regions of a partially crystalline polymer changes to or from a hard and relatively brittle state to a more flexible or rubbery condition. At sufficiently low temperatures, all amorphous polymers or amorphous 20 regions of sernicrystalline polymers assume characteristics of glasses, such as hardness, stiffness, and brittleness. Polyrners in the glassy state are characterized by a low - 20~8830 volume coef~lcient of expansio4 when compared with that of the polymer in the ~uid state. In this respect, polymers in the glassy state resemble crystalline polymers which are also characterized by a low volume coefficient of expansion. The temperatureinterval at which thc volume coef~cient of expansion of the amorpbous polymer S changes f~om a high to a low value is the glass transition temperature range.
Bire&ingence ( a n) is obtained in the following manner:
Sodium D rays (wavelength 589 millimicrons) are used as a light source, and the filaments are disposed in a diagonal position. The bireringence (Q n) of the specimen is computed from the following equation:
a n = n ~ + r a when n is the ioterference fringe due to the degree of orientatio~ of the polymer molecular chaio; r is the relardation obtained by measuring the orientation not developing into the interference fringe by means of a Berek's compensator; a is the diameter of the filarnent; and ~1 is the wavelength of the sodium D rays.
Detailed Descri~tion of the Preferred Fmbodiments A number of procedures are known ;D the art for producing Slarnents having a variable denier. One such method, for example, is that of Stanko et al. U. S.
Patent No. 4,906,519. Fiber-forming synthetic polymers suitable for use in ~he 20~8830 present invention include synthetic polyrners having a glass transition temperature (T,) of at least 30C.
Preferred synthetic polymers include linear terephthalate polyesters (PET), i.e., polyesters of a glycol containing f~om 2 to 20 carbon ator~s and a dicarboxylic acid S component comprising at least about 75% terephthalic acid. The remainder, if any, of the dicarboxylic acid component may be any suitable dicarboylic acid such as sebacic acid, adipic acid, isophthalic acid, sulfonyl-4,4-dibenzoic acid, or 2,8-dibenzofurandicarboxylic acid.
Examples of linear terephthalate polyesters which may be employed include poly(ethyleneterephthalate), poly(butylene terephthalate), poly(elhyleneterephlhalate/s-chloroisophthalate)(85lls)~
poly(ethyleneterephthalate/S-[sodiurn sulfo] isophthalate)(97/3), or poly(cyclohexane-1,4dimethyleneterephthalate/hexahydroterephthalate) (75/25).
T~e preferred polyester is poly(ethylene terephthalate), which includes a linear 20 polyester in which at least about 85% of the recurring structural units are ethylene terephthalate units of the following formula:
OcHtcH2~
o o More preferably, the linear polyester contains at least ninety percent (90%) recurring structural units of ethylene terephthalate. In a particularly preferred S embodiment of the process, the polyester is substantially all poly(etbylene terephthalate). Up to lS mole percent of other copolymerizable ester units otherthan poly(ethylene terephthalate) can also be present.
The feeder yarn utilized to prepare the yarn and filaments of the present invention must have su~lcient molecular orientation (birefringence- n). The amount of birefringence in the feeder yarn will be an amouot in the range of from about 0.01 to about O.OS, and, more preferably, from about 0.015 to 0.031, and, most preferably, about Q018.
In order for the feeder yarn to have sufficient molecular orientation, the lake-up spèed will generally be in the range of from about 1,600 to about 4,000 meters/rn~nute, preferably, from about 1,800 to about 2,800 meters/minute, and most prcferably, about 2,000 meters/minute.
In order to achieve maximum contrast between the thick and thin sections of tbe yarn, the feeder yarn should be aged for a sufficient amount of time, typicaUy about 24 hours to about 7 days.
The variable denier filaments of the present invention are prepared by drawiDg, at ambient temperature, i.e., 15-30~C, the feeder yarn having thc abovc 20~8830 described molecular orientation (birefringence) at ~ draw ratio of from about 1.27 to about 2.07 and in a draw zone having a length of frsm about 15.2 to about 300 cmMore preferably, tho draw ratio is from about 1.69 to about 1.97 and the draw zone has a length of from about 30.5 to about 813 cr~ Most preferably, the draw ratio is about 1.97 and the length of the draw zone is 61 c~
The resulting thick and thin filarnents contain slubs which preferably have a length in the range of from about 1.4 inches to 30.9 inches, an average length of slub of from about 9.1 to about 16.2 inches, and occupy ~om about 16.4 to about 49.8 percent of the longitudinal axis of the filarnents. The above-recited percent ofoccupancy, length of slub, and average length of slub are obtained by measuring 50 feet of at least 10 filaments which have been selected at random.
Melt-coloring agents suitable for use in the present invention are inorganic and organic pigments in a thermoplastic carrier. This carrier can be PET, nylon,polyethylene or any other carrier suitable for pigment dispersion. Fxamples are carbon black pigment in a PET carrier and navy blue pigment in a PET carrier. The preferred melt coloring agent is a colored pigrnent in a polyethylene carrier. The most preferred melt coloring agent is a colored pigment in a PET carrier. The yarns comprising the variable denier filaments can be processed into fabrics which find particular use in draperies, upholstery fabrics, and automotive upholstery applications.
The following examples present illustrative but non-limiting embodiments of the present invention, 20~8830 A PET yarn was produced by melt spirming molten PET and winding up the yarn at different winding speeds ranging from 1600 to 2725 mp~ Carbon black pigment in a concentration range up to 0.25 wt. percent was added to the molten PET
S prior to spinning. The fecder yarns were then drawn at ambient temperature, using a draw ratio range of 1.69 to 2.07, and a draw zone of 24 inches.
Test Sampl~ Winding Speed (mpm~ Birefringence Pigment (wt. ~!
1600 0.014 0.10 2 2000 0.015 0.10 3 2400 0.023 0.10 4 2725 0.031 0.10 1600 0.014 0.17 6 2000 0.015 0.17 7 2400 0.023 0.17 8 2725 0.031 0.17 9 1600 0.014 0.25 2000 0.015 0.25 11 2400 0.0~3 0.25 12 2725 0.031 0.25 The yarns produced at these conditions had a random distribution of light and dark sections without the necessity of dyeing, and showed improved dye lightfastness.
20~8830 Example 2 A PET yarn was produced by melt spinning molten PET with 0.20 wt. percent navy pigment added to the molten PET prior to spinning. This yam was wound at 1600 mpm and drawn at ambient temperature at a draw ratio of 2.02 and a draw 5 zone of 24 inches.
Test Sample Windin~ Speed (mpm) Birefrin~ence Pi~ment (wt- ~!
1600 0.014 0.10 2 1600 0.014 0.20 3 1600 0.014 0.25 A yarn with random dark blue and light blue sections was produced, without dyeing, and showing improved dye lightfastness.
Claims (17)
1. A process for producing a variable denier melt-colored synthetic polymeric filamentous yarn comprising creating a melt- colored polymer mixture, spinning a melt-colored yarn from said synthetic melt- colored polymer mixture, and subjecting said melt-colored synthetic yarn to a thick and thin drawing process so as to produce a filamentous yarn of variable denier having a random distribution of light and dark sections, produced without dyeing and which exhibits improved dye lightfastness.
2. A process according to Claim 1 wherein the melt-colored synthetic polymer is pigmented at a concentration up to 5 wt. percent.
3. A process according to Claim 1 wherein said melt-coloring agents are selected from a group comprising carbon black pigment and navy blue pigment.
4. A process according to Claim 1 wherein the melt-colored synthetic polymer of said melt colored synthetic polymer mixture is a polyester.
5. A process according to Claim 1 wherein said polymer is selected from a group comprising:
poly(ethyleneterephthalate), poly(butylene terephthalate), poly(ethyleneterephthalate/5-chloroisophthalate)(85/15), poly(ethyleneterephthalate/5-[sodium-sulfo] isophthalate)(97/3), or poly(cyclohexane-1,4dimethyleneterephthalate/hexahydroterephthalate) (75/25).
poly(ethyleneterephthalate), poly(butylene terephthalate), poly(ethyleneterephthalate/5-chloroisophthalate)(85/15), poly(ethyleneterephthalate/5-[sodium-sulfo] isophthalate)(97/3), or poly(cyclohexane-1,4dimethyleneterephthalate/hexahydroterephthalate) (75/25).
6. A process according to Claim 1 wherein the preferred melt-colored synthetic polymer of said melt-colored polymer mixture is a linear terephthalate polyester.
7. A process according to Claim 1 wherein said suitable dicarboxylic acids are selected from a group comprising:
sebacic acid, adipic acid, isophthalic acid, sulfonyl-4,4-dibenzoic acid, or 2,8-dibenzofurandicarboxylic acid.
sebacic acid, adipic acid, isophthalic acid, sulfonyl-4,4-dibenzoic acid, or 2,8-dibenzofurandicarboxylic acid.
8. A process according to Claim 1 wherein the melt-colored synthetic polymer mixture is spun in a range of from about 1,600 mpm to about 3,000 mpm to form a yarn.
9. A process according to Claim 1 wherein the thick and thin drawing process takes place at ambient temperature.
10. A process according to Claim 1 wherein the ambient temperature is in a range from about 15°C to about 30°C.
11. A process according to Claim 1 wherein the take-up speed is in a range of from about 1,600 to about 4,000 mpm.
12. A process according to Claim 1 wherein the take-up speed is more preferably from about 1,800 to about 2,800 mpm.
13. A process according to Claim 1 wherein said birefringence of said feeder yarn is about 0.01 to about 0.05.
14. A process according to Claim 1 wherein said birefringence of said feeder yarn is more preferably about 0.015 to about 0.031.
15. A process according to Claim 1 wherein said draw ratio is about 1.27 to about 2.07.
16. A process according to Claim 1 wherein said draw ratio is more preferably about 1.69 to about 1.97.
17. An article of manufacture containing filamentous yarn produced according to the process of Claim 1.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US63824691A | 1991-01-07 | 1991-01-07 | |
| US07/638,246 | 1991-01-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2058830A1 true CA2058830A1 (en) | 1992-07-08 |
Family
ID=24559231
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2058830 Abandoned CA2058830A1 (en) | 1991-01-07 | 1992-01-06 | Melt-colored thick and thin yarn |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP0494432A3 (en) |
| JP (1) | JPH04289217A (en) |
| CA (1) | CA2058830A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2309041A4 (en) * | 2008-07-31 | 2012-01-18 | Yi Yung Chen | Spun dyeing chromatographic fiber and the preparation method thereof |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL302595A (en) * | 1962-12-26 | 1900-01-01 | ||
| US4906519A (en) * | 1988-06-06 | 1990-03-06 | Basf Corporation | Variable denier filaments and method of producing same |
-
1991
- 1991-12-20 EP EP19910122036 patent/EP0494432A3/en not_active Withdrawn
-
1992
- 1992-01-06 JP JP19892A patent/JPH04289217A/en active Pending
- 1992-01-06 CA CA 2058830 patent/CA2058830A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| EP0494432A3 (en) | 1993-01-27 |
| EP0494432A2 (en) | 1992-07-15 |
| JPH04289217A (en) | 1992-10-14 |
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