KR20230022889A - Method for producing bicomponent fibers and articles comprising the same - Google Patents

Abstract

The disclosure relates generally to bicomponent fibers, and more particularly to methods of making bicomponent fibers and articles comprising the same, wherein the first extruded component has a lower moisture level than the second extruded component. Bicomponent fibers may include polyester and are useful in articles such as carpets and textiles.

Description

Method for producing bicomponent fibers and articles comprising the same

The present disclosure relates generally to bicomponent fibers and more particularly to methods of making bicomponent fibers and articles comprising the same.

Bicomponent fibers produced by side-by-side spinning of two types of polyester are widely used in the textile industry mainly to impart stretch to final garments or articles. The level of stretch can be manipulated through the relative shrinkage of the two polyesters, which can depend in part on the intrinsic viscosity (I.V.) of the two polymers. In the production process of bicomponent fibers, ideally, the polyester starting material used has the desired I.V., is readily available and inexpensive. If not, often a compromise must be made in the fiber manufacturing process, the physical properties of the bicomponent fiber, or both to achieve the desired performance characteristics of the bicomponent fiber.

Summary of Invention

In a first embodiment, a) extruding first and second components on a spinning machine capable of producing at least two independent melt streams; b) combining the melt streams in a spinneret suitable for making bicomponent fibers; c) quenching the bicomponent fibers produced in step (b) in air; d) drawing and heat setting the quenched bicomponent fibers; and e) winding the bicomponent fibers in step (d) by any suitable means; Disclosed herein is a method of making a bicomponent fiber wherein the first extruded component has a lower moisture level than the second extruded component.

DETAILED DESCRIPTION OF THE INVENTION

All patents, patent applications, and publications cited are incorporated herein by reference in their entirety.

range and variant

Where present, all ranges are inclusive and combinable. For example, when a range of "1 to 5" is recited, the stated range is "1 to 4", "1 to 3", "1-2", "1-2 and 4-5", "1 It should be construed as including ranges such as -3 and 5". As used herein with reference to a numerical value, the term "about" refers to a range of +/- 0.5 of that numerical value, unless the context specifically dictates otherwise to the term. For example, the phrase “a pH value of about 6” refers to a pH value between 5.5 and 6.5 unless the pH value is specifically defined otherwise.

Every maximum numerical limitation given throughout this specification is intended to include every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range within such broader numerical range, as if all narrower numerical ranges were expressly written herein.

Justice

As used herein, the term “embodiment” or “disclosure” is not intended to be limiting and applies generally to any embodiment described herein or defined in the claims. These terms are used interchangeably herein. In this disclosure, a number of terms and abbreviations are used. Unless specifically stated otherwise, the following definitions apply.

The singular expression preceding an element or ingredient is intended to be non-limiting as to the number of instances (ie occurrences) of the element or ingredient. Thus, singular expressions should be read as including one or at least one, and singular word forms of an element or ingredient include the plural unless the number clearly implies that it is singular.

The term "comprising" means the presence of the specified features, integers, steps, or components as recited in a claim, but does not exclude the presence or addition of one or more other features, integers, steps, components, or groups thereof. The term “comprising” is intended to include embodiments encompassed by the terms “consisting essentially of” and “consisting of”. Similarly, the term “consisting essentially of” is intended to include embodiments encompassed by the term “consisting of”.

As used herein, the term “bicomponent fiber” refers to fibers composed of different polymer types, two different polymer components that may be composed of the same polymer type but with different intrinsic viscosities, or a blend of two or more polymers. Bicomponent fibers may also be referred to as conjugate fibers and the terms may be used interchangeably.

The term “BCF” refers to bulk or bulked continuous bicomponent filaments. It is essentially one long continuous strand of fiber used to make carpets. The terms “bulking” and “bulking” are used interchangeably herein.

As used herein, the term "carpet" refers to a floor covering composed of pile yarns or fibers and a backing system. It can be tufted or woven. As used herein, the term "carpet" includes wall-to-wall carpets, carpet tiles, rugs, and mats for vehicle and building entrances, such as those designed to collect foot fouling. do.

The term “face” refers to the side of a carpet that contains tufted or woven yarns.

As used herein, the term "face fibers" refers to the fibrous content of a carpet, including those visible to an observer. Face fibers are primarily composed of yarns, which may be styled in cuts, loops, cuts and loops, or any number of styles known to those skilled in the art.

The term "copolymer" refers to a polymer composed of a combination of more than one monomer. Copolymers may form the basis of some manufactured fibers.

The term “crimp” refers to wavyness of fibers expressed as crimps per unit length. "Crimping" is the process of crimping filament yarns.

The term "crimp shrinkage" is a measure of fiber crimp and refers to the shrinkage of yarn length from a fully extended state (ie, a substantially straightened state of filaments). This is because crimps are formed on individual filaments under specified crimping conditions. It is expressed as a percentage of the extended length. Crimp shrinkage can be measured before and/or after treatment of the fibers to partially or completely generate crimp, eg, by heating; Typically, crimp shrinkage after heating is more interesting and provides more information because it includes the crimp caused by heating. Unless otherwise specified, crimp shrinkage values disclosed herein are crimp shrinkage values after heating (Cca).

The term “denier” is a measure of the weight per unit length of any linear material.

The term "fiber" refers to a unit of matter, natural or synthetic, that forms the basic elements of fabrics and other textile structures. It is characterized by having a length at least 1000 times its diameter or width. Typically, textile fibers are units that can be spun into yarns or made into fabrics by a variety of methods including weaving, knitting, braiding, felting and twisting. A fiber is characterized by its denier (weight in grams per 9000 meters of fiber) and the number of filaments it contains.

"Filament" refers to a thin thread or continuous strand of fiber. There are two types of filament: mono-filament and multi-filament. Filaments are characterized by their denier per filament (“dpf”).

The term "homofilament" means that the filament is made of one type of polymer.

"Staple" refers to cut lengths from natural fibers or filaments.

The term “intrinsic viscosity” (“IV”) refers to the ratio of the specific viscosity of a solution of known concentration to the concentration of the solute extrapolated to a concentration of zero.

The term "tufting" refers to the process of creating textiles such as carpets on special multi-needle machines. "Tufts" are clusters of soft yarns that are drawn through the fabric and protrude from the surface in the form of cut yarns or loops. Cut or uncut loops form the face of the tuft or woven carpet.

The term “yarn” refers to a collection of individual filaments plied either alone or with another collection of filaments. The terms "fiber" and "yarn" are used interchangeably herein.

The term “quenching” refers to rapid cooling in water, oil or air to obtain specific physical or material properties.

The term “poly(ethylene terephthalate)” or PET refers to a polymer derived substantially only from ethylene glycol and terephthalic acid (or equivalents such as dimethyl terephthalate), also referred to as poly(ethylene terephthalate) homopolymer. As used herein, the term "poly(ethylene terephthalate) copolymer" or "co-PET" includes repeating units derived from ethylene glycol and terephthalic acid (or equivalent) and further monomers such as isophthalic acid (IPA) or a polymer that also contains at least one additional unit derived from cyclohexanedimethanol (CHDM). The poly(ethylene terephthalate) copolymer may contain from about 1 mol% to about 30 mol% additional monomer, for example from about 1 mol% to about 15 mol% additional monomer.

The term "poly(butylene terephthalate)" or PBT means a polymer derived substantially only from 1,4-butanediol and terephthalic acid, also referred to as poly(butylene terephthalate) homopolymer. As used herein, the term “poly(butylene terephthalate) copolymer comprises repeating units derived from 1,4-butanediol and terephthalic acid and is capable of forming additional monomers such as PTT copolymers as disclosed herein. Refers to a polymer that also contains at least one additional unit derived from a comonomer.

The term “poly(trimethylene terephthalate)” or PTT refers to a polyester prepared by polymerizing 1,3-propanediol and terephthalic acid. It is characterized by its high elastic recovery and resilience. PTT is known to provide stain resistance, antistatic properties, and improved dyeability. The term “poly(trimethylene terephthalate) homopolymer” means a polymer of substantially only 1,3-propanediol and terephthalic acid (or equivalent). The term "poly(trimethylene terephthalate)" also includes PTT copolymers, which include repeating units derived from 1,3-propanediol and terephthalic acid (or equivalents) and at least one additional unit derived from additional monomers. It also means a polymer containing.

Examples of PTT copolymers include copolyesters made using three or more reactants, each having two ester forming groups. For example, copoly(trimethylene terephthalate) can be used, wherein the comonomers used to prepare the copolyesters are linear, cyclic, and branched aliphatic dicarboxylic acids having 4-12 carbon atoms ( eg butanedioic acid, pentanedioic acid, hexanedioic acid, dodecanedioic acid, and 1,4-cyclo-hexanedicarboxylic acid); aromatic dicarboxylic acids having 8-12 carbon atoms other than terephthalic acid (eg isophthalic acid and 2,6-naphthalenedicarboxylic acid); Linear, cyclic, and branched aliphatic diols having 2-8 carbon atoms (in addition to 1,3-propanediol, e.g. ethanediol, 1,2-propanediol, 1,4-butanediol, 3-methyl- 1,5-pentanediol, 2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and 1,4-cyclohexanediol); and aliphatic and aromatic ether glycols having 4-10 carbon atoms (e.g., poly(ethylene ether) having a molecular weight less than about 460, including hydroquinone bis(2-hydroxyethyl) ether, or diethylene ether glycol) glycol) is selected from the group consisting of Comonomers are typically present in the copolyester at levels ranging from about 0.5 mole % to about 15 mole %, and can be present in amounts up to about 30 mole %.

The term “Triexta” refers generically to PTT, a subclass of polyester. The terms triexta and PTT may be used interchangeably herein.

Poly(trimethylene terephthalate) typically has an intrinsic viscosity greater than about 0.5 deciliters per gram (dl/g) and typically less than or equal to about 2 dl/g. poly(trimethylene terephthalate) is preferably at least about 0.7 dl/g, more preferably at least 0.8 dl/g, even more preferably at least 0.9 dl/g, and typically at least about 1.5 dl/g; It preferably has an intrinsic viscosity of 1.4 dl/g or less, and currently available commercial products have an intrinsic viscosity of 1.2 dl/g or less. Poly(trimethylene terephthalate) is manufactured by Lee of Wilmington, Delaware under the trade name "Sorona®". kid. It is commercially available from E. I. du Pont de Nemours and Company.

Carpets made from poly(trimethylene terephthalate) monofibers and their manufacture, as well as fibers and manufacture of fibers, are disclosed in U.S. Patent Nos. 5,645,782 to Howell et al., 6,109,015 to Roark et al., and Chua ( Chuah, 6,113,825; U.S. Patent Nos. 6,740,276, 6,576,340, and 6,723,799; WO 99/19557 by Scott et al.; H. Modlich, "Experience with Polyesters Fibers in Tufted Articles of Heat-Set Yarns, Chemiefasern/Textilind. 41/93, 786-94 (1991); and H. Chuah, "Corterra Poly(trimethylene terephthalate) - New Polymeric Fiber for Carpets", The Textile Institute Tifcon '96 (1996), all of which are incorporated herein by reference. Staple fibers are primarily used to make residential carpets. BCF yarns are used for all types of It is used to make carpets and is generally preferred for carpeting.

Typically, PTT-containing bicomponent fibers are used to make fabrics and garments with durable stretch properties. In contrast, such stretch properties are not required for the manufacture of carpets. Rather, fibers for use in making carpets are typically mechanically bulked to provide a high level of bulk; Such fibers are typically referred to as “BCF” fibers.

Generally

Applicants have advantageously discovered a method for making bicomponent fibers by controlling the I.V. of the starting polymers on-line, which allows for the optional use of inexpensive polymers in the fiber making process; It allows optimizing bulk fiber properties without being limited to polymer I.V.

Applicants have also discovered a method of producing bicomponent fibers by advantageously controlling the I.V. of the starting polymers off-line.

Methods of making bicomponent fibers are disclosed herein.

The method comprises a) extruding first and second components on a spinning machine capable of producing at least two independent melt streams; b) combining the melt streams in a spinneret suitable for making bicomponent fibers; c) quenching the bicomponent fibers produced in step (b) in air; d) drawing and thermally setting the quenched bicomponent fibers; and e) winding the bicomponent fibers in step (d) by any suitable means; wherein the first extruded component has a lower moisture level than the second extruded component.

The first and second components of the methods disclosed herein may independently include polyester and nylon, and combinations thereof.

The first and second components of the bicomponent fibers may be present in a weight percent ratio ranging from 20:80 to 80:20. Weight percent ratios of 20:80, 25:75, 30:70, 35:65, 40:60, 45:55, 50:50, 55:45, 60:40, 65:35, 70:30, 75: 25, and 80:20.

The first and second components may independently include homopolymers, copolymers, blends, and combinations thereof of polyester and nylon.

In one embodiment, the first and second components comprise polyesters independently selected from the group consisting of poly(trimethylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate), and combinations thereof. can do.

In one embodiment, the polyester of the bicomponent fiber may be a copolyester, which copolyesters are included within the meaning of poly(ethylene terephthalate) and poly(trimethylene terephthalate), provided that such modifications are entangled yarns It does not adversely affect the amount of crimp in the fiber or the processing properties of the fiber. For example, the comonomers used to prepare the copolyesters are linear, cyclic, and branched aliphatic dicarboxylic acids having 4 to 12 carbon atoms (e.g. butanedioic acid, pentanedioic acid, hexanedioic acid , dodecanedioic acid, and 1,4-cyclohexanedicarboxylic acid); aromatic dicarboxylic acids having 8 to 12 carbon atoms other than terephthalic acid (eg isophthalic acid and 2,6-naphthalenedicarboxylic acid); Linear, cyclic, and branched aliphatic diols having 3 to 8 carbon atoms (e.g. 1,3-propanediol, 1,2-propanediol, 1,4-butanediol, 3-methyl-1,5-pentane diols, 2,2-dimethyl-1,3-propanediol, 2-methyl-1,3-propanediol, and 1,4-cyclohexanediol); and aliphatic and araliphatic ether glycols having 4 to 10 carbon atoms (e.g., poly(ethyleneethers having molecular weights less than about 460, including hydroquinone bis(2-hydroxyethyl)ether, or diethyleneether glycols). ) glycol) may be used. Comonomers can be present in the copolyester at levels of about 0.5 to about 15 mole percent. Isophthalic acid, pentanedioic acid, hexanedioic acid, 1,3-propane diol, and 1,4-butanediol are typically used because they are readily commercially available and inexpensive. The copolyester(s) may also contain trace amounts of other comonomers. Such other comonomers include, but are not limited to, 5-sodium-sulfoisophthalate at levels of about 0.2 to about 5 mole percent. Very small amounts of trifunctional comonomers such as trimellitic acid may also be incorporated for viscosity control.

In one embodiment, the first and second components are independently poly(ethylene terephthalate) (PET) homopolymer or poly(ethylene terephthalate) copolymer (co-PET), poly(trimethylene) terephthalate (PTT) polymers or blends of PTT and PET homopolymers or PET copolymers (co-PET).

In one embodiment of the bicomponent fiber, the first component may include PTT and the second component may include PET, wherein the bicomponent fiber is self-stretching due to differential shrinkage. The first component may include PTT having a pellet intrinsic viscosity ranging from about 0.9 dL/g to about 1.25 dL/g and the second component may include PET pellets having an intrinsic viscosity ranging from about 0.50 dL/g to about 0.80 dL/g. wherein the PET pellets include a blend of dried pellets (about 50 ppm moisture level) and undried pellets (about 2500 ppm moisture level).

In one embodiment, the moisture level of the undried PET pellets described herein may range from 300 ppm to about 5000 ppm. Examples of moisture levels in pellets are 300 ppm, 310 ppm, 320 ppm, 330 ppm, 340 ppm, 350 ppm, 360 ppm, 370 ppm, 380 ppm, 390 ppm, 400 ppm, 410 ppm, 420 ppm, 430 ppm, 440 ppm, 450 ppm, 460 ppm, 470 ppm, 480 ppm, 490 ppm, 500 ppm, 510 ppm, 520 ppm, 530 ppm, 540 ppm, 550 ppm, 560 ppm, 570 ppm, 580 ppm, 590 ppm, 600 ppm, 610 ppm, 620 ppm, 630 ppm, 640 ppm, 650 ppm, 660 ppm, 670 ppm, 680 ppm, 690 ppm, 700 ppm, 710 ppm, 720 ppm, 730 ppm, 740 ppm, 750 ppm, 760 ppm, 770 ppm , 780 ppm, 790 ppm, 800 ppm, 810 ppm, 820 ppm, 830 ppm, 840 ppm, 850 ppm, 860 ppm, 870 ppm, 880 ppm, 890 ppm, 900 ppm, 910 ppm, 920 ppm, 930 ppm, 940 ppm, 950 ppm, 960 ppm, 970 ppm, 980 ppm, 990 ppm, 1000 ppm, 1010 ppm, 1020 ppm, 1030 ppm, 1040 ppm, 1050 ppm, 1060 ppm, 1070 ppm, 1080 ppm, 1090 ppm, 1100 ppm, 1110 ppm, 1120 ppm, 1130 ppm, 1140 ppm, 1150 ppm, 1160 ppm, 1170 ppm, 1180 ppm, 1190 ppm, 1200 ppm, 1210 ppm, 1220 ppm, 1230 ppm, 1240 ppm, 1250 ppm, 1260 ppm, 1270 ppm , 1280 ppm, 1290 ppm, 1300 ppm, 1310 ppm, 1320 ppm, 1330 ppm, 1340 ppm, 1350 p pm, 1360 ppm, 1370 ppm, 1380 ppm, 1390 ppm, 1400 ppm, 1410 ppm, 1420 ppm, 1430 ppm, 1440 ppm, 1450 ppm, 1460 ppm, 1470 ppm, 1480 ppm, 1490 ppm, 1500 ppm, 1510 ppm, 1520 ppm, 1530 ppm, 1540 ppm, 1550 ppm, 1560 ppm, 1570 ppm, 1580 ppm, 1590 ppm, 1600 ppm, 1610 ppm, 1620 ppm, 1630 ppm, 1640 ppm, 1650 ppm, 1660 ppm, 1670 ppm, 1680 ppm , 1690 ppm, 1700 ppm, 1710 ppm, 1720 ppm, 1730 ppm, 1740 ppm, 1750 ppm, 1760 ppm, 1770 ppm, 1780 ppm, 1790 ppm, 1800 ppm, 1810 ppm, 1820 ppm, 1830 ppm, 1840 ppm, 1850 ppm, 1860 ppm, 1870 ppm, 1880 ppm, 1890 ppm, 1900 ppm, 1910 ppm, 1920 ppm, 1930 ppm, 1940 ppm, 1950 ppm, 1960 ppm, 1970 ppm, 1980 ppm, 1990 ppm, 2000 ppm, 2010 ppm, 2020 ppm, 2030 ppm, 2040 ppm, 2050 ppm, 2060 ppm, 2070 ppm, 2080 ppm, 2090 ppm, 2100 ppm, 2110 ppm, 2120 ppm, 2130 ppm, 2140 ppm, 2150 ppm, 2160 ppm, 2170 ppm, 2180 ppm , 2190 ppm, 2200 ppm, 2210 ppm, 2220 ppm, 2230 ppm, 2240 ppm, 2250 ppm, 2260 ppm, 2270 ppm, 2280 ppm, 2290 ppm, 2300 ppm, 2310 ppm, 2320 ppm, 2330 ppm, 2340 ppm, 2350 p pm, 2360 ppm, 2370 ppm, 2380 ppm, 2390 ppm, 2400 ppm, 2410 ppm, 2420 ppm, 2430 ppm, 2440 ppm, 2450 ppm, 2460 ppm, 2470 ppm, 2480 ppm, 2490 ppm, 2500 ppm, 2510 ppm, 2520 ppm, 2530 ppm, 2540 ppm, 2550 ppm, 2560 ppm, 2570 ppm, 2580 ppm, 2590 ppm, 2600 ppm, 2610 ppm, 2620 ppm, 2630 ppm, 2640 ppm, 2650 ppm, 2660 ppm, 2670 ppm, 2680 ppm , 2690 ppm, 2700 ppm, 2710 ppm, 2720 ppm, 2730 ppm, 2740 ppm, 2750 ppm, 2760 ppm, 2770 ppm, 2780 ppm, 2790 ppm, 2800 ppm, 2810 ppm, 2820 ppm, 2830 ppm, 2840 ppm, 2850 ppm, 2860 ppm, 2870 ppm, 2880 ppm, 2890 ppm, 2900 ppm, 2910 ppm, 2920 ppm, 2930 ppm, 2940 ppm, 2950 ppm, 2960 ppm, 2970 ppm, 2980 ppm, 2990 ppm, 3000 ppm, 3010 ppm, 3020 ppm, 3030 ppm, 3040 ppm, 3050 ppm, 3060 ppm, 3070 ppm, 3080 ppm, 3090 ppm, 3100 ppm, 3110 ppm, 3120 ppm, 3130 ppm, 3140 ppm, 3150 ppm, 3160 ppm, 3170 ppm, 3180 ppm , 3190 ppm, 3200 ppm, 3210 ppm, 3220 ppm, 3230 ppm, 3240 ppm, 3250 ppm, 3260 ppm, 3270 ppm, 3280 ppm, 3290 ppm, 3300 ppm, 3310 ppm, 3320 ppm, 3330 ppm, 3340 ppm, 3350 p pm, 3360 ppm, 3370 ppm, 3380 ppm, 3390 ppm, 3400 ppm, 3410 ppm, 3420 ppm, 3430 ppm, 3440 ppm, 3450 ppm, 3460 ppm, 3470 ppm, 3480 ppm, 3490 ppm, 3500 ppm, 3510 ppm, 3520 ppm, 3530 ppm, 3540 ppm, 3550 ppm, 3560 ppm, 3570 ppm, 3580 ppm, 3590 ppm, 3600 ppm, 3610 ppm, 3620 ppm, 3630 ppm, 3640 ppm, 3650 ppm, 3660 ppm, 3670 ppm, 3680 ppm , 3690 ppm, 3700 ppm, 3710 ppm, 3720 ppm, 3730 ppm, 3740 ppm, 3750 ppm, 3760 ppm, 3770 ppm, 3780 ppm, 3790 ppm, 3800 ppm, 3810 ppm, 3820 ppm, 3830 ppm, 3840 ppm, 3850 ppm, 3860 ppm, 3870 ppm, 3880 ppm, 3890 ppm, 3900 ppm, 3910 ppm, 3920 ppm, 3930 ppm, 3940 ppm, 3950 ppm, 3960 ppm, 3970 ppm, 3980 ppm, 3990 ppm, 4000 ppm, 4010 ppm, 4020 ppm, 4030 ppm, 4040 ppm, 4050 ppm, 4060 ppm, 4070 ppm, 4080 ppm, 4090 ppm, 4100 ppm, 4110 ppm, 4120 ppm, 4130 ppm, 4140 ppm, 4150 ppm, 4160 ppm, 4170 ppm, 4180 ppm , 4190 ppm, 4200 ppm, 4210 ppm, 4220 ppm, 4230 ppm, 4240 ppm, 4250 ppm, 4260 ppm, 4270 ppm, 4280 ppm, 4290 ppm, 4300 ppm, 4310 ppm, 4320 ppm, 4330 ppm, 4340 ppm, 4350 p pm, 4360 ppm, 4370 ppm, 4380 ppm, 4390 ppm, 4400 ppm, 4410 ppm, 4420 ppm, 4430 ppm, 4440 ppm, 4450 ppm, 4460 ppm, 4470 ppm, 4480 ppm, 4490 ppm, 4500 ppm, 4510 ppm, 4520 ppm, 4530 ppm, 4540 ppm, 4550 ppm, 4560 ppm, 4570 ppm, 4580 ppm, 4590 ppm, 4600 ppm, 4610 ppm, 4620 ppm, 4630 ppm, 4640 ppm, 4650 ppm, 4660 ppm, 4670 ppm, 4680 ppm , 4690 ppm, 4700 ppm, 4710 ppm, 4720 ppm, 4730 ppm, 4740 ppm, 4750 ppm, 4760 ppm, 4770 ppm, 4780 ppm, 4790 ppm, 4800 ppm, 4810 ppm, 4820 ppm, 4830 ppm, 4840 ppm, 4850 including ppm, 4860 ppm, 4870 ppm, 4880 ppm, 4890 ppm, 4900 ppm, 4910 ppm, 4920 ppm, 4930 ppm, 4940 ppm, 4950 ppm, 4960 ppm, 4970 ppm, 4980 ppm, 4990 ppm, and 5000 ppm It is not limited to this.

The weight ratio between dried and undried pellets can vary between 0 and 100%. Examples of % weight ratios of dried to undried pellets are 0:100, 5:95, 10:90, 15:85, 20:80, 25:75, 30:70, 35:65, 40:60, Includes 45:55, 50:50, 55:45, 60:40, 65:35, 70:30, 75:25, 80:20, 85:15, 90:10, 95:5, and 100:0 However, it is not limited thereto.

In one embodiment, varying the moisture level of the undried PET pellets (as described above) in combination with varying the % weight ratio of the dried and non-dried pellets (as described above) to the subsequently formed The final bulk measurement value (% crimp) of the bicomponent fibers can be controlled.

In another embodiment of the bicomponent fiber, the first component can include PTT and the second component can include PET, wherein the first component has a PTT ranging from about 0.9 dL/g to about 1.25 dL/g. The PTT pellets may have an intrinsic viscosity of about 245° C. to about 265° C. and the second component may have an intrinsic viscosity of about 0.50 dL/g to about 0.80 dL/g of PET pellets, and the PET pellets may not be dried. (about 2500 ppm moisture level) and can be extruded at temperatures of about 250°C to 280°C.

In one embodiment the moisture level of undried PET pellets may range from 300 ppm to about 5000 ppm.

Extrusion temperatures used for undried PET pellets may include, but are not limited to, 250°C, 255°C, 260°C, 265°C, 270°C, and 280°C.

In one embodiment, bicomponent fibers formed thereafter by varying the moisture level of the undried PET pellets (as described above) in combination with varying the extrusion temperature of the undried PET pellets (as described above) You can control the final bulk measurement value (% crimp) of

In one embodiment of the methods described herein, a PET extruder may be fed a feed of dried PET pellets and a feed of undried PET pellets in a desired ratio as described herein, wherein the raw pellets and the dried PET pellets may be fed. The difference is adding them individually to the extruder rather than pre-mixing them.

In one embodiment of the methods described herein, the drying conditions in the PET pellet feed hopper can be adjusted to provide the necessary moisture for hydrolysis. For example, PET pellets are typically dried to 50 ppm moisture during bicomponent manufacturing. By "less drying" the PET pellets (eg to 300 ppm moisture), the retained pellet moisture can promote hydrolysis in the extruder leading to a desired lower I.V. In this way, the desired PET IV can be "dialed in" into the spinning process.

In one embodiment of the methods described herein, a vacuum system may be supplied to the PET extruder to control PET I.V. In this way, high IV PET wet pellets with little or no drying can be “trimmed” by the amount of vacuum applied to achieve the desired I.V.

In one embodiment of the methods described herein, PET pellets can be dried in the manner described herein (about 50 ppm) and a small amount of water is injected into the heated extruder to achieve the desired level of hydrolysis and subsequent I.V. can affect the value.

The on-line hydrolysis method described herein is an efficient way to control I.V. It may be desirable to use the techniques described herein off-line. For example, the hydrolysis method described herein can be run off-line on an extruder not associated with fiber spinning. The hydrolyzed PET exiting the extruder may have the desired I.V., and may then be re-pelletized. The re-pelletized pellets with the desired I.V. can then be dried in a conventional manner without the need to control the I.V. on-line.

The measure of stretch (% crimp) values of bicomponent fibers prepared by the methods disclosed herein can be increased in the range of about 10% to about 85%. Examples of increased stretch measurement values are 10%, 12%, 17%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, including but not limited to 75%, 80%, and 85%.

In another embodiment of the bicomponent fiber, the first component can include PTT and the second component can include PET, wherein the first component has a PTT ranging from about 0.9 dL/g to about 1.25 dL/g. PTT pellets may have an intrinsic viscosity of pellets extruded at 260° C. and the second component may have an intrinsic viscosity of PET pellets of about 0.50 dL/g, wherein the PET pellets may be dried pellets (about 50 ppm moisture) and dry blends of untreated pellets (approximately 2500 ppm moisture). The weight ratio between dried and undried pellets can vary from 0 to 20%.

The first and second components may independently be PET or co-PET, and PTT or a blend of PTT and PET or coPET may be present in the bicomponent fiber in a weight ratio ranging from about 80:20 to about 20:80. For example, the weight ratio of the first component to the second component is 80:20, 75:25, 70:30, 65:35, 60:40, 55:45, 50:50, 45:55, 40:60, 35:65, 30:70, 25:75, 20:80, or any ratio within these ranges.

In one embodiment, the measure of stretch (% crimp) value of the bicomponent fibers made by the methods disclosed herein may not need to increase, but may depend on the moisture level of the undried component; It can be controlled by varying the ratio of dried to undried pellets of a component, and/or the extrusion temperature of a particular component. Controlling as well as increasing the stretch measurement value depends on the type of polymer(s) used to make a particular bicomponent fiber.

Various additives may be added to either or both of the first and second component polymers. These include, but are not limited to, lubricants, nucleating agents, antioxidants, ultraviolet light stabilizers, pigments, dyes, antistatic agents, antifouling agents, antistain agents, antimicrobial agents, and flame retardants.

Bicomponent fibers can be made by delivering a polymer to a spinneret in a desired volume or weight ratio. Although any conventional multicomponent spinning technique may be used, exemplary spinning apparatus and methods of making bicomponent fibers are described in US Pat. No. 5,162,074 to Hills, which is incorporated herein by reference in its entirety. included

The bicomponent fibers described herein may be in parallel ("S/S") or eccentric sheath core ("S/C") configurations. Bicomponent fibers can be formed in a variety of cross-sectional shapes, such as round, triangular, and triangular, using spinnerets specific to each shape, as disclosed, for example, in U.S. Patent No. 6,803,102, which is incorporated herein by reference in its entirety. It can be made into a trilobal, scalloped, or other shape.

Also disclosed herein are articles comprising bicomponent fibers made by the methods described herein. Articles include, but are not limited to, apparel, textiles, fully drawn yarn (FDY), partially oriented yarn (POY), staple fibers, nonwoven fibers, nonwoven fabrics, and carpets.

In one embodiment, disclosed herein is a carpet wherein the face fibers comprise bicomponent fibers made from a process disclosed herein.

For use in carpet, the bicomponent fibers disclosed herein may have a denier ranging from about 300 to about 1400 grams/denier. Useful denier per filament may range from about 2 to about 20.

The bicomponent fibers disclosed herein can be used with all other types of synthetic and natural fibers used to make carpets. Carpets can be made mechanically or through hand tufting, weaving and hand knotting. Examples include 1) broadloom carpets (also known as wall-to-wall carpets) where tufted carpets are manufactured in long continuous lengths several meters wide for home and commercial applications, 2) various sizes for ease of installation carpet tiles produced in the squares of 3) rugs for home use, or 4) mats for vehicle and building entrances designed to collect foot grime before entering a building.

Any method known in the art for making carpets from fibers can be used to make the carpets described herein. Typically, the bicomponent fibers disclosed herein can be used in the same carpet making process that other synthetic and natural fibers are used. Bicomponent fibers can be used alone (i.e., as a "single" yarn) in carpet making, or rather in combination with the same bicomponent fiber or other fiber types (e.g. nylon, polypropylene, polyester) to increase denier. can be combined. Optionally, the single and plied fibers may be entangled with an air jet prior to plying and may also be subjected to thermal curing by specially designed machines to thermally fix the physical properties of the single and tuft yarns.

One example of a heat curing machine suitable for this purpose is manufactured by Superba® (Muhouse, France). Whether the bicomponent fibers are optionally air entangled, plied or thermally set, the fibers can then be tufted into standard non-woven or woven backing sheets typical of the carpet industry. In a tufted carpet, the face fiber loops may be cut to provide a cut loop carpet. After tufting, adhesive is often applied to the back side of the carpet (ie, the side opposite from the face fibers) to hold the tufts in place. An additional backing layer may also be added to the carpet backing. The adhesive layer may contain fillers or flame retardants, depending on the specific carpet end use. The carpet can then be dyed by standard processes common to the carpet making industry; Alternatively, pigments may be added to the bicomponent fibers and/or to companion fibers during fiber extrusion to impart color to the finished fabric. Face yarns may also be treated with materials designed to impart fire resistance, antistatic properties, or stain and stain resistance. Finished carpets are often dried to remove residual water from the dyeing process.

The manufacturing process described above is common for wide tufted carpets. Variations on this process known in the art can be used for the production of rugs, carpet tiles and vehicle mats.

Face fibers, including bicomponent fibers, may have a circular or non-circular cross-section, such as trilobal.

Example

The disclosure is further defined in the following examples. It should be understood that the examples, while representing specific embodiments, are given by way of example only. From the above discussion and examples, those skilled in the art can ascertain the essential features of the present disclosure, and can make various changes and modifications to suit various uses and conditions without departing from its spirit and scope.

As used herein, "Comp. Ex." means comparative example; “Ex.” means an example; “No.” means a number; "%" means percent or percent; “wt%” means weight percent; “IV” means intrinsic viscosity; "dL/g" is deciliter per gram; "g" is gram; "mg" is milligram; “°C” means temperature in degrees Celsius; “°F” means temperature in degrees Fahrenheit; "temp" means temperature; "min" is minutes; “h” is time; “sec” is seconds; "lb" is pound; "kg" is a kilogram; "mm" is millimeter; "m" is meter; “gpl” is grams per liter; “m/min” is meters per minute; "mol" is mole; "kg" is a kilogram; "ppm" is parts per million; “wt” is weight; “dpf” is denier per filament; “gpd” or “g/d” is grams per denier; "dtex" means decitex; “dN/tex” means “decinewtons per tex; “mL” means milliliters; “IV” means intrinsic viscosity;

Unless otherwise stated, all materials were used as received.

Test Methods

Determination of Crimp Shrinkage after Heating (% CCa) - Crimp Shrinkage Method:

Crimp shrinkage after heating (% CCa, also known as stretch value) was determined according to the method described herein. The fibers of each Example and Comparative Example were independently formed into skeins of about 5000 +/- 5 total denier (5550 dtex) using a skein reel at a tension of about 0.1 gpd (0.09 dN/tex). . The skein was then folded in two to halve the length of the skein to be accommodated inside an oven used for heat curing. The folded skeins were hung from hooks at their mid-parts and conditioned at 70 +/- 1° F. (21 +/- 1° C.) and 65 +/- 2% relative humidity for a minimum of 16 hours. The folded skein was then suspended substantially vertically from the hook at its mid-part to the rack and a 1.5 mg/den (1.35 mg/dtex) weight was suspended from the bottom of the skein through the two loops of the folded skein. The weighed skein is then heated in an oven at 250°F (121°C) for 5 minutes, then the rack and skein are removed and cooled for 5 minutes, then 70°F +/- 1°F (21 +/- 1°C) and 65% Conditioned for a minimum of 2 hours at +/- 2% relative humidity, leaving the 1.5 mg/denier weight on the skein for the rest of the test. The length of the skein was measured to within 1 mm and recorded as "Ca". Then, a 1000 g weight was hung from the bottom of the skein, brought to equilibrium, and the length of the skein was measured to within 1 mm and recorded as "La". The crimp shrinkage "CCa" value (%) after heating was calculated according to the formula:

%CCa=100x (La-Ca)/La

Determination of Intrinsic Viscosity

Intrinsic viscosity (IV) was determined using a Viscoteck Y 501 C Forced Flow Viscometer (Malvern Corporation, Houston, TX). A 0.15 g sample was weighed into a 40 mL glass vial containing 30 mL solvent (phenol/1,1,2,2-tetrachloroethane (60/40 weight percent)) and a stir bar. The sample was then placed in a 100° C. preheated heat block, heated and stirred for 30 minutes, removed from the block, allowed to cool for 30-45 minutes before being placed in the autosampler rack of the viscometer. The samples were then analyzed by ASTM method D5225-92 (Standard Test Method for Measuring Solution Viscosity of Polymer with A Differential Viscometer).

polymer manufacturing

Lee of Wilmington, Delaware, USA. kid. Two grades of PTT homopolymer pellets were obtained from DuPont Di Nemoir & Company. One class had an IV of 1.02 dL/g and the second class had an IV of 0.92 dL/g. PET homopolymer pellets were obtained from Sinopec Shanghai Petrochemical Company, Ltd., Shanghai, China and had an IV of 0.50 dl/g. PET copolymer (containing 1.9 mol% isophthalic acid) pellets with an IV of 0.80 dl/g were obtained from NanYa Plastics Corporation, Livingston, NJ.

In preparation for melt spinning, PET and PTT pellets were dried in a vacuum oven for 15 hours under a 25 inch mercury vacuum and a temperature of 120° C. under nitrogen. Under these conditions, both PET and PTT pellet moisture are reduced to about 50 ppm. The dried pellets were transferred directly into the nitrogen-purged feed hopper of the spinning machine. In the examples where a mixture of dried and undried PET pellets was used, the undried pellets were taken directly from the bag and had a residual moisture content of about 2500 ppm.

textile manufacturing

For spinning parallel and eccentric sheath/core bicomponent fibers, as disclosed, for example, in U.S. Patent Nos. 6,641,916 B1, U.S. Patent No. 6,803,102, and U.S. Patent No. 7,615,173 B2, which are incorporated herein by reference in their entirety. The first and second components of the bicomponent fibers were melt spun using generally applicable processes and equipment.

In spinning the bicomponent fibers of the examples, the polymer was melted in a pair of Werner & Pfleiderer co-rotating 28-mm twin screw extruders with 0.5-40 pound/hour (0.23-18.1 kg/hour) capacity. made it Using one extruder, referred to herein as an East extruder, either 1) dried PET pellets to about 50 ppm or 2) dried some of the pellets to a residual moisture level of about 50 ppm and left the remaining pellets undried to about A mixture of PET pellets having a residual moisture level of 2500 ppm was melted. A second extruder, referred to herein as a West extruder, was used to melt the dried PTT pellets to about 50 ppm residual moisture. The temperatures of the west extruder, spinning block and yeast extruder are mentioned in the examples. Each extruder fed a spin block containing a concave spinneret. The spinneret used was a post-coalescence parallel, two-component spinneret with 34 pairs of capillaries arranged in a circle, an internal angle between each capillary pair of 30 degrees, a capillary diameter of 0.64 mm, and a capillary length of 4.24 mm. It was a sand dune.

The bicomponent filaments exiting the spinneret were cooled by cross-flow quench air at nominally 20° C. and 0.5 mm/sec face velocity. The filaments were then advanced with dual feed rolls operating at about 800-1200 meters/minute depending on the draw ratio. Between the spinneret and the feed rolls, a finish applicator was used to apply lubricant to the filament bundle. The feed rolls were typically heated to 70° C. to affect the draw. The filament bundle was then accelerated with an annealing roll operating at a speed of about 3000-3600 m/min depending on the desired draw ratio, the annealing roll temperature being typically 170°C. The annealed bicomponent fibers were then run through two sets of double letdown rolls operating at room temperature and then wound on a Barmag SW6 600 winder. The fiber had a snowman (oblong) cross-sectional shape. The bicomponent fibers in all examples were 75 denier, 34 filaments.

Comparative Example A and Examples 1-3 Changes in Pellets Moisture Content

Comparative Example A illustrates a typical manufacturing process for making PET/PTT bicomponent fibers, wherein 0.50 I.V. The PET pellets were dried to about 50 ppm residual moisture and then extruded by yeast extruder at 270° C., 1.02 I.V. The PTT pellets are dried to about 50 ppm residual moisture and extruded by a West extruder at 260°C. The ratio of PET to PTT in bicomponent fibers is 50/50. The measured stretch value of 48% is in the typical range for commercial bicomponent fibers.

Examples 1 to 3 are 0.80 I.V. Using PET, the use of on-line hydrolysis to control the amount of fiber stretch produced in bicomponent fibers is illustrated. In Examples 1-3, 1.02 IV PTT was dried to about 50 ppm and extruded at the indicated temperature. The only variable in this example was the amount of undried PET (about 2500 ppm residual moisture) mixed with the dried PET. As is evident from Example 1, drying the 0.80 IV to the same level as PTT (e.g. 50 ppm moisture) produces fibers with little stretch. The relatively small difference in pellet I.V. between PET and PTT does not promote fiber differential shrinkage or percent stretch. In Example 2, the ratio of undried PET pellets to dried PET pellets was 10/90 weight percent. Under these process conditions, the residual moisture in the undried polymer was 0.80 I.V. Accelerates the hydrolysis of PET. The effect of hydrolysis can be seen by reducing the pack pressure from 950 psi to 370 psi. This reduction in pack pressure is associated with reduced polymer melt viscosity, reduced polymer molecular weight, increased differential shrinkage, and increased fiber stretch. The examples show the effect of increasing the undried to dried PET ratio to 20/80 weight percent, where additional residual moisture further reduces pack pressure and melt viscosity and increases differential shrinkage and percent stretch. promote

Table 1. Process conditions and stretch values for Comparative Example A and Examples 1 to 3

Example 4-7 Change of extrusion temperature

Examples 4-7 illustrate the use of on-line hydrolysis to control the amount of fiber stretch produced in bicomponent fibers by varying the temperature at which hydrolysis occurs in a PET extruder. In Examples 4-7, the 0.92 IV PTT dried to about 50 ppm and the 0.80 IV PET did not dry to 100% (ie about 2500 ppm residual moisture). The polymer ratio between PET and PTT in the fiber was 70/30 weight percent. The degree of hydrolysis was controlled by the PET extruder temperature rather than by the concentration of the undried pellets. Hydrolysis is a chemical reaction between polyester and residual moisture, and the extent of the reaction increases with increasing extrusion temperature. In Example 4, the PET extruder was set at 250 C. At this relatively low temperature, little hydrolysis occurs, pack pressure is high, molecular weight remains high, little fiber differential shrinkage occurs, and fiber stretch levels are low (10.8%). In Example 5, the PET extruder temperature is increased from 10°C to 260°C. At this higher extruder temperature, hydrolysis increased, pack pressure decreased, molecular weight decreased, fiber differential stretch increased and fiber stretch increased to 22%. A comparison of Examples 4 and 5 shows that increasing PET by 10°C more than doubles the fiber stretch. Examples 6 and 7 show that increasing the PET extruder to 270° C. and 280° C. increases the stretch measurement to 27.2% and 50.5%, respectively. These examples show the important role of extrusion temperature on the extent of hydrolysis and fiber properties.

Table 2. Process conditions and stretch values for Examples 4-7

Examples 8-10 Formation of elasticity

Examples 8-10 illustrate the use of on-line hydrolysis to create bicomponent fibers with stretch values higher than those obtainable by traditional methods. 0.50 I.V. preferred by PET/PTT bicomponent fiber manufacture. PET was generally the lowest IV PET commercially producible because it was difficult to pelletize low IV PET. Lowering the PET IV by hydrolysis is an option, as there is a desire to increase the stretchability to levels higher than those generally available with 0.50 IV PET. Example 8 is completely dried (about 50 ppm residual moisture) 0.50 I.V. Process and results are shown for a 50/50 weight ratio PET/PTT bicomponent fiber made with PET and 1.02 IV PTT. Examples 9 and 10 were prepared by mixing dried PET with 5% and 10% undried 0.50 I.V. Stretch results are shown for fibers prepared by mixing each with PET (approximately 2500 ppm residual moisture). The stretch values of 65.8% and 69.3% are significantly higher than commercially available fibers. In these embodiments, additional residual moisture further promotes reduced pack pressure and melt viscosity and increased differential shrinkage and percent stretch.

Table 3. Process conditions and stretch values for Examples 9-11

Claims (26)

As a method for producing bicomponent fibers,
a) extruding the first and second components on a spinning machine capable of producing at least two independent melt streams;
b) combining the melt streams in a spinneret suitable for making bicomponent fibers;
c) quenching the bicomponent fibers produced in step (b) in air;
d) drawing and heat setting the quenched bicomponent fibers; and
e) winding the bicomponent fibers in step (d) by any suitable means;
includes; wherein the first extruded component has a lower moisture level than the second extruded component. The method of claim 1 , wherein the first and second components are independently selected from the group consisting of polyester, nylon, and combinations thereof. The method of claim 1 or 2, wherein the first and second components are independently from the group consisting of poly(trimethylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate), and copolymers thereof. and the second component is a polyester selected from the group consisting of poly(trimethylene terephthalate), poly(ethylene terephthalate), poly(butylene terephthalate), and copolymers thereof. 4. The process according to any one of claims 1 to 3, wherein the first component is poly(ethylene terephthalate) and the second component is poly(trimethylene terephthalate). 5. The method of any one of claims 1-4, wherein the first component has a moisture level in the range of about 10% to about 20% and the second component has a moisture level in the range of about 90% to about 80%. way of being. 6. The method of any one of claims 1-5, wherein the first component has a moisture level of about 50 ppm or less and the second component has a moisture level of greater than about 50 ppm. 2. The method of claim 1 , wherein the stretch measurement of the bicomponent fiber produced in step (e) is such that the first extruded component does not have a moisture level lower than that of the second extruded component, from steps (a) to an increase in the range of about 10% to about 85% compared to the bicomponent fiber prepared by (e). 8. The method of claim 7, wherein the stretch measurement increase is selected from the group consisting of 12%, 17%, and 40%. The method of claim 1 wherein the first and second components of the bicomponent fibers are present in a weight percent ratio ranging from 20:80 to 80:20. The method of claim 1 , wherein the bicomponent fibers have a configuration selected from the group consisting of side-by-side, eccentric sheath core configuration, and trilobal. 12. The method of claim 11 wherein the crimp shrinkage after heating of the bicomponent fibers of step (e) ranges from about 10% to about 85% as determined according to the crimp shrinkage method. The method of claim 1 , wherein the extruder temperature of one of the components in step (a) ranges from about 240° C. to about 320° C. 13. The method of claim 12, wherein the extruder temperature of one of the two extruded components in step (a) is selected from the group consisting of 260°C, 270°C, 280°C, 290°C, 300°C, 310°C, and 320°C. how it would be. An article of clothing comprising bicomponent fibers made by the method of claim 1 . A fabric comprising bicomponent fibers produced by the method of claim 1 . A fully drawn yarn comprising bicomponent fibers produced by the method of claim 1. A partially oriented yarn comprising bicomponent fibers produced by the method of claim 1. A staple fiber comprising a bicomponent fiber produced by the method of claim 1. A carpet wherein the face fibers comprise bicomponent fibers produced from the method of claim 1 . 20. The carpet of claim 19, wherein the bicomponent fibers have a configuration selected from the group consisting of parallel, eccentric sheath core configuration, and trilobal. 21. The carpet of claim 20, wherein the face fibers further comprise at least one additional fiber selected from the group consisting of bulked continuous filaments, synthetic staple fibers, and natural fibers. 22. The carpet of claim 21, wherein the at least one additional fiber is a bulked continuous filament, and wherein the bulked continuous filament comprises nylon, polypropylene, or polyester. 22. The carpet of claim 21, wherein the at least one additional fiber is a synthetic staple fiber, and wherein the synthetic staple fiber comprises nylon or polyester. 22. The carpet of claim 21, wherein the at least one additional fiber is a natural fiber, and wherein the natural fiber comprises wool, silk, or cotton. Non-woven fibers comprising bicomponent fibers produced by the method of claim 1. A nonwoven fabric comprising bicomponent fibers produced by the method of claim 1.