KR20140074984A - Fabric comprising poly(trimethylene arylate) filaments - Google Patents

Abstract

Three denier poly (trimethylene arylate) radiation-spun fibers are characterized by high denier uniformity. A method for producing a uniform Sedanian yarn at a spinning speed of 4000 to 6000 m / min is also disclosed. The poly (trimethylene arylate) fiber of the present invention comprises 0.1 to 3% by weight of polystyrene dispersed therein. Transitions fabricated therefrom are also disclosed.

Description

FABRIC COMPRISING POLY (TRIMETHYLENE ARYLATE) FILAMENTS <br> <br> <br> Patents - stay tuned to the technology FABRIC COMPRISING POLY (TRIMETHYLENE ARYLATE)

The present invention relates to a process for spinning poly (trimethylene arylate) fibers, fibers produced, and uses thereof.

Poly (trimethylene arylate), especially poly (trimethyleneterephthalate) (also referred to as 3GT, Triexta or PTT) has attracted much attention recently as fiber-forming polymers useful in textiles. PTT fibers have excellent physical and chemical properties. Continuous textured polyester yarns made from partially oriented polyester yarn (POY) or spun drawn yarn (SDY), most of which are polyethylene terephthalate (PET) Have broad commercial applications in textile applications, such as knit fabrics and woven fabrics, as well as nonwovens, such as spunbonded PET. The textile term "yarn " refers to a bundle of individual fibers. For example, shirts and blouses are often made of yarns consisting of bundles of 30 to 40 filaments.

Polyester yarns, including both PET yarns and PTT yarns, are produced by a so-called melt spinning process and are referred to as "melt spinning. &Quot; Melt spinning is a process in which a polymer is melted and extruded through a hole in a so-called spinneret. In typical textile applications, the spinnerets are provided with a plurality of holes, often 30 to 40 holes, each about 0.25 mm in diameter. Whereby a plurality of filaments are extruded from one radiator. Such filaments are combined to form a bundle called yarn.

The polyester yarns may be used in any combination with or without other types of yarns. Therefore, the polyester yarn can constitute the entire fabric or can constitute a warp, weft or fill in the woven fabric; Or one of two or more yarns in a yarn blend having, for example, cotton, wool, rayon, acetate, other polyesters, spandex, and / or combinations thereof.

U.S. Patent No. 6,284,370 to Fujimoto et al. Discloses a method of heating a first roll at 30-80 占 폚, heating a second roll at 100-160 占 폚, and determining a stretching ratio between the first roll and the second roll draw ratio is in the range of from 1.3 to 4. In 13 Examples and 11 Comparative Examples, Fujimoto did not heat the first roll to a temperature above 60 占 except for one comparative example. In all embodiments, the first roll temperature ranged from 50 to 60 占 폚.

U.S. Patent No. 7,785,507 to Ding discloses a method for making 2 to 3 dpf PTT fibers wherein the first godet is heated to 85-160 ° C and the second godet is heated to 125-195 ° C And the stretching ratio applied between the first roll and the second roll is in the range of 1.1 to 2. [ Ding teaches that the first high temperature of 75 ° C caused excessive line breaks. The Uster result was approximately 0.90 to 0.95%. In all embodiments, the temperature of the first goethite was above 90 ° C.

U.S. Patent No. 6,287,688 to Howell et al. Describes the manufacture of textured PTT yarns that exhibit increased stretchability, luxurious bulk and improved hand compared to PET yarns. Howell et al. Describe the fabrication of partially oriented PTT yarns at a spinning speed of up to 2600 m / min. In contrast, PET is routinely melt-spun at a multiple of such velocity. For reasons of cost, it is highly desirable to be able to radiate PTT yarns at velocities exceeding 2600 m / min.

U.S. Patent No. 6,923,925 to Chang et al. Discloses a composition comprising PTT containing about 2% polystyrene (PS) that can be melt-spun into a radiation elongat at a rate of up to 5000 m / min. The windows etc. do not refer to the denier uniformity (denier CV) of the yarn so produced, nor to the temperature of the high detol roll used to make the spinneret.

There is a need for a low denier spin-drawn filament yarn of PTT that can be radiated at commercially viable spinning speeds and has sufficient denier uniformity to be practical in the manufacture of high quality fabrics and garments.

In a first aspect, the present invention provides a composition comprising from 0.1 to 3% by weight of polystyrene dispersed in poly (trimethylene arylate), said weight percent being based on the total weight of the polymer in the composition, Wherein the filament has a denier per filament (dpf) of 3 or less, a denier coefficient of variation of 2.5% or less, and a birefringence of 0.055 or more.

In one embodiment, the poly (trimethylene arylate) is poly (trimethylene terephthalate).

In another aspect, the present invention provides a method of forming a novel radially drawn filament, wherein the filament has a denier per filament of 3 or less and a modulus of variation of 2.5 or less, Polymer melt comprising polystyrene in weight percent based on the total weight of the polymer, extruding through an orifice having a predetermined cross-sectional shape to form a continuous filamentary extrudate, The filaments are wound on a first driven roll heated to a temperature in the range of 70 to 100 DEG C and rotated at a first rotational speed before the filaments are heated to a temperature in the range of 100 to 130 DEG C, Rolling on a roll and rotating at a second rotational speed; And winding the filament onto a take-up roll at a linear velocity of at least 4,000 meters per minute (m / min), wherein the ratio of the first rotational velocity to the second rotational velocity is in the range of 1.75 to 3 -; Thereby providing a method of forming a radially drawn filament having a denier per filament of 3 or less and a denier coefficient of variation of 2.5% or less.

In one embodiment, the poly (trimethylene arylate) is poly (trimethylene terephthalate).

In another aspect, the present invention relates to a filament comprising a composition comprising from 0.1 to 3% by weight of polystyrene dispersed in poly (trimethylene arylate), said weight percent being based on the total weight of the polymer in the composition Wherein the filament has a denier per filament of 3 or less, a denier coefficient of 2.5% or less, and a birefringence of 0.055 or more.

In one embodiment, the poly (trimethylene arylate) is poly (trimethylene terephthalate).

&Lt; 1 >
BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic diagram of one embodiment for supplying a melt to a spinneret according to the present invention.
2,
2 is a schematic diagram of one embodiment of a fiber spinning process in accordance with the present invention.
3,
Figure 3 shows a loom suitable for making the woven fabric of the present invention.
<Fig. 4>
4 is a schematic view of the spinning machine used in the embodiment.
5,
5 is a graph of experimental results showing the effect of the temperature of the first high temperature on the denier coefficient of variation, in contrast to the results obtained using spinning machine # 1, with the results obtained using spinning machine # 2.

In one aspect, the present invention provides a composition comprising from 0.1 to 3% by weight of polystyrene dispersed in poly (trimethylene arylate), the weight percent being based on the total weight of the polymer in the composition, The denier (dpf) is 3 or less, the denier coefficient (denier CV) is 2.5% or less, and the birefringence is 0.055 or more.

In one embodiment, the poly (trimethylene arylate) is poly (trimethylene terephthalate).

In one embodiment, the filament of the present invention is a continuous filament. In an alternative embodiment, the filament of the present invention is a staple filament. In one embodiment, a plurality of filaments of the present invention are combined to form a multifilament yarn. The multifilament yarns so formed are suitable for texturing and for end use in such textile applications where a fine denier yarn is desirable, such as shirts, blouses, lingerie, hosiery, and the like.

The multifilament yarns of the present invention are useful for forming knitted fabrics, woven fabrics, and nonwoven fabrics by methods known in the art.

In alternative embodiments, the filaments of the present invention are also suitable for use in a wide variety of nonwoven structures. The filaments of the present invention can be arranged in random or quasi-random webs to form filamentary nonwoven fabrics. In a further embodiment, the filamentary nonwoven fabric comprises a plurality of continuous filament strands of the present invention. In an alternative additional embodiment, the filamentary nonwoven fabric comprises a single continuous filament strand. In an alternative embodiment, the filamentary nonwoven fabric comprises a plurality of staple filaments formed from the filaments of the present invention. For the purposes of the present invention, a filamentary nonwoven fabric is a nonwoven fabric whose basic component is not a multifilament yarn segment but a single random or semi-randomly arranged filament segment.

In another aspect, the present invention provides a method of forming a novel radially drawn filament, wherein the filament has a denier per filament of not more than 3 and a modulus of variation of not more than 2.5%, the method being characterized in that the poly (trimethylene arylate) From 0.1 to 3% by weight of polystyrene dispersed in an amount of from 0.1 to 3% by weight based on the total weight of the polymer; - extruding a polymer melt through an orifice having a predetermined cross-sectional shape to form a continuous filamentary extrudate , Quenching the extrudate to solidify it into a continuous filament, winding the filament over a first driven roll heated to a temperature in the range of from 70 to 100 占 폚 and rotating at a first rotational speed, Winding on a second driven roll heated to a second rotational speed and rotating at a second rotational speed; And winding the filament over a winding roll at a linear speed of at least 4,000 meters per minute (m / min), wherein the ratio of the first rotational speed to the second rotational speed is in a range of from 1.75 to 3.

As demonstrated in the embodiment provided below, the yarn denier CV of less than or equal to 3 dpf when radiated at a speed of at least 4,000 m / min when the first godet is set above 70 DEG C, Lt; RTI ID = 0.0 &gt; 60 C &lt; / RTI &gt; at the same speed.

The term "denier coefficient of variation" (denier CV) refers to the coefficient of variation of the denier determined by a worsted yarn evenness tester available from Uster Technologies. The so-called "Worcester tester " measures denier fluctuations along the length of a single continuous strand of fiber or yarn. The denier CV is a standard statistical parameter indicating a value obtained by dividing the standard deviation of the denier by the average denier, which is determined from the Worster tester.

In the present invention, concentrations are referred to as weight percentages unless otherwise stated. In particular, it will be appreciated that the concentration of the polystyrene blended with the poly (trimethylene terephthalate) or other poly (trimethylene arylate) of the present invention is expressed as the weight percentage of polystyrene to the total weight of the polymer in the composition.

It will be understood that when a range of numerical values is provided herein, it includes the end-point of the range unless specifically stated otherwise. Numerical values should be understood to have a precision of the number of significant digits provided as described in ASTM E29-08. For example, figure 3 should be understood to include a range of 2.5 to 3.4, while figure 3.0 should be understood to include a range of 2.95 to 3.04.

For purposes of the present invention, the detailed description relates to embodiments in which the poly (trimethylene arylate) is poly (trimethylene terephthalate) (PTT), unless explicitly stated otherwise. Expansion of the invention to another poly (trimethylene arylate) will be accomplished by adjusting the weight-based concentration to suit the difference in molecular weight of the particular arylate monomer units involved, assuming the same degree of polymerization.

Both homopolymers and copolymers of polystyrene and PTT are suitable for use in the present invention. For purposes of the present invention, the term "copolymer" will be understood to include binary copolymers, as well as ternary copolymers, The term "copolymer" will be understood to include any number of monomers polymerized together. In practice, very many applications are limited to homopolymers, binary copolymers, and terpolymers.

In one embodiment, the filament comprises a composition comprising 97 to 99.9 wt% of PTT and 3 to 0.1 wt% of polystyrene (PS). In another embodiment, the filament comprises a composition comprising 70 to 99.5 wt% of PTT, 3 to 0.5 wt% of PS, and optionally, up to 29.5 wt% of other polyesters. In another embodiment, the filament comprises a composition comprising 98 to 99.5 wt% PTT and 2 to 0.5 wt% PS.

In one embodiment, the filaments consist essentially of a composition consisting essentially of 97 to 99.9 wt% PTT and 3 to 0.1 wt% polystyrene (PS). In another embodiment, the filaments consist essentially of a composition consisting essentially of 70 to 99.5 wt% of PTT, 3 to 0.5 wt% of PS, and, optionally, up to 29.5 wt% of other polyesters. In another embodiment, the filaments consist essentially of a composition consisting essentially of 98 to 99.5 wt% of PTT and 2 to 0.5 wt% of PS.

Suitable PTT polymers are formed by condensation polymerization of 1,3-propanediol with terephthalic acid or dimethyl terephthalate. One or more suitable comonomers for copolymerization therewith are linear, cyclic and branched aliphatic dicarboxylic acids or esters having from 4 to 12 carbon atoms (for example, butane dioic acid, pentane dioxy acid, hexane dioic acid , Dodecanedioic acid, and 1,4-cyclohexanedicarboxylic acid, and the corresponding esters thereof); Aromatic dicarboxylic acids or esters other than terephthalic acid or esters and having 8 to 12 carbon atoms (e.g., isophthalic acid and 2,6-naphthalene dicarboxylic acid); Linear, cyclic and branched aliphatic diols (other than 1,3-propanediol) having from 2 to 8 carbon atoms, such as ethanediol, 1,2-propanediol, 1,4- Butanediol, 3-methyl-1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, 2-methyl- Diol; And aliphatic and aromatic ether glycols having from 4 to 10 carbon atoms such as hydroquinone bis (2-hydroxyethyl) ether or poly (ethylene ether) glycols having a molecular weight of less than 460 (including diethylene ether glycol) &Lt; / RTI &gt; The comonomer is typically present in the PTT copolymer at levels ranging from 0.5 to 15 mol%, and may be present in an amount up to 30 mol%.

The PTT may contain minor amounts of other comonomers selected so as not to have significant side effects on the properties. Such other comonomers include, for example, 5-sodium-sulfoisophthalate at a level ranging from about 0.2 to 5 mol%. Very small amounts of trifunctional comonomers, such as trimellitic acid, can be incorporated for viscosity control. PTT can be blended with up to 30 mole% of other polymers. Examples include polyesters made from other diols, such as those mentioned above.

In one embodiment, the PTT contains at least 85 mole percent of trimethylene terephthalate repeating units. In a further embodiment, the PTT contains at least 90 mole% of trimethylene terephthalate repeat units. In yet another further embodiment, the PTT contains 98 mole% or more of trimethylene terephthalate repeat units. In yet another further embodiment, the PTT comprises 100 mole percent of the trimethylene terephthalate repeating unit.

In one embodiment, a suitable PTT is characterized by an intrinsic viscosity (IV) in the range of 0.70 dl / g to 2.0 dl / g. In a further embodiment, suitable PTTs are characterized by an IV ranging from 0.80 dl / g to 1.5 dl / g. In a still further embodiment, suitable PTTs are characterized by an IV ranging from 0.90 dl / g to 1.2 dl / g.

In one embodiment, a suitable PTT is characterized by a number average molecular weight (M _n ) in the range of 10,000 Da to 40,000 Da. In a further embodiment, suitable PTT is characterized in that M _n of 20,000 Da to 25,000 Da range.

In one embodiment, suitable polystyrenes are selected from the group consisting of polystyrene homopolymers,? -Methyl-polystyrene, and styrene-butadiene copolymers and blends thereof. In one embodiment, the polystyrene is a polystyrene homopolymer. In a further embodiment, the polystyrene homopolymer is characterized by a M _n of 5,000 Da to 300,000 Da range. In yet additional embodiments, polystyrene M _n of the homopolymer is in the range of 50,000 Da to 200,000 Da. In yet additional embodiments, polystyrene M _n of the homopolymer is in the range of 75,000 Da to 200,000 Da. In yet additional embodiments, polystyrene M _n of the homopolymer is in the range of 120,000 Da to 150,000 Da. Useful polystyrenes can be isotactic, atactic, or syndiotactic. High molecular weight atactic polystyrene homopolymers are preferred.

Polystyrenes useful in the present invention may be obtained from Dow Chemical Co., Midland, Michigan, BASF (Mount Olive, NJ) and Sigma-Aldrich (St. Louis, Mo.) And many other suppliers.

The PTT and PS are melt blended and then extruded in the form of strands, which are then cut into pellets. Other forms of melt blending and subsequent milling, such as milling into flakes, chips or powders, may also be performed. In some circumstances, after producing pellets comprising a first PTT / PS blend having a PS concentration of greater than 15%, the pellets are re-melted and the remelted material is diluted with additional PTT to obtain a second It may be convenient to form a melt blend and extrude the second melt blend into the filament of the present invention.

Filaments of the present invention include compositions comprising PTT and PS. In some embodiments, there will be only these two materials in the blend, which will total 100 wt%. However, in many cases, the blend will have other components, such as are typically included in the polyester polymer composition in commercial applications. Such additives include, but are not limited to, other polymers, plasticizers, UV absorbers, flame retardants, dyes, and the like. Therefore, the total poly (trimethylene terephthalate) and polystyrene will not be 100% by weight. Other polymers may include, for example, polyamides that impart acid dyeability to the yarn blend. In such cases where additional, non-polyester, polymer is added, the ratio of the weight percent concentration of the polyester to the weight percent concentration of PS is the same as for those compositions that do not contain other polymers.

According to the present invention, PS is in the form of particles having an average size of less than 500 nanometers. In one embodiment, the polystyrene is a polystyrene homopolymer at a concentration of 2% or less; The poly (trimethylene arylate) is a PTT comprising 98 mole% or more of trimethylene terephthalate monomer units.

The filament of the present invention is characterized in that the dpf is 3 or less, the denier CV is 2.5% or less, and the birefringence is 0.055 or more. Typical physical properties of the filament of the present invention include a tenacity of greater than 3 grams / denier and elongation to break of 30 to 70%. In one embodiment, the filament denier is less than or equal to 2.5. In another embodiment, the birefringence is at least 0.060.

In another aspect, the present invention provides a process for making a polymer melt blend comprising: (a) preparing a melt blend consisting essentially of PTT and from 0.1 to 3 weight percent (wt%) of polystyrene (PS); (b) , And forming at least one filament of the PTT containing dispersed PS.

The filaments of the present invention are conveniently produced as spinning drawn filaments, i.e. filaments fully drawn in the spinning process. "Completely stretched" means that the filament after quenching has been stretched to near its extreme breaking elongation. Preferably, the spinning comprises extruding the polymer blend of the present invention through one or more openings of the spinneret at a spinning speed of at least 4,000 m / min. The term "spinning speed " refers to the rate of accumulation of the spinning fiber, for example on a mechanical wind-up.

The high birefringence of 0.055 or more, which is characteristic of the filament of the present invention, is a direct result of the high degree of stretching applied to the filament in the spinning process. The high birefringence is a principled way of distinguishing a radially oriented filament from a partially oriented oriented filament, which is subsequently stretched - textured.

1 is a schematic view of one embodiment of a melt spinning machine suitable for use in the present invention. 1, a PTT is produced in a continuous molten polymerizer 1 and is transported therefrom through a transfer line 2 in a molten form to a counter-rotating twin-screw extruder 3, where a twin-screw extruder is equipped with a mixing zone do. At the same time, the pellets containing PS are fed to the satellite extruder 5 via a weight-loss feeder 4 or other pellet feeder means, where the pellets are melted and transferred to the transfer line 6 To the twin-screw extruder (3) at or upstream of the mixing zone of the twin-screw extruder (3). In a twin-screw extruder, a PTT / PS melt blend is formed. The resulting melt blend is fed via a transfer line 7 to a spin block comprising a spinneret 8 from which one or more continuous filaments 9 are extruded.

Figure 2 shows one arrangement suitable for melt spinning according to the invention. 34 filaments 22 (not all 34 filaments are shown) are extruded through the hole radiating apertures 21. These filaments pass through the cooling zone 23 to form a yarn bundle and pass over the finish applicator 24. The cooling zone includes an air quench zone where the air hits the yarn bundle at a rate of 12 m / min (40 ft / min) at room temperature and 60% relative humidity. The air quenching zone may be a so-called cross-air-quench in which air flows across the yarn bundles, or in the so-called &lt; RTI ID = 0.0 &gt; It can be designed as a radial quench. Radial quenching is a more uniform and effective quenching method. After the finish applicator 24, the yarn travels to a first driven high detoller 25, also known as a feed roll, which is paired with a separator roll and is set at 60-100 ° C, in one embodiment at 70-100 ° C . The yarn is wound 6 to 8 times around the first high detol and separator rolls. From the first high detol roll, the yarn travels to a second driven high detolor, also known as a stretch roll, which is paired with a second separator roll and set at 110-130 ° C. The yarn is wound 6 to 8 times around the second high detoller and separator rolls. The stretching roll speed is 4000-6000 m / min while the ratio of the stretching roll speed to the feed roll speed is in the range of 1.75-3. From the stretching roll, the yarn travels to the third driven high detol roll 27, which is paired with the third separator roll and operates at a rate of 1 to 2% faster than the roll speed of the second high detol roll and at room temperature . The yarn is wound 6 to 10 times around the third pair of rolls. From the third pair of rolls, the yarn passes through an interlace jet 28 and then into a take-up machine 29, which operates at a speed that corresponds to the calculation of the third roll pair.

2, according to the method of the present invention, the quenched filaments are stretched at least once around the first high detall roll, so that the first high detol roll is subjected to a stretching force on the extruded filament, But is preferably wound a plurality of times; At the downstream of the first high detol roll, the filaments are heated at least once around the second high detol roll in such a manner that the second high detent applies a stretching force to the filament portions lying between the first high and low detet rolls, But is preferably wound a plurality of times. In the embodiment shown in Fig. 2, from the second godet roll, the filaments are directed to a third godet roll, which acts as a let down roll and extends from the first Moves 2% faster. From the third goethite, the filament is directed to a winder. The speed at which the filament winds on the winder is described as the spinning speed. In a typical installation, the winder is a tension controlled wind-up.

According to the present invention, the first godet roll is heated to a temperature in the range of 70 to 100 DEG C and the second godet roll is heated to a temperature in the range of 100 to 130 DEG C. The first high detector roll is driven at a first rotational speed; And the second high detol roll is driven at the second rotation speed. According to the present invention, the ratio of the second rotation speed to the first rotation speed (stretching ratio) is in the range of 1.75 to 3. [

In one embodiment, a plurality of filaments, each individually a filament of the present invention, are extruded through a multi-hole spinneret. The extruded filaments thus combine to form the yarn. Typically, yarns are bonded to each other by causing interlacing of the filaments by application of some agitation, twisting, or both of the extruded filaments or thread lines. The yarn thus formed includes a plurality of filaments, wherein each filament has a dpf of 3 or less, a denier CV of 2.5% or less, and a birefringence of 0.055 or more. In one embodiment, the filament denier is less than or equal to 2.5. In another embodiment, the birefringence is at least 0.060. Typical yarns include 34, 48, 68, and 72 filaments, but the number of filaments that are combined to make the yarn is not limited in any way.

The yarn formed in accordance with the present invention is not limited to a plurality of filaments according to the present invention, but may also contain other filaments. For example, yarns formed in accordance with the present invention may contain polyamides, polyacrylates as well as other filaments of other polyesters, and other such filaments that may be required. Other filaments may also be staple fibers.

The yarns formed in accordance with the present invention, which may be formed by the radiation-induced stretching process described above, may be subjected to false twist texturing, such as is commonly done to provide textile-like aesthetics to continuous polyester fibers, As a feed yarn for &lt; / RTI &gt; While there are several types of texturing devices all of which are well known in the art, the texturing process comprises the steps of: a) providing a yarn package such as formed according to the spinning process described above; (b) unwinding the yarn from the package, (c) threading the yarn end through a friction twisting element or a false-twist spindle, d) Rotating the spindle to impart a twist in the yarn upstream of the rotating spindle and untwist the upstream twist downstream from the rotating spindle while applying heat; And (e) winding the yarn onto the package.

The present invention allows for increased productivity in the spinning of three denier (3 dpf or less) radially stretched PTT yarns. The filaments and yarns of the present invention were prepared at a spinning speed 30 to 70% greater than the maximum spinning speed that could be achieved by neat PTT. The resulting yarn is characterized in that the elongation and strength are within 20% of the elongation and strength of the PTT multifilament yarns different from (and necessarily radiating at about 3000 m / min) the inventive yarn only in that they do not contain PS . Thus, the yarn consisting essentially of the filaments of the present invention is useful in a wide variety of textile applications, with only minor adjustments necessary to use a textile machine. The resulting yarn is useful for making texturized yarns, textured fabrics and textured carpets, especially under the same or similar conditions as those used for PTT yarns made at 3000 m / min without PS .

In the filament of the present invention, the PTT is a continuous phase or "matrix " and the PS is a discontinuous phase dispersed within the PTT matrix. In one embodiment, the size of the PS particles dispersed in the PTT matrix is less than or equal to 500 nm. In a further embodiment, the size of the PS particles dispersed in the PTT matrix is 200 nm or less.

A beneficial feature of the present invention includes the ability to spin three denier, high strength, strong radially stretched PTT yarns at a spinning speed of at least 4000 m / min. This advantageous feature depends on both the fine particle size of the PS and the volume uniformity of the dispersion of PS in the PTT, which ultimately depends on the application of meltblending which is sufficiently high shear. There is no threshold particle size at which the radiated performance and / or physical properties of the radiated yarn are suddenly degraded. However, the larger the PS particle size, the more slowly the performance deteriorates. At particle sizes in the range of 500 nm or more, the denier CV becomes progressively larger. Similarly, there is no specific threshold of homogeneity with respect to particle distribution in the PTT matrix. The better the uniformity of the dispersion, the more uniform the resulting filament yarn. One particularly useful advantage of the present invention is the production of a yarn drawn yarn characterized in that the denier CV is 2.5% or less. Low denier CVs are essential in the manufacture of three denier yarns for textile applications. Unless the process of dispersing the PS in the PTT is characterized by a shear force sufficient to ensure a particle size of less than 500 nm and a sufficiently high dispersion uniformity, the denier CV is very unlikely to be less than 2.5%.

The amount of shear force applied to the melt depends on the rotational speed of the mixing element, the viscosity of the melt, and the residence time of the melt in the mixing zone. If the shear force is too low, the PS will not split and will tend to agglomerate with droplets that start in size above 500 nm or rapidly with these droplets.

The melt blending method may be performed both batchwise and continuously. So-called high shear mixers, such as are commonly used in the polymer blending field. Examples of suitable high available batch batch mixers include, but are not limited to, Banbury mixers and Brabender mixers. Examples of continuous high-shear mixers include co-rotating twin-screw extruders and Farrel continuous mixers. A counter rotating twin-screw extruder is also suitable. In general, suitable high shear mixers are those that can provide a minimum shear rate of 50 / s, preferably 100 / s, for the polymer melt. After melt blending, the resulting blend can later be pelletized to feed the spinning machine, or the melt blend can be fed directly to the spinning machine. Another useful method is to combine polymeric melts. An example of such a method may be to provide a PTT melt from a continuous polymerizer to a first stage of a twin-screw extruder and supply a PS melt from a satellite extruder to a mixing zone of a twin-screw extruder to produce a melt blend. In another method, the non-fusible polymers can be dry blended, such as by tumbling, prior to feeding to a twin-screw extruder for melt blending.

An average particle size of more than 500 nm is not preferred from the standpoint of good fiber spinning performance. Additionally, the uniform filament emission along both ends and across both ends is clearly dependent on the uniformity of the volume distribution of the PS particles. Although not limiting the scope of the invention in any way, in its actual melting process it is assumed that the PS particles are melted to form molten droplets and that these droplets are dispersed in the molten PTT matrix.

The temperature in the melt mixer should be higher than the melting point of both PTT and PS, but lower than the lowest decomposition temperature of any of the components. The specific temperature will depend on the particular properties of the polymer used. In a typical run, the melt temperature ranges from 200 ° C to 270 ° C.

In one embodiment, the concentration of PS in the PTT / PS blend pellets ranges from 0.5 to 1.5%.

As shown in Figure 1 and as is generally applied to melt spinning of polymer fibers, the polymer melt is fed to the spinnerette via a transfer line. The melt entering the transfer line from the extruder is turbulent. However, the spinnerette feed must be laminar to achieve a uniform flow through the plurality of holes in the spinnerette. It is within the transfer line that the melt flow changes from turbulent to laminar flow.

Filament radiation can be achieved using conventional equipment and procedures that have been used in a wide variety of commercial applications. As a practical matter, in the case of spinning of three denier filaments of less than 3 dpf, a PS concentration of greater than 3% appears to result in a reduction in the mechanical properties of the resulting fibers. In addition, at 5% PS, three denier filaments appear to be unable to melt spin at all.

Prior to melt spinning, the polymer blend pellets are preferably dried to a moisture level of less than 30 ppm to avoid hydrolysis during melt spinning. Any drying method known in the art is satisfactory. In one embodiment, a closed loop hot air dryer is used. Typically, the PTT / PS blend is dried at 130 占 폚 and at a dew point of less than -40 占 폚 for 6 hours. The thus dried PTT / PS polymer blend is melt-spun into fibers at 250-265 占 폚.

In a typical melt spinning process-one embodiment of which is described in detail below-the dried polymer blend pellets are fed to an extruder which melts the pellets and feeds the resulting melt to a metering pump, Transfers the volumetrically controlled flow of the polymer through a transfer line into a heated spinning pack. The pump provides a pressure of 10 to 20 MPa to force the spinning pack through a filter medium (including a filter medium, for example a sand bed and a filter screen) to provide any particles larger than a few micrometers Should be removed. The mass flow rate through the spinneret is controlled by a metering pump. At the bottom of the pack, the polymer exits the air quenching zone through a plurality of small holes in a thick metal plate (spinneret). The number of holes and the size of the holes can vary widely, but typically one hole is in the range of 0.2 to 0.4 mm in diameter. The radiation is advantageously achieved at a spin valve temperature of 235 to 295 ° C, preferably 250 to 290 ° C.

Typical flow rates through holes of that size tend to range from about 1 to 5 g / min. A large number of cross-sectional shapes are used for the spinneret holes, but the circular cross-section is the most common. Typically, a highly controlled rotary roll system in which the spun filaments are wound controls the line speed. The diameter of the filament is determined by the flow rate and take-up speed; It is not determined by the spinner hole size.

The properties of the filaments thus produced are determined by the threadline dynamics, particularly in the region between the exit from the filament and the solidifying point of the filament, which is known as quenching zone. The specific design of the quench zone, ie the air flow across the newly formed still motile filament, has a great influence on the properties of the quenched filament. Both cross-flow quench and radial quench are commonly used. After quenching or solidification, the filament travels at a winding speed, which is typically 100 to 200 times faster than the escape speed from the spinnerette aperture. Thus, significant acceleration (and extension) of the thread line occurs after escape from the spinning hole. The amount of orientation frozen into the radiated filament is directly related to the level of stress in the filament at the solidification point.

The melt-spun filaments thereby produced are collected in a manner consistent with the desired end use. For example, in filaments intended to be converted into staple fibers, a plurality of continuous filaments can be combined into a tow, which is accumulated in a so-called fiddling can. Filaments intended for continuous use, such as in texturing, are typically wound onto a yarn package mounted on a tension-controlled winding machine. According to the present invention, the accumulation rate is 4,000 m / min or more.

Texturing imparts a crimp by twisting, heat setting, and untwisting by a process commonly known as flame-retardant texturing. Such multifilament yarns (also known as "bundles") include the same number of filaments as the yarn stretch yarns used to make them. Thus, it comprises at least 10, more preferably at least 25 filaments, and typically at most 150 filaments, preferably at most 100 filaments, more preferably at most 80 filaments. The yarns typically have a total denier of at least 1, more preferably at least 20, preferably at least 50, more preferably at most 250, and at most 1,500. The filament is preferably at least 0.1 dpf, more preferably at least 0.5 dpf, even more preferably at least 0.8 dpf, and most preferably at most 3 dpf.

The PTT staple fibers are obtained by melt spinning the PTT / PS-blend into filaments at a temperature of 245-285 占 폚, quenching the filaments, stretching the quenched filaments, crimping the drawn filaments, To 15 cm (0.2 to 6 inches) of staple fiber. One preferred method comprises the steps of (a) providing a polymer blend comprising PTT and 0.1 to 3% PS, (b) melt spinning the molten blend into a filament at a temperature of 245 to 285 ° C, (c) (D) stretching the quenched filament; (e) stretching the drawn filament to a crimp level of from 3 to 12 crimps / cm (8 to 30 crimps / inch) using a mechanical crimper; (F) relaxing the crimped filament at a temperature of from 50 to 120 DEG C, and (g) stretching the loosened filaments to a staple fiber preferably having a length of from 0.5 to 15 cm (0.2 to 6 inches) . In one embodiment of this process, the drawn filaments are annealed at 85 to 115 캜 before crimping. Preferably, the annealing is carried out under tension using a heated roller. In another preferred embodiment, the drawn filaments are not annealed prior to crimping. Staple fibers are useful for making textile yarns and textile fabrics or non-wovens, and may also be used for man-made fiberfill applications and carpet manufacturing.

Although the invention has been described primarily with respect to multifilament yarns, it should be understood that the preferences described herein are also applicable to monofilaments.

The filaments may be circular or have other shapes such as octalobal, delta, solar (also known as sol), scalloped oval, trilobal, tetrachannel (Also known as quartz channel type), scalloped ribbon type, ribbon type, starburst type, and the like. These filaments may be solid, hollow or multi-hollow.

In another aspect, the present invention relates to a composition comprising from 0.1 to 3% by weight of polystyrene dispersed in poly (trimethylene arylate), the weight percent being based on the total weight of the polymer in the composition, Wherein the filament has a denier per filament of 3 or less, a denier coefficient of 2.5% or less, and a birefringence of 0.055 or more. In one embodiment, the poly (trimethylene arylate) is poly (trimethylene terephthalate).

In one embodiment, the filaments are bundled into yarns and the fabric is woven. In an alternative embodiment, the filament is bundled with at least one yarn, and the fabric is a knitted fabric. In another embodiment, the fabric is a nonwoven; In a further embodiment, the nonwoven is a spunbonded fabric.

In one definition, the nonwoven is a nonwoven or nonwoven fabric. The weaving and knitting structure is characterized by a regular pattern of interlocking yarns produced by either interlacing (fabric) or looping (knitting). In both cases, the yarns follow a regular pattern, which repeats over and over again from one side of the fabric to the other. The integrity of the woven or knitted fabric is created by the structure of the fabric itself.

In nonwovens, the filaments are most commonly laid down in a random pattern and are joined together by chemical or thermal means rather than by mechanical means. One possible example of a non-woven fabric produced by such means is Sontara Spun-Bonded Polyester available from DuPont Company. In some cases, the nonwoven may be a complex three-dimensional topology array (such as those described in U.S. Patent No. 6,579,815 to Popper et al.) That does not include interlacing or roofing and fibers do not alternate from one side to the other by laying down layers of fibers in a topological array.

The woven fabrics are made of a plurality of yarns interlaced at right angles to each other. Yarns parallel to the longitudinal direction of the fabric are referred to as "warp yarns ", and yarns that are orthogonal to that direction are referred to as" weft yarns " Each slope is referred to as the "end ". As can be seen in any cloth or garment shop, the large changes in the aesthetics are due to the specific manner in which the yarn is interlaced, the denier of the yarn, the tactile aesthetics and visual aesthetics of the yarn itself, the yarn density, Can be achieved by changing the ratio of the slope. In general, the structure of the woven fabric imparts some degree of rigidity to the fabric; Woven fabrics are generally not stretched as much as swings.

In the woven fabric of the present invention, at least a portion of the warp comprises from 0.1 to 3% by weight of polystyrene dispersed in poly (trimethylene arylate), said weight percent being based on the total weight of the polymer in the composition Wherein the filament has a denier per filament of 3 or less, a denier coefficient of 2.5% or less, and a birefringence of 0.055 or more. In one embodiment, the poly (trimethylene arylate) is poly (trimethylene terephthalate).

In one embodiment, both the warp and the weft comprise a yarn comprising a filament of the present invention. In one embodiment, the warp comprises at least 40% by number of yarns comprising filaments of the invention, and at least 40% by number of yarns. In one embodiment, the warp comprises at least 80% by number of yarns comprising the filaments of the invention, and the warp yarns comprise at least 80% cotton yarn. In general, there are greater physical demands imposed on slopes than wefts.

Woven fabrics are made in looms as they have been for thousands of years. The loom has undergone a lot of changes, but the basic working principle is still the same. Figure 3a is a schematic view of one embodiment of a loom, shown in side view; A beam 31 consisting of a plurality of, often hundreds, parallel slopes 32 is positioned as a loom feed. The tilted beam 31 is shown in front view in Figure 3b. In Fig. 3A, two harness looms are shown. Each harness 34a, 34b is a frame that holds a plurality, often hundreds, of so-called "heddles ". Referring to FIG. 3C, which shows a front view of the harness 34, each of the hands 311 is a vertical wire having an aperture 312 therein. These harnesses are arranged to move up and down, one moving up while the other moving down. The portion 33a of the warp thread is threaded through the hole 312 in the heel 311 of the upper harness 34a while the other portion 33b of the warp thread is threaded through the hole in the heel of the lower harness 34b, Thereby opening a gap between the warp yarns 33a and 33b. In the illustrated type of loom, as the harness moves up and down, the shuttlecock 36 is propelled to move left or right or shuttle by a means (not shown), typically a wooden paddle. The shuttlecock has a bobbin of weft yarn 37 which loosens as the shuttlecock moves through the gap in the warp yarns. The so-called "reed " or" batten " 35 is a frame that maintains a series of vertical wires - Figure 3d shows the body 35 in a front view showing a vertical wire 313 and a space 314 between the wires through which a slope passes. The thickness of the vertical wire 314 determines the spacing of the slope in the crossfabric direction and hence the density of slope. The body serves to push the newly inserted weft to the right side of the drawing to enter a predetermined position in the fabric 38 being formed. The fabric is wound on the ceiling beam (310). The roll 39 is a guide roll.

The winding of the tilted beam is typically carried out by the same number of yarn packages or spools as the desired number of tilts are mounted on a so-called creel and each tilting is carried out by a series of precision guides and tensioners, And then the entire inclined beam is wound at one time.

The type of woven fabric being produced is determined by the specific pattern of interlacing, the ratio of warp to weft. The basic patterns include plain weave, twill weave, and runner weave. A number of other, more ornamental weave patterns are also known.

Knitting is the process of fabricating fabrics by interlooping one or more yarns. Knit tends to be more elastic and elastic than woven. Knit fabrics tend to be less durable than fabrics. There are a number of knitting patterns and knitting styles, as in the case of fabrics. According to the present invention, in one embodiment, the fabric of the present invention comprises from 0.1 to 3% by weight of polystyrene dispersed in poly (trimethylene arylate), said weight percent being based on the total weight of the polymer in the composition -, wherein the filament has a denier per filament of 3 or less, a denier coefficient of variation of 2.5% or less, and a birefringence of 0.055 or more. In one embodiment, the poly (trimethylene arylate) is poly (trimethylene terephthalate).

Garments sewn from the fabric of the present invention are also contemplated by the present invention. The garment of the present invention comprises a filament comprising a composition comprising from 0.1 to 3% by weight of polystyrene dispersed in poly (trimethylene arylate), said weight% being based on the total weight of the polymer in the composition Wherein the filament has a denier per filament of 3 or less, a denier coefficient of 2.5% or less, and a birefringence of 0.055 or more. In one embodiment, the poly (trimethylene arylate) is poly (trimethylene terephthalate).

Fabricating fabrics from fabrics is well known in the art. The manufacture of garments from fabrics is generally carried out in accordance with a pattern, for example, by making patterns of computerized form, usually from paper or for an automated process, cutting the necessary pieces of fabric, cutting the fabric to prepare the required pieces, And sewing together. The garment may be made exclusively of one or more styles of the fabric of the present invention. Alternatively, the garment may be made from a combination of one or more styles of the present invention and other fabrics.

The invention is further illustrated in the following specific embodiments, but is not limited thereto.

Example

Test Methods

Intrinsic viscosity

The intrinsic viscosity (IV) of PTT was determined using Viscotek Forced Flow Viscometer Y900 (Viscotek Corporation, Houston, Tex.). According to the procedure of ASTM D-5225-92, a 0.4 g / dl solution of PTT in a 50/50 wt% solvent mixture of trifluoroacetic acid and methylene chloride was formed at 19 &lt; 0 &gt; C and the viscosity was determined. These measured IV values were correlated with IV values measured manually in 60/40 wt% phenol / 1,1,2,2-tetrachloroethane according to ASTM D 4603-96.

Number average molecular weight

The number average molecular weight of polystyrene was determined according to ASTM D 5296-97. The calibration standards except that the poly (ethylene terephthalate), and hexafluoro-isopropanol solvent Loa of M _w 44,000 has, and the same method was used for poly (trimethylene terephthalate).

Strength and elongation at break

Using an Instron Corp. tensile tester, Model No. 1122, the physical properties of the filaments and yarns were measured. More specifically, elongation at break, E _b , and strength were measured according to ASTM D-2256.

Influence of spinning campaign and spinning machine on results

Fiber spinning was performed in four separate campaigns. Campaign # 1, # 3 and # 4 were run on spinning machine # 2, while Campaign # 2 was run on spinning machine # 1, as described in more detail below.

The results obtained from spinning machine # 1 are sporadic as shown in Table 4 and Figure 5 and are not considered definitive. In particular, the denier coefficient of variation was higher than the limit as specified in the present invention, and did not seem to change systematically with the temperature of the first goat.

5 is a graph showing the denier CV versus the first high temperature. Here, all the data obtained from Campaigns # 1, # 3 and # 4 are summed together and plotted in diamond form. Data obtained from Campaign # 2 is used as a triangle Respectively. As shown in Tables 3 to 6 below, not all of the data points obtained from the three campaigns using the spinning machine # 2 are obtained using the same setting radiation conditions. Nevertheless, as shown in Figure 5, data from spinning machine # 2, shown in diamond form, showed a clear tendency that the first high dead temperature in the range of about 75 to 85 占 폚 corresponded to the minimum value of the denier CV . A similar trend was not observed in the data of Campaign # 2.

The denier coefficient of variation is a measure of the short-range denier variability, which ultimately represents the stability of the melt spinning process. The melt spinning process may be unstable because the spinning composition causes instability. Since the machine is unstable, the melt spinning process may also be unstable. From Figure 5 it is clear that the high denier CV generated from Campaign # 2 in this case was an artifact of machine performance and design.

The spinning machine # 1 was a laboratory-built spinning machine provided with only the most basic equipment for achieving melt spinning. Spinning machine # 1 was usually only used to obtain the most basic information on whether the experimental composition was melt spinnable with fibers. Because of the scheduling mix-up, that is, because the spinning machine # 2 was not available on the scheduled date of the campaign # 2, the spinning machine # 1 was used in the campaign # 2 of this specification. The spinning machine # 2 was a pilot plant spinning line. The conditions for it were fully scalable to full-size commercial-scale radiation lines. This was the radiation line chosen to demonstrate the difference in results characterizing the present invention.

Figure 4 schematically shows spinning machine # 2. The silo dryer 41 gravity fed the dried resin blend pellets to the single screw extruder 42. The output of the single-screw extruder 42 is fed directly under pressure to the input of a gear pump 43 equipped with an overflow port 44. The output of the gear pump is fed through a short (several inches long) feed line 45, with six end spin packs 46, of which four slopes are used. Each of the four thread lines 47 (one shown) was extruded from a 36-hole spinneret (not shown), and each hole in the spinnerette was characterized by a 0.50 mm length and a 0.27 mm diameter circular cross-section . Each thread line 47 has passed through a transverse quench air zone 48 of approximately 1.75 m in length where the ambient air flows across the thread line from one side to the other in Campaign # In # 4, ambient air passed radial quench zone 48, approximately 1.75 m long, which radially flows around the thread line to produce a much more uniform filament. Each of the quenched thread lines is then brought into contact with the finish roll 49 and then wound 6 to 8 times around the first heated goat (feed roll 410) and the corresponding first separator roll 411, Were kept spaced apart. The thread line is then directed through a interlace jet (not shown) to a second heated high dot (stretching roll 412) and a corresponding second separator roll 413 from which it is directed to a winder 414. Although not shown, each godet was partially surrounded by a hot chest to maintain the temperature. The extruder has three heating zones and a head zone at the output.

The spinning machines # 1 and # 2 were substantially identical with respect to the layout described in FIG. One difference is that the quench air chimney of spinning machine # 1 is much narrower than its counterpart in spinning machine # 2.

In all examples and comparative examples, the average result for four thread lines simultaneously emitted under each condition setting is reported. After changing the set point condition, the test sample was run for approximately 45 minutes before manufacturing to allow the spinning machine to reach a steady state. When the composition of the polymer was changed, the spinning machine was purged with PTT containing no PS. When the spinnerets were exchanged, the machine was purged between spinning experiments.

Preparation of polymer blends

Dried PTT and PS were fed together in a 30 mm T / S extruder to prepare a sample of PS (0.8 and 0.55 wt%) in PTT. Sorona TM Semi-Dull PTT resin pellets (1.02 IV, available from DuPont Company, Wilmington, Del.) Polytrimethylene terephthalate in the amounts shown in Table 1 And combined with polystyrene (168 M KG 2, available from BASF) pellets. The PTT was dried in a vacuum oven using nitrogen purge at 120 &lt; 0 &gt; C for 14 hours before use. The two polymers were fed continuously and continuously into a fourth barrel section of a Werner &amp; Pfleiderer ZSK-30 reverse rotation twin-screw extruder. The feed rates used are shown in Table 1 in pounds per hour (pph). The extruder had a 30 mm diameter barrel with 13 barrel sections arranged in an alternating arrangement with two kneading sections and three transport sections, and the extruder had an L / D ratio of 32. Each barrel section was heated independently. Sections 1 to 4 were set at 25 DEG C, sections 5 to 13 were set at 210 DEG C and 3/16 inch strand dies were also set at 210 DEG C. A vacuum was applied to the barrel segment 8 Immediately after exiting the die, the extrudate was quenched in water and then 0.32 cm (1/8 ") pellet was pelletized using standard pelletizing equipment. &Lt; / RTI &gt;

Melt spinning

Melt spinning of the fibers was performed in four individual spinning campaigns as described below. Table 2 shows the emission parameters that remained constant for each campaign.

Campaign # 1 - Spinning Machine # 2

The melt-blended pellets of the PTT / PS blends thus prepared were dried in a drying silo overnight at 140 ° C to reduce the water content to less than 50 ppm. The dried melt blend was gravity fed into spinning machine # 2, Figure 4, the single screw extruder described above. The extruder set points in zones 1 to 3 were 230/255/263, in degrees Celsius, respectively. The extruder output was melt fed to the spinning pack through a gear pump. The spinning pack was provided with six spinning positions, four of which were provided with spinnerets, each spinneret having 36 holes, each hole having a diameter of 0.27 mm and a length of 0.5 mm, Respectively. Each yarn so produced was 75 filament yarns of 75 denier. The settings of the first and the higher detector rolls are shown in Table 3. Note that the second high detol roll was maintained at 110 DEG C and 4500 rpm. The quench air was a crossflow quench with an air velocity of 0.35 cm / s.

The following protocol was as follows: The second high detol roll (stretching roll) was set at 4500 m / min and 110 ° C and not changed during the experiment. Experiments were then conducted using a first high detol (feed roll) set at 60 DEG C and the speed was varied to determine the draw ratio leading to the highest strength when the elongation at break was adjusted in the range of 55 to 65%. For polymer blend # 2 (0.055% PS), the stretch ratio resulting in the highest strength when the elongation at break is within the desired range (i.e., when the feed roll is set to 2150 m / min) is 2.09. The spinning was then continued at an additional feed roll temperature of 85 and 110 ° C. The same procedure was followed for polymer blend # 1 (0.8% PS); The draw ratio, which causes the highest strength when the elongation at break is within the desired range (i.e., when the feed roll speed is 1900 m / min) is 2.37.

The results are shown in Table 3.

Campaign # 2 - Spinning Machine # 1

0.80 wt.% Of a new melt blend in the same PTT as in blend # 1 above. The melt-blended pellets of the PTT / PS blends thus prepared were dried in a drying silo overnight at 140 ° C to reduce the water content to less than 50 ppm. The dried melt-blended pellets were gravity fed into spinning machine # 1, the single-screw extruder described above in Figure 4. The extruder set points in zones 1 to 3 were 230/255/263, in degrees Celsius, respectively. The extruder output was melt fed to the spinning pack through a gear pump. The spinning pack was provided with six spinning positions, four of which were provided with spinnerets, each spinneret having 36 holes, each hole having a diameter of 0.27 mm and a length of 0.5 mm, Respectively. Each yarn so produced was 75 filament yarns of 75 denier. The setting of the first high detector roll is shown in Table 4. Note that the second high detol roll was maintained at 110 DEG C and 4500 rpm. The quench air was a crossflow quench with an air velocity of 0.35 cm / s.

The following protocols were as follows: The second high detol roll (stretching roll) was set at 4500 m / min and 110 ° C and not changed during the experiment. Experiments were then conducted using a first high detol (feed roll) set at 60 DEG C and the speed was varied to determine the draw ratio leading to the highest strength when the elongation at break was adjusted in the range of 55 to 65%. For the subsequent polymer blend # 1 (0.8% PS), the draw ratio leading to the highest strength was found to be 2.37 when the elongation at break was within the desired range (i.e., the first high detall rate was 1900 m / min).

Example 5 and Example 6 were performed using a spinnerette orifice having a diameter of 0.27 mm. Example 7 and Example 8 were performed using a spinnerette orifice having a diameter of 0.32 mm. Other spinning conditions are shown in Table 2 and Table 4. The results are shown in Table 4.

Campaign # 3 - Spinning Machine # 2

A PS / PTT containing 0.80 wt.% PS in the same batch as used in Campaign # 2 was used.

In these examples melt spinning was accomplished using the same spinning machine procedures and settings described above for Campaign # 1, except that 75 denier / 36 filament yarns were spun and quench was radially quenched. The spinning conditions are shown in Tables 3 and 5. Similarly, extruder heating zones were set at 230/255/263 ° C respectively. The spinneret diameter was 0.27 mm. The flow rate was controlled at 37.5 g / min. The results are shown in Table 5.

Campaign # 4 - Spinning Machine # 2

A third blend of 0.8% PS in PTT was prepared in the same manner as in blend # 2 described above.

In these examples, melt spinning was accomplished using the same spinning machine procedures and settings as described for Campaign # 3, except that 75 denier / 72 filament yarns were spun. The spinning conditions are shown in Tables 3 and 6. Similarly, extruder heating zones were set at 230/255/263 ° C respectively. The spinneret diameter was 0.27 mm. The flow rate was controlled at 37.5 g / min except for those mentioned in Example 12 and Example 13. The results are shown in Table 6.

Claims (8)

A composition comprising from 0.1 to 3% by weight of polystyrene dispersed in poly (trimethylene arylate), said weight percent being based on the total weight of the polymer in the composition, A denier per filament of 3 or less, a denier coefficient of variation of 3% or less, and a birefringence of 0.055 or more. The fabric according to claim 1, wherein the poly (trimethylene arylate) is poly (trimethylene terephthalate). 2. The fabric of claim 1, wherein the composition comprises 0.5 to 2% by weight of polystyrene dispersed in poly (trimethylene arylate), the weight percent being based on the total weight of the polymer in the composition. 4. The fabric according to claim 3, wherein the composition consists essentially of 0.5 to 2 weight percent polystyrene dispersed in poly (trimethylene arylate), the weight percent being based on the total weight of the polymer in the composition. 3. The fabric according to claim 2, wherein the composition comprises 0.5 to 2% by weight of polystyrene dispersed in poly (trimethylene terephthalate), the weight percent being based on the total weight of the polymer in the composition. 3. A fabric according to claim 2, wherein the composition consists essentially of 0.5 to 2% by weight of polystyrene dispersed in poly (trimethylene terephthalate), the weight percent being based on the total weight of the polymer in the composition. The fabric according to claim 1, wherein the fabric is a fabric. A garment containing the fabric of paragraph 1.

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