CA1125969A - Deep-dyeing self-crimping polyester yarn - Google Patents
Deep-dyeing self-crimping polyester yarnInfo
- Publication number
- CA1125969A CA1125969A CA324,731A CA324731A CA1125969A CA 1125969 A CA1125969 A CA 1125969A CA 324731 A CA324731 A CA 324731A CA 1125969 A CA1125969 A CA 1125969A
- Authority
- CA
- Canada
- Prior art keywords
- filament
- stream
- crimp
- spinning
- angstroms
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 229920000728 polyester Polymers 0.000 title claims abstract description 21
- 238000004043 dyeing Methods 0.000 title claims description 6
- 238000002788 crimping Methods 0.000 title description 2
- 238000009987 spinning Methods 0.000 claims abstract description 25
- 238000010791 quenching Methods 0.000 claims abstract description 21
- 230000000171 quenching effect Effects 0.000 claims abstract description 20
- 238000000034 method Methods 0.000 claims abstract description 15
- 229920000642 polymer Polymers 0.000 claims abstract description 11
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 claims description 6
- 238000002441 X-ray diffraction Methods 0.000 claims description 6
- 238000001125 extrusion Methods 0.000 claims description 5
- 150000002148 esters Chemical class 0.000 claims description 3
- 238000002074 melt spinning Methods 0.000 claims description 2
- 150000001298 alcohols Chemical class 0.000 claims 2
- 239000000975 dye Substances 0.000 abstract description 4
- 239000000835 fiber Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000000543 intermediate Substances 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- -1 Polyethylene terephthalate Polymers 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 229940108928 copper Drugs 0.000 description 1
- 235000014987 copper Nutrition 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920000136 polysorbate Polymers 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000001988 small-angle X-ray diffraction Methods 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 239000013598 vector Substances 0.000 description 1
- 238000004736 wide-angle X-ray diffraction Methods 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Artificial Filaments (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
Abstract
ABSTRACT OF DISCLOSURE
Polyester polymer is melt spun at a spinning speed above the crimp reversal speed, the filament cross section and spinning and quenching conditions being selected to give certain crystalline structure. The resulting crimped yarn dyes deeper than crimped yarns made by other techniques.
Polyester polymer is melt spun at a spinning speed above the crimp reversal speed, the filament cross section and spinning and quenching conditions being selected to give certain crystalline structure. The resulting crimped yarn dyes deeper than crimped yarns made by other techniques.
Description
~112~6~ `
DEEP-DYEING SELF-CRIMP`ING YARN
SPECIFICATION
The invention relates to the art of melt-spinning, and more ~articularly relates to the art of such spinning of crimped polyester filaments which dye deeper than crimped polyester yarns made by other techniques.
It is known to spin polyester filaments which are then crimped by various known ~echniques. The resulting crimped filaments are normally rather expensive due to the costs of the crimping process, and suffer somewhat in dye-~: ability as compared to uncrimped yarns.
Nakagawa U.S. patent 3,920,784 discloses crimp de-velopment in polyesters by selection of filament cross-sec-tion and spinning parameters. However Nakagawa's disclosed spinning parameters are far removed from those critically se-lected and disclosed and Nakagawa's yarns do not give the un-expected results attained by the present invention.
It is likewise known according to Ono U.S. patent3,623,939 that a waxy hand can be avoided and some degree of crimp developed during the spinning process by selection of filament cross-section and spinning par~meters, ~he Ono ex-amples all being directed to polyamides. While Ono perfunc-torily speculates that polyesters are usable in his process,there is no disclosure that polyester yarn has unusual and advantageous properties when the filament cross-section and spinning conditions are critically selected as disclosed by the present invention.
5~6~
According to the present invention, there is provided a noveI textured polyester yarn having unique deep-dyeing and other physical properties, and a process for making such a yarn during the spinning process by critical : 5 selection of spinning conditions.
The process comprises meIt spinning a helically crimped deep-dying polyester filament, comprising extruding at a given extrusion rate molten melt spinnable polyester polymer of fiber-formlng molecular weight through~a non-round spinneret orifice to form a molten stream, differen-tially ~uenching the molten stream into a filament by exposing a first side of the stream to more rapid quenching than the opposite side of the stream, the orifice being selected such that the first side of the stream comprises a fin exposed to quenching air while the opposite side of the stream is shielded from quenching air by the fin; and ~ withdrawing the filament from the molten stream at a spinning :~ speed faster than the crimp reversal speed, the given extrusion ; rate and the spinning speed being seIected such.that the filament has a crimp of at least 8%, a shrinkage less than 15%, an elonga-tion less than 80%, and a stress-induced crystallïne structure having, as determined by X-ray diffraction, an average crystallite volume of at least 4 x 10 cubic angstroms and an average lateral dimension of at least 50 angstroms~
According to another aspect of the invention, thé filament has a shrinkage less than 6% and an elongation less than 40%.
The novel filament has a crimp of at least 8%, a shrinkage less than 15%, an elongation less than 80% and a stress-induced crystalline structure having, as determined by X-ray difEraction, an average crystallite volume of at least 4 x 105 cubic angstroms and an averaye lateral minimum dimension o~ at least 50 angstroms. According to another aspect of the invention, the filament has a shrinkage less than 6% and an elongation less than ~0~.
.~ . . .. ..
.
:' :'': ~
5~
In the accompanying drawings, FIGURE 1 iS a schematic front elevation view of the process;
FIGURE 2 iS a bottom plan view (looking up) of an exemplary spinneret orifice which can be used in accordance with the invention; and FIGURE 3 iS a graph showing the relationship between yarn shrinkage and spinning speed.
As shown in FIGURE 1, molten polymer is extruded through non-round oriEices in spinneret 20 as a plurality of molten streams 22 into quench chamber 24 supplied with quench-ing air moving transversely with respect to the streams. The filaments 26 resulting from quenching the molten streams are withdrawn from the streams at a predetermined spinning speed by feed roll 28 and its associated separator roll 30, ~ila-ments 26 then being collected by winder 32~ Liquid finish is applied as desired, as by finish roll 34 slowly rotating with its lower periphery immersed in finish pan 36. The process as thus described in this paragraph is the same as that disclosed in the Ono patent referred to above.
The process differs from that of Ono by critical selection of parameters, as will be disclosed below. The ~ preferred spinneret 20 iS shown in FIGURE 2, wherein the i orifice is in the form of a helix. The arrow in FIGURE 2 shows the preferred direction of ~uenching air flow with respect to orifice 38, the direction being selected such that the outer fin portion of the molten s-tream issuing from orifice, 38 is exposed to more rapid quenching than the inner portion of the helix, -thus differentially quenching the streams into filaments.
At low and intermediate spinning speeds such as those disclosed in the Ono examples (4000 meters per minute or less), the exposed fin in the spun yarn is found to lie at the outside of the spiral crimp. Polyester yarns spun at inter-mediate speeds require hot-drawing in order to lower their elongations and increase their tenacities. The step of hot drawing causes reversal of the yarn crimp so that the fin then lies on the inside of the yarn spiral crimp. It has been ~;k ... ..
... .... .
6g found that, with polyester yarns spun at considerably higher spinning speeds than those in the Ono examples, the spiral crimp reverses so that the exposed fin lies at the inner part of the spiral yarn crimp without a separate drawing step. Fur~hermore, and more significantly, the crystalline form o~ the yarn changes due to stress-induced crystalliza-tion during spinning so that the yarn produced dyes considerably deeper than polyester yarns spun at the speeds in the Ono ex~mples and then hot drawn to obtain practical elongations and tenacities.
The crimp reversal speed varies with spinning and quenching conditions, and coincides with an abrupt decrease in yarn shrinkage as spinning speed increases. This phenomenon is illustrated in FIGURE 3 for two different round orifices. Determination of the crimp reversal speed ~or a given non-round spinneret orifice and gîven spinning and quenchi~g conditions may be done by microscopic examination of yarn spun over a range of spinning speeds, or may be done by no~ing the speed at which shrinkage abruptly decreases to under 10%.
Yarns spun at speeds below the crimp reversal spee~, whether or not further drawn or draw-textured, have smaller crystallites than yarns spun according to the present inven-tion. Thus, yarns spun at speeds above the crimp reversal speed are readily distinguishable from other yar~s by having as determined by X-ray difraction an a~erage crystallite volume o~ at least 4 X 105 cubic angstroms, and an average crystallite lateral dimension of at least 50 angstroms. This particular-crystalline structure leads to considerably deeper dyeing as compared to yarns having smaller crystallite structure according to the prior art.
The following is an exam~le Oæ the preferred embodiment of the invention.
Example I
An orifice similar to that in FIGURE 2 is u.sed, the slot being 0.1 mm. wide and 4 mm. long along its spiral length. Polyethylene terephthalate polymer of no~mal textile molecular weight i5 extruded at a temperature of 290C.
through the orifice and is solidified by transversely .. . ...... , , ,, .. ,,,,, ......... , .. ... , ... ................................ ......................... _ ......... .. .... ....... ...
directed quenching air into a filament which is wound at 5000 meters per minute. The polymer extrusion rate is selected such that the filament has a denier of 8. The quenching air has a temperature of 18C. and 68% relative humidity, and is directed horizontally at the molten stream in a direction parallel to the arrow in FIGURE 2, the quenching zone being 1.5 meters long. The quenching air has an average velocity of 20 meters per minute and impinges on the relatively thin fin-like outer portion of the spiral cross-section while the remainder of the molten s-tream is shielded from the quenching air by the outer portion. The resulting filament has an elongation of 35, a crimp of 12~, and as determined by X-ray diffraction has an average crystallite volume of 5.6 X 105 cubic angstroms and an average lateral crystallite dimension of greater than 60 angstroms.
xample II
Example I is repeated except no quenching air is provided. The resulting yarn has no appreciable crimp.
EXAMPLE III
Example I is repeated except that the orifice is round. The resulting yarn has a small amount of crimp, but not to a useful degree.
EXAMPLE IV
The process of Example I is repeated except that the spinneret orifice is rotated 130 in its own plane so that the quenching air has a direction opposite to the arrow in FIGURE
DEEP-DYEING SELF-CRIMP`ING YARN
SPECIFICATION
The invention relates to the art of melt-spinning, and more ~articularly relates to the art of such spinning of crimped polyester filaments which dye deeper than crimped polyester yarns made by other techniques.
It is known to spin polyester filaments which are then crimped by various known ~echniques. The resulting crimped filaments are normally rather expensive due to the costs of the crimping process, and suffer somewhat in dye-~: ability as compared to uncrimped yarns.
Nakagawa U.S. patent 3,920,784 discloses crimp de-velopment in polyesters by selection of filament cross-sec-tion and spinning parameters. However Nakagawa's disclosed spinning parameters are far removed from those critically se-lected and disclosed and Nakagawa's yarns do not give the un-expected results attained by the present invention.
It is likewise known according to Ono U.S. patent3,623,939 that a waxy hand can be avoided and some degree of crimp developed during the spinning process by selection of filament cross-section and spinning par~meters, ~he Ono ex-amples all being directed to polyamides. While Ono perfunc-torily speculates that polyesters are usable in his process,there is no disclosure that polyester yarn has unusual and advantageous properties when the filament cross-section and spinning conditions are critically selected as disclosed by the present invention.
5~6~
According to the present invention, there is provided a noveI textured polyester yarn having unique deep-dyeing and other physical properties, and a process for making such a yarn during the spinning process by critical : 5 selection of spinning conditions.
The process comprises meIt spinning a helically crimped deep-dying polyester filament, comprising extruding at a given extrusion rate molten melt spinnable polyester polymer of fiber-formlng molecular weight through~a non-round spinneret orifice to form a molten stream, differen-tially ~uenching the molten stream into a filament by exposing a first side of the stream to more rapid quenching than the opposite side of the stream, the orifice being selected such that the first side of the stream comprises a fin exposed to quenching air while the opposite side of the stream is shielded from quenching air by the fin; and ~ withdrawing the filament from the molten stream at a spinning :~ speed faster than the crimp reversal speed, the given extrusion ; rate and the spinning speed being seIected such.that the filament has a crimp of at least 8%, a shrinkage less than 15%, an elonga-tion less than 80%, and a stress-induced crystallïne structure having, as determined by X-ray diffraction, an average crystallite volume of at least 4 x 10 cubic angstroms and an average lateral dimension of at least 50 angstroms~
According to another aspect of the invention, thé filament has a shrinkage less than 6% and an elongation less than 40%.
The novel filament has a crimp of at least 8%, a shrinkage less than 15%, an elongation less than 80% and a stress-induced crystalline structure having, as determined by X-ray difEraction, an average crystallite volume of at least 4 x 105 cubic angstroms and an averaye lateral minimum dimension o~ at least 50 angstroms. According to another aspect of the invention, the filament has a shrinkage less than 6% and an elongation less than ~0~.
.~ . . .. ..
.
:' :'': ~
5~
In the accompanying drawings, FIGURE 1 iS a schematic front elevation view of the process;
FIGURE 2 iS a bottom plan view (looking up) of an exemplary spinneret orifice which can be used in accordance with the invention; and FIGURE 3 iS a graph showing the relationship between yarn shrinkage and spinning speed.
As shown in FIGURE 1, molten polymer is extruded through non-round oriEices in spinneret 20 as a plurality of molten streams 22 into quench chamber 24 supplied with quench-ing air moving transversely with respect to the streams. The filaments 26 resulting from quenching the molten streams are withdrawn from the streams at a predetermined spinning speed by feed roll 28 and its associated separator roll 30, ~ila-ments 26 then being collected by winder 32~ Liquid finish is applied as desired, as by finish roll 34 slowly rotating with its lower periphery immersed in finish pan 36. The process as thus described in this paragraph is the same as that disclosed in the Ono patent referred to above.
The process differs from that of Ono by critical selection of parameters, as will be disclosed below. The ~ preferred spinneret 20 iS shown in FIGURE 2, wherein the i orifice is in the form of a helix. The arrow in FIGURE 2 shows the preferred direction of ~uenching air flow with respect to orifice 38, the direction being selected such that the outer fin portion of the molten s-tream issuing from orifice, 38 is exposed to more rapid quenching than the inner portion of the helix, -thus differentially quenching the streams into filaments.
At low and intermediate spinning speeds such as those disclosed in the Ono examples (4000 meters per minute or less), the exposed fin in the spun yarn is found to lie at the outside of the spiral crimp. Polyester yarns spun at inter-mediate speeds require hot-drawing in order to lower their elongations and increase their tenacities. The step of hot drawing causes reversal of the yarn crimp so that the fin then lies on the inside of the yarn spiral crimp. It has been ~;k ... ..
... .... .
6g found that, with polyester yarns spun at considerably higher spinning speeds than those in the Ono examples, the spiral crimp reverses so that the exposed fin lies at the inner part of the spiral yarn crimp without a separate drawing step. Fur~hermore, and more significantly, the crystalline form o~ the yarn changes due to stress-induced crystalliza-tion during spinning so that the yarn produced dyes considerably deeper than polyester yarns spun at the speeds in the Ono ex~mples and then hot drawn to obtain practical elongations and tenacities.
The crimp reversal speed varies with spinning and quenching conditions, and coincides with an abrupt decrease in yarn shrinkage as spinning speed increases. This phenomenon is illustrated in FIGURE 3 for two different round orifices. Determination of the crimp reversal speed ~or a given non-round spinneret orifice and gîven spinning and quenchi~g conditions may be done by microscopic examination of yarn spun over a range of spinning speeds, or may be done by no~ing the speed at which shrinkage abruptly decreases to under 10%.
Yarns spun at speeds below the crimp reversal spee~, whether or not further drawn or draw-textured, have smaller crystallites than yarns spun according to the present inven-tion. Thus, yarns spun at speeds above the crimp reversal speed are readily distinguishable from other yar~s by having as determined by X-ray difraction an a~erage crystallite volume o~ at least 4 X 105 cubic angstroms, and an average crystallite lateral dimension of at least 50 angstroms. This particular-crystalline structure leads to considerably deeper dyeing as compared to yarns having smaller crystallite structure according to the prior art.
The following is an exam~le Oæ the preferred embodiment of the invention.
Example I
An orifice similar to that in FIGURE 2 is u.sed, the slot being 0.1 mm. wide and 4 mm. long along its spiral length. Polyethylene terephthalate polymer of no~mal textile molecular weight i5 extruded at a temperature of 290C.
through the orifice and is solidified by transversely .. . ...... , , ,, .. ,,,,, ......... , .. ... , ... ................................ ......................... _ ......... .. .... ....... ...
directed quenching air into a filament which is wound at 5000 meters per minute. The polymer extrusion rate is selected such that the filament has a denier of 8. The quenching air has a temperature of 18C. and 68% relative humidity, and is directed horizontally at the molten stream in a direction parallel to the arrow in FIGURE 2, the quenching zone being 1.5 meters long. The quenching air has an average velocity of 20 meters per minute and impinges on the relatively thin fin-like outer portion of the spiral cross-section while the remainder of the molten s-tream is shielded from the quenching air by the outer portion. The resulting filament has an elongation of 35, a crimp of 12~, and as determined by X-ray diffraction has an average crystallite volume of 5.6 X 105 cubic angstroms and an average lateral crystallite dimension of greater than 60 angstroms.
xample II
Example I is repeated except no quenching air is provided. The resulting yarn has no appreciable crimp.
EXAMPLE III
Example I is repeated except that the orifice is round. The resulting yarn has a small amount of crimp, but not to a useful degree.
EXAMPLE IV
The process of Example I is repeated except that the spinneret orifice is rotated 130 in its own plane so that the quenching air has a direction opposite to the arrow in FIGURE
2. The resulting filament has slight crimp, but not to a useful degree.
EXAMPLE V
3a Example I is repeated except the spinning speed is reduced to 3500 meters per minute. The resul-ting yarn has as determined by X-ray diffrLlction an average crystallite lateral dimension of 10 angstroms, but there is no observable reflec-tion in the longi-tudinal or D103 direction so the crystallite volume :is too small to be observed. The yarn is draw--textured on a Leesona* 555 at a draw ra-tio selected to give an elongation-to-break of about 30~. The resulting yarn has an average crystallite lateral dimension of ~1 angstroms and an average crystallite volume of jus-t over 2 X 105 ` * Trademark ' ' ~25~
angstroms. This yarn dyes much lighter -than the Example I yarn made accordin~ to the invention, due to the differences in mor-phology as set forth in the crystalline dimensions given.
Test Procedures The following procedures are used to determine the average crystallite dimensions and volumes of polyester feed yarn fibers.
X-Ray Patterns Wide and small angle x-ray diffraction patterns are obtained using Statton flat film vacuum cameras. Three Kodak*
N-Screen Medical X-ray films are used in each film cassette:
the front film receives the most intense exposure ancl reveals weak diffraction maxima. The second and third films are suc-cessively lighter by factors of about 3.8 and 14.4 and show increasing detail in the strong maxima and provide reference intensities for estimation of crystallite dimensions and other structural parameters. 0.5 mm~ diameter pinholes are used with Statton yarn holders, providing a 0.5 mmO thick sheath of mutually aligned yarn filaments. The yarn is wound on to the holder with just enough tension to remove most of the visible crimp in the case of textured yarn. A fine focus cop-per target X-ray tube (1200 watts maximum load, 0.4 X 0.8 mm.
spot focus as observed at 6 take-oEf angle) is used with a nickel ~eta filter and a take~off angle of 4.5. Wide angle patterns of the polyester feed yarn fibers are taken with a three inch collimator, 2~ minute exposure times, a five centi-meter specimen-to-film distance, 40 KV and 26.25 MA (87.5% o~
the maximum load) under vacuum. Small angle patterns of the polyester draw-textured yarn fibers are taken with a six inch collimator, a 32 centimeter specimen--to-film distance, the same tube loading, sixteen hour exposure times under vacuum.
Average Cr~stallite Dimensions and Vol~lmes - Wide An~le Patterns 'rhe diameter be-tween diffraction peak centers ~Z
and widths Wz at which the intensity has ~allen to approxi-mately 1/3.8 of the maximum value are measured for the principal diffraction maxima: 010, lI0, 100 and I03. The * Trademark , ~R~5~6i~
next lighter film, lighter by about 113.8 is used for intensity references. A bow divider is used to measure these distances. The divider is adjusted to simultaneously fit the width on the darkest film using the second ilm as a refer-ence, and the width on the second film using'the third filmas a reference. Occasionally the intensities are such that only one pair of films are usable for a particular maximum.
One estimate of the diameter, ~7, is made and two estimates of the less precise width, Wz, are made using differen~ but equivalent max~ma for each principal maximum. The tendency to overestimate the width of intense maxima and underestimate that of weak ma~ima is minimized by practicing making the same width fit simultaneously the first film relative to the second and the second film relative to the third, learning to use the re~erence intensity of the lighter film more critically.
- The'd-spacing is calculated by Bragg's relation:
d - ~/2 sin ~ (1) where ~ = 1.$418 for CuK~ radiation and the Bragg angle g is giv~n ~y the camera geometry:
tan 20 - QZ/2r. ' (2) The spec~men-to-film distance, r, is 50 mm. The measured diffr~ction width, Wz, is corrected for instrumental broaden-ing by Warren's method:
w2 = w~2 _ ~ (3) where ~2 = 0.154 mm obtained from the line width of inorganic references. The peak width in degrees 2 is calculated from the camera geometry:
~1/3.8 - 20D ~ 20C~ ' ' (4) 30 where ' tan 20D - (~Z + W)/2r, (5) tan 20C - (~Z - W)/2r. (6) The peak wldth is converted'to thP average crystallite dime~-sion in the associated crystallographic direction by Scherre$'s rPlation:
D ~ 1/3.8 ~os = 102-5/~1/3 8 cos ~ (8) in a~gstroms where K = 1.16 is adopted for the width at 1/3.8 5~ 6~
C-14-54-03~3 height. The crystallite dimension is also calculated in terms of the number of crystallographic repeats, N = D/d. (9) In this ashion the average lateral crystallite d~mPnsions in S angstroms Dolo, DlTo, and Dloo are obtained, and likewise the average longitudinal crystallite d~mension DTo3~ In addition, the corresponding dimensions in crystallographic repeats are obtained (equation 9):
Nolo, NlIo~ Nloo and N103 The average length of the crystallites along the polymer chain direction, Qc, is estimated as Qc = cos (c, dIo3) DT~3 (10) = 0.94~8 ~03 (11) where (c, dl03) is the angle between the crystallographic c axis (the polymer chain direction) and the normal to the 103 crystallographic planes. The average cross-sectional area of the crystallites, Ac, is estim~ted as Ac - N2/a*b* sin y* (12) = 20.37 N2 (13) where N2 is the average product of t~e crystallographic repeats in two principal la~eral directions; namely, ~ (NlOON010 + NlOO~lT0 ~ NOlONlI0)/3 (14) a*, b* are the reciprocal unit cell lattice vectors perpen-dicular to the c ax~s and Y* is the angle between them.
Finally, the average crystallite vol~me, Vc, is calculated asthe product of the length,Qc, and the cross-sectional area, Ac. Specifically, Vc ~ QcAc (15) = 19.16 ~03 N2 I'Crimp'' is measured as follows. The prepared yarn is wound into a skein with a 1.25 meter perimeter, the nu~ber of loops equalling 6250 divided by the yarn denier and the tension during skeining being 0.035 grams per yarn denier.
The skein is then carefully hung on a 1/2 inch (1.27 centimeter) diameter rod, and a 0.6 gram weight in the form of a metal hook is attached to the bottom of the skeln. A
................. ..........................................................................................................................................................................
.........
. .
_g_ 1000 gram weight is suspended from the hook and, after 30 seconds, the skein length from top of rod to top of hook is measured to the nearest millimeter, this measurement being designated hereafter as Lo. The 1000 gram weight is then removed, and the skein with hook attached is placed in a 120 oven suffi iently large that the skein is suspended from the rod whil~ supporting the hook. After 5 minutes in the oven, the skein is removed and hung, still suspended from the rod, in an. atmosphere of 23C. and 72V/o relative humidity. After one mi~ute, a 20 gxam weight is carefully lowered onto th~
hook until the skein supports the weight. Care must be taken not to let the weigh~ drop, bounce or otherwise stre~ch the skein beyond the loading tension. Ater 30 seconds, the skein length from the top of the rod to the top of the hook ; 15 is me~sured to the nearest millimeter, this quanti~y being identified as ~f. The crimp in percent then equals ` . (Lo-Lf) ( 100) Lo The te~m "polyester" as used herein refers to polymers o~ fiber-forming molecular weight composed of at least 85% by weight of an ester of one or more dihydric -alcohols and terephthalic acid.
The term 'lspiral" as used herein comprehends not only cross-sections composed of smooth curves, but cross-sections ormed for intersecting straight line segments aswell.
, .
. .
EXAMPLE V
3a Example I is repeated except the spinning speed is reduced to 3500 meters per minute. The resul-ting yarn has as determined by X-ray diffrLlction an average crystallite lateral dimension of 10 angstroms, but there is no observable reflec-tion in the longi-tudinal or D103 direction so the crystallite volume :is too small to be observed. The yarn is draw--textured on a Leesona* 555 at a draw ra-tio selected to give an elongation-to-break of about 30~. The resulting yarn has an average crystallite lateral dimension of ~1 angstroms and an average crystallite volume of jus-t over 2 X 105 ` * Trademark ' ' ~25~
angstroms. This yarn dyes much lighter -than the Example I yarn made accordin~ to the invention, due to the differences in mor-phology as set forth in the crystalline dimensions given.
Test Procedures The following procedures are used to determine the average crystallite dimensions and volumes of polyester feed yarn fibers.
X-Ray Patterns Wide and small angle x-ray diffraction patterns are obtained using Statton flat film vacuum cameras. Three Kodak*
N-Screen Medical X-ray films are used in each film cassette:
the front film receives the most intense exposure ancl reveals weak diffraction maxima. The second and third films are suc-cessively lighter by factors of about 3.8 and 14.4 and show increasing detail in the strong maxima and provide reference intensities for estimation of crystallite dimensions and other structural parameters. 0.5 mm~ diameter pinholes are used with Statton yarn holders, providing a 0.5 mmO thick sheath of mutually aligned yarn filaments. The yarn is wound on to the holder with just enough tension to remove most of the visible crimp in the case of textured yarn. A fine focus cop-per target X-ray tube (1200 watts maximum load, 0.4 X 0.8 mm.
spot focus as observed at 6 take-oEf angle) is used with a nickel ~eta filter and a take~off angle of 4.5. Wide angle patterns of the polyester feed yarn fibers are taken with a three inch collimator, 2~ minute exposure times, a five centi-meter specimen-to-film distance, 40 KV and 26.25 MA (87.5% o~
the maximum load) under vacuum. Small angle patterns of the polyester draw-textured yarn fibers are taken with a six inch collimator, a 32 centimeter specimen--to-film distance, the same tube loading, sixteen hour exposure times under vacuum.
Average Cr~stallite Dimensions and Vol~lmes - Wide An~le Patterns 'rhe diameter be-tween diffraction peak centers ~Z
and widths Wz at which the intensity has ~allen to approxi-mately 1/3.8 of the maximum value are measured for the principal diffraction maxima: 010, lI0, 100 and I03. The * Trademark , ~R~5~6i~
next lighter film, lighter by about 113.8 is used for intensity references. A bow divider is used to measure these distances. The divider is adjusted to simultaneously fit the width on the darkest film using the second ilm as a refer-ence, and the width on the second film using'the third filmas a reference. Occasionally the intensities are such that only one pair of films are usable for a particular maximum.
One estimate of the diameter, ~7, is made and two estimates of the less precise width, Wz, are made using differen~ but equivalent max~ma for each principal maximum. The tendency to overestimate the width of intense maxima and underestimate that of weak ma~ima is minimized by practicing making the same width fit simultaneously the first film relative to the second and the second film relative to the third, learning to use the re~erence intensity of the lighter film more critically.
- The'd-spacing is calculated by Bragg's relation:
d - ~/2 sin ~ (1) where ~ = 1.$418 for CuK~ radiation and the Bragg angle g is giv~n ~y the camera geometry:
tan 20 - QZ/2r. ' (2) The spec~men-to-film distance, r, is 50 mm. The measured diffr~ction width, Wz, is corrected for instrumental broaden-ing by Warren's method:
w2 = w~2 _ ~ (3) where ~2 = 0.154 mm obtained from the line width of inorganic references. The peak width in degrees 2 is calculated from the camera geometry:
~1/3.8 - 20D ~ 20C~ ' ' (4) 30 where ' tan 20D - (~Z + W)/2r, (5) tan 20C - (~Z - W)/2r. (6) The peak wldth is converted'to thP average crystallite dime~-sion in the associated crystallographic direction by Scherre$'s rPlation:
D ~ 1/3.8 ~os = 102-5/~1/3 8 cos ~ (8) in a~gstroms where K = 1.16 is adopted for the width at 1/3.8 5~ 6~
C-14-54-03~3 height. The crystallite dimension is also calculated in terms of the number of crystallographic repeats, N = D/d. (9) In this ashion the average lateral crystallite d~mPnsions in S angstroms Dolo, DlTo, and Dloo are obtained, and likewise the average longitudinal crystallite d~mension DTo3~ In addition, the corresponding dimensions in crystallographic repeats are obtained (equation 9):
Nolo, NlIo~ Nloo and N103 The average length of the crystallites along the polymer chain direction, Qc, is estimated as Qc = cos (c, dIo3) DT~3 (10) = 0.94~8 ~03 (11) where (c, dl03) is the angle between the crystallographic c axis (the polymer chain direction) and the normal to the 103 crystallographic planes. The average cross-sectional area of the crystallites, Ac, is estim~ted as Ac - N2/a*b* sin y* (12) = 20.37 N2 (13) where N2 is the average product of t~e crystallographic repeats in two principal la~eral directions; namely, ~ (NlOON010 + NlOO~lT0 ~ NOlONlI0)/3 (14) a*, b* are the reciprocal unit cell lattice vectors perpen-dicular to the c ax~s and Y* is the angle between them.
Finally, the average crystallite vol~me, Vc, is calculated asthe product of the length,Qc, and the cross-sectional area, Ac. Specifically, Vc ~ QcAc (15) = 19.16 ~03 N2 I'Crimp'' is measured as follows. The prepared yarn is wound into a skein with a 1.25 meter perimeter, the nu~ber of loops equalling 6250 divided by the yarn denier and the tension during skeining being 0.035 grams per yarn denier.
The skein is then carefully hung on a 1/2 inch (1.27 centimeter) diameter rod, and a 0.6 gram weight in the form of a metal hook is attached to the bottom of the skeln. A
................. ..........................................................................................................................................................................
.........
. .
_g_ 1000 gram weight is suspended from the hook and, after 30 seconds, the skein length from top of rod to top of hook is measured to the nearest millimeter, this measurement being designated hereafter as Lo. The 1000 gram weight is then removed, and the skein with hook attached is placed in a 120 oven suffi iently large that the skein is suspended from the rod whil~ supporting the hook. After 5 minutes in the oven, the skein is removed and hung, still suspended from the rod, in an. atmosphere of 23C. and 72V/o relative humidity. After one mi~ute, a 20 gxam weight is carefully lowered onto th~
hook until the skein supports the weight. Care must be taken not to let the weigh~ drop, bounce or otherwise stre~ch the skein beyond the loading tension. Ater 30 seconds, the skein length from the top of the rod to the top of the hook ; 15 is me~sured to the nearest millimeter, this quanti~y being identified as ~f. The crimp in percent then equals ` . (Lo-Lf) ( 100) Lo The te~m "polyester" as used herein refers to polymers o~ fiber-forming molecular weight composed of at least 85% by weight of an ester of one or more dihydric -alcohols and terephthalic acid.
The term 'lspiral" as used herein comprehends not only cross-sections composed of smooth curves, but cross-sections ormed for intersecting straight line segments aswell.
, .
. .
Claims (5)
1. A process for melt spinning a helically crimped deep-dyeing polyester filament comprising polymers of fiber-forming molecular weight composed of at least 85% by weight of an ester of one or more dihydric alcohols and terephthalic acid, characterized by:
(a) extruding at a given extrusion rate molten melt spinnable polyester polymer of fiber-forming molecular weight through a non-round spinneret orifice to form a molten stream;
(b) differentially quenching said molten stream into a filament by exposing a first side of said stream to more rapid quenching than the opposite side of said stream, said orifice being selected such that said first side of said stream comprises a fin exposed to quenching air while said opposite side of said stream is shielded from quenching air by said fin; and (c) withdrawing said filament from said molten stream at a spinning speed faster than the crimp reversal speed, said given extrusion rate and said spinning speed being selected such that said filament has a crimp of at least 8%, a shrinkage less than 15%, an elongation less than 80%, and a stress-induced crystalline structure having as determined by X-ray diffraction, an average crystallite volume of at least 4 x 105 cubic angstroms and an average lateral dimension of at least 50 angstroms.
(a) extruding at a given extrusion rate molten melt spinnable polyester polymer of fiber-forming molecular weight through a non-round spinneret orifice to form a molten stream;
(b) differentially quenching said molten stream into a filament by exposing a first side of said stream to more rapid quenching than the opposite side of said stream, said orifice being selected such that said first side of said stream comprises a fin exposed to quenching air while said opposite side of said stream is shielded from quenching air by said fin; and (c) withdrawing said filament from said molten stream at a spinning speed faster than the crimp reversal speed, said given extrusion rate and said spinning speed being selected such that said filament has a crimp of at least 8%, a shrinkage less than 15%, an elongation less than 80%, and a stress-induced crystalline structure having as determined by X-ray diffraction, an average crystallite volume of at least 4 x 105 cubic angstroms and an average lateral dimension of at least 50 angstroms.
2. The process of claim 1 characterized in that said filament has a shrinkage less than 6% and an elongation less than 40%.
3. The process of claim 1 characterized in that said spinneret orifice is in the form of a helix.
4. A helically crimped deep-dyeing polyester filament comprising polymers of fiber-forming molecular weight composed of at least 85% by weight of an ester of one or more dihydric alcohols and terephthalic acid, characterized by having a crimp of at least 8%, a shrinkage less than 15%, an elongation less than 80%, and a stress-induced crystalline structure having, as determined by X-ray diffraction, an average cry-stallite volume of at least 4 x 105 cubic angstroms and an average lateral minimum dimension of at least 50 angstroms.
5. The filament of claim 4, characterized in that said filament has a shrinkageless than 6% and an elongation less than 40%.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US89198478A | 1978-03-31 | 1978-03-31 | |
| US891,984 | 1978-03-31 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1125969A true CA1125969A (en) | 1982-06-22 |
Family
ID=25399168
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA324,731A Expired CA1125969A (en) | 1978-03-31 | 1979-03-30 | Deep-dyeing self-crimping polyester yarn |
Country Status (6)
| Country | Link |
|---|---|
| JP (1) | JPS54134121A (en) |
| CA (1) | CA1125969A (en) |
| DE (1) | DE2912647A1 (en) |
| FR (1) | FR2421226A1 (en) |
| GB (1) | GB2017574B (en) |
| IT (1) | IT1112985B (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4600644A (en) * | 1982-06-10 | 1986-07-15 | Monsanto Company | Polyester yarn, self-texturing in fabric form |
| JP2702128B2 (en) * | 1987-10-09 | 1998-01-21 | 東レ株式会社 | Pile yarn for napping fabric |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL6401806A (en) * | 1963-12-02 | 1965-06-03 | ||
| GB1218066A (en) * | 1967-06-30 | 1971-01-06 | Toray Industries | Crimped synthetic filament having a branched cross-section and a method for manufacturing the same |
| JPS5631364B2 (en) * | 1971-11-25 | 1981-07-21 | ||
| FR2149572A1 (en) * | 1971-08-19 | 1973-03-30 | Kuraray Co | Crimped linear polymeric yarns - spinning non symmetric yarns for padding a carpet |
| JPS5020021A (en) * | 1973-06-27 | 1975-03-03 | ||
| US3977175A (en) * | 1973-12-13 | 1976-08-31 | Teijin Limited | Draw-texturing polyester yarns |
| US4176150A (en) * | 1977-03-18 | 1979-11-27 | Monsanto Company | Process for textured yarn |
| US4128989A (en) * | 1977-04-04 | 1978-12-12 | Monsanto Company | Deep-dyeing polyester spinning process |
| CA1124021A (en) * | 1977-12-12 | 1982-05-25 | James E. Bromley | Multilobed feed yarn for texturing |
-
1979
- 1979-03-30 CA CA324,731A patent/CA1125969A/en not_active Expired
- 1979-03-30 IT IT21454/79A patent/IT1112985B/en active
- 1979-03-30 FR FR7908147A patent/FR2421226A1/en active Granted
- 1979-03-30 DE DE19792912647 patent/DE2912647A1/en not_active Withdrawn
- 1979-03-30 JP JP3829079A patent/JPS54134121A/en active Pending
- 1979-03-30 GB GB7911339A patent/GB2017574B/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| GB2017574B (en) | 1982-07-14 |
| GB2017574A (en) | 1979-10-10 |
| DE2912647A1 (en) | 1979-10-04 |
| JPS54134121A (en) | 1979-10-18 |
| FR2421226B1 (en) | 1984-04-27 |
| IT7921454A0 (en) | 1979-03-30 |
| FR2421226A1 (en) | 1979-10-26 |
| IT1112985B (en) | 1986-01-20 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US4496505A (en) | Process for the production of a polyester fiber dyeable under normal pressure | |
| US4301102A (en) | Self-crimping polyamide fibers | |
| AU637152B2 (en) | Low shrinkage, high tenacity poly(hexamethylene-adipamide) yarn and process for making same | |
| EP0423806B1 (en) | High tenacity, high modulus polyamide yarn and process for making same | |
| EP0808384B1 (en) | High speed process for making fully-oriented nylon yarns and yarns made thereby | |
| US4176150A (en) | Process for textured yarn | |
| US4233363A (en) | Polyester draw-texturing feed yarns | |
| US4542063A (en) | Uniformly dyeable nylon 66 fiber and process for the production thereof | |
| US4343860A (en) | Self-crimping polyamide fibers | |
| CA1125969A (en) | Deep-dyeing self-crimping polyester yarn | |
| JP2755820B2 (en) | Melt spinning of super oriented crystalline filament | |
| US4254181A (en) | Filaments having alternate S-twisted and Z-twisted helical sections produced by crimping filaments provided with an eccentric anisotropy of shrinkable property by a preferential cooling on one side upon extrusion thereof through a spinneret | |
| EP0009883A1 (en) | Self crimping yarn, process for producing a self crimping yarn, and textured yarn having a wool-like hand | |
| CA1107023A (en) | Poly(ethylene terephthalate) flat yarns, tows and staple fibre | |
| US4975325A (en) | Self crimpable nylon 66 carpet yarn | |
| US3816992A (en) | Crimped polyester filament yarn and process for making same | |
| KR920007106B1 (en) | Viscose Rayon Fiber with Excellent Appearance | |
| EP0013498B1 (en) | Process for producing self-crimping yarns, multifilament yarns containing latent crimp filaments, and multifilament yarns containing developed crimp filaments | |
| CA1124021A (en) | Multilobed feed yarn for texturing | |
| US4128989A (en) | Deep-dyeing polyester spinning process | |
| KR830000998B1 (en) | Method for producing spirally crimped thick dye polyester filament | |
| EP0126055B1 (en) | Improved partially oriented nylon yarn and process | |
| US4816550A (en) | Polyamide feed yarn for air-jet texturing | |
| EP0087124B1 (en) | Process and apparatus for producing easily dyeable polyester false-twisted yarns | |
| KR810001779B1 (en) | Spinning method of multifilament polyester yarn |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry | ||
| MKEX | Expiry |
Effective date: 19990622 |