CA1189265A - Textured nylon-6 filament - Google Patents
Textured nylon-6 filamentInfo
- Publication number
- CA1189265A CA1189265A CA000404869A CA404869A CA1189265A CA 1189265 A CA1189265 A CA 1189265A CA 000404869 A CA000404869 A CA 000404869A CA 404869 A CA404869 A CA 404869A CA 1189265 A CA1189265 A CA 1189265A
- Authority
- CA
- Canada
- Prior art keywords
- filament
- nylon
- cross
- section
- present
- 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
Classifications
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
- D02G3/24—Bulked yarns or threads, e.g. formed from staple fibre components with different relaxation characteristics
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
- D02G1/16—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using jets or streams of turbulent gases, e.g. air, steam
- D02G1/165—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using jets or streams of turbulent gases, e.g. air, steam characterised by the use of certain filaments or yarns
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
- D02G1/20—Combinations of two or more of the above-mentioned operations or devices; After-treatments for fixing crimp or curl
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Artificial Filaments (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
Abstract
TITLE
ABSTRACT OF THE DISCLOSURE
A textured nylon-6 continuous filament is characterized by the absence of a spherulitic ring structure along the periphery of the cross section thereof when the cross section is viewed under polarized light.
ABSTRACT OF THE DISCLOSURE
A textured nylon-6 continuous filament is characterized by the absence of a spherulitic ring structure along the periphery of the cross section thereof when the cross section is viewed under polarized light.
Description
BACKGROUND OF TIE INVENTION
Field ox the Invention The present invention relates generally to textiles, spinning, twisting, and twining. More particularly, the invention relates to a crlmped, continuous nylon-6 filament.
Prior Art Background .
In the majority ox textile products, two important functional properties are required--viz., protection and thermal insulation-- both of which can be satisfied by adequate bulkiness l of the product. In general, a bulky product will have to be made of a bulky fiber or filament, as the basic cons-tructional element of any textile product is the fiber or filament.
As a consequence 3 a considerable e-f-Eort has been made over the years to impart higher bulk to fibers and filaments by texturing or crimping thereof, especially those which are man-made, for example, from polyamides such as nylon-6. lhe present invention is an improved crimped, continuous nylon-6 filament.
Statement ox Closest known Prlor art
Field ox the Invention The present invention relates generally to textiles, spinning, twisting, and twining. More particularly, the invention relates to a crlmped, continuous nylon-6 filament.
Prior Art Background .
In the majority ox textile products, two important functional properties are required--viz., protection and thermal insulation-- both of which can be satisfied by adequate bulkiness l of the product. In general, a bulky product will have to be made of a bulky fiber or filament, as the basic cons-tructional element of any textile product is the fiber or filament.
As a consequence 3 a considerable e-f-Eort has been made over the years to impart higher bulk to fibers and filaments by texturing or crimping thereof, especially those which are man-made, for example, from polyamides such as nylon-6. lhe present invention is an improved crimped, continuous nylon-6 filament.
Statement ox Closest known Prlor art
2(1 L~he closest prior art of Wtl:iCh toe inventors are aware is set :Eorth below.
1. U.S. 3,186,155, Breen, et al., disclose a monocomponent synthetic organic filament, such as a nylon-6 filament, which has: (a) alternate and Z twist sections throughout its length; (b) a random number of turns between twist reversals; a a random, continuously varying angle of twist along its length; a random number of twist reversals per inch; at least one S turn and at leas-t one Z turn per inch which have a twist angle averaging a-t least 5 degrees.
2. U.S. 4,~96,Z26, Martln, et al., discloses the production of a crimped nylon-6 fllament similar to that disclosed in Breen, et al., U.~. 3,186,155, supra. However, the Martin process lS an integrated process, in contradistinction to that of Breen, wherein the following steps are effected in immediate succession: (a) melt spinning; (b) drawing the spun filaments at a draw ratio such that the drawn filaments on leaving the drawing stage have an extensibility of between 2~ and 35 percent;
and (c) texturing the drawn filaments at a velocity of between 800 and 3,000 meters per minute by an air jet process, the temperature of the filaments being between 50 and 180 prior to texturing.
1. U.S. 3,186,155, Breen, et al., disclose a monocomponent synthetic organic filament, such as a nylon-6 filament, which has: (a) alternate and Z twist sections throughout its length; (b) a random number of turns between twist reversals; a a random, continuously varying angle of twist along its length; a random number of twist reversals per inch; at least one S turn and at leas-t one Z turn per inch which have a twist angle averaging a-t least 5 degrees.
2. U.S. 4,~96,Z26, Martln, et al., discloses the production of a crimped nylon-6 fllament similar to that disclosed in Breen, et al., U.~. 3,186,155, supra. However, the Martin process lS an integrated process, in contradistinction to that of Breen, wherein the following steps are effected in immediate succession: (a) melt spinning; (b) drawing the spun filaments at a draw ratio such that the drawn filaments on leaving the drawing stage have an extensibility of between 2~ and 35 percent;
and (c) texturing the drawn filaments at a velocity of between 800 and 3,000 meters per minute by an air jet process, the temperature of the filaments being between 50 and 180 prior to texturing.
3. U.S. 3,975,484, Okada, et al., discloses the production of a crimped nylon-6 filament similar to that disclosed in Breen, et al., U.S. 3,1867155, supra, by a process somewhat similar to that disclosed in Martin, et al., U.S. 4,096,226, supra.
; Non-circular cross section polyamide filaments are melt spun, allowed to cool, and treated with an oil. Thereupon the fila-ments are passed around a feed roll havlng a peripheral speed of more than about 200 meters per minute, passed in contact with a heated body through a contact angle between about ~0 and 160U with the surface temperature ox the heated body main-tained in the range of about 170U-~50O~. The filaments are thereby subjected to one-sided heating and drawing, whereupon they are passed through a steam jet crimper which is supplied with steam at a temperature in the range of about Z00-350C.
; Non-circular cross section polyamide filaments are melt spun, allowed to cool, and treated with an oil. Thereupon the fila-ments are passed around a feed roll havlng a peripheral speed of more than about 200 meters per minute, passed in contact with a heated body through a contact angle between about ~0 and 160U with the surface temperature ox the heated body main-tained in the range of about 170U-~50O~. The filaments are thereby subjected to one-sided heating and drawing, whereupon they are passed through a steam jet crimper which is supplied with steam at a temperature in the range of about Z00-350C.
4. leijin Limited, British 1,5~5,007, discloses a nylon-6 multifila~ent yarn wherein the individual filaments have an internal microstructure characterized by OC-type crystal-linity in combination with -type crystallinity in a given proportion. In partlcular, each ox the individual filaments of the yarn has a birefringence of at minimum 0.~45, a maximum denier of 0.8, and an x-ray diffraction intensl~y ratio satisfying a specific equation.
None of the filamentary products described above is descril as having no characteristic spherulltic ring structure along the periphery of the cross section thereof when the cross section is viewed undeT polarized light. Spherulitic rings normally havea diffused transition to a non-spheruli~ic coTe. The depth of the spherulitic ring varies usually from about 10 to about l 20 .
Completely unsuggested by the prior art teachings, the crimped nylon-6 continuous filament of the present inven-tion shows a complete absence of a spherulitic ring structure when the cross section thereof is viewed under polaTized light.
The result of the absence of such a spherulitic ring structure is that the filament is more lustrous than available prior art fila-ments under otherwise identical conditions. As a consequence, the fiber producer may increase bulk and cover in a fibrous structure such as a carpet without any loss ln luster.
JO SUMMARY OF 'l'HE INVENTION
In ordeT to furnish a textile fiber whlch affords increased bulk and cover in a ibrous s~TuctuTe abricated therefrom without any sacrifice in luster there is provided a crimped nylon-6 continuous filament characterized by the absence of a spherulitic ring structuTe along the periphery of the cross section thereof when the cross section is viewed under polarized light.
In accordance with. the specific teachings, a crimped nylon-6 con$inuous filament is provided which has a denier of at least 5, a modification ratio of between about 2 and 3, a tank bulk of at least 8% and is characterized by the absence of a spherulitic ring structure along the periphery of the cross secti.on of the filament when the cross section is teed under polarized light.
Jo \
BRIEF DESCRIPTION OF THE DRAWING
.
For a more complete understanding of the present invention, including the primary object and benefits thereon - 4a -;5 which are set forth immediately above, reference should be made to the Detailed description ox the Preferred Embodiments, which is set forth below. This detailed description should be read together with the accompanying drawlng, wherein:
FIG. 1 depicts two cross sections of crimped nylon-6 continuous filaments ox the prior art, which show a characteristic spherulitic ring structure along the perlphery of the cross sections; and FIG. 2 depicts two cross sections ox crimped nylon-6 continuous filaments according to the present lnvention, which show a complete absence of the spherulitic ring structure which is characteristic of the prior art filaments shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED E~!BODIMENTS
KefeTring now to the drawlng, FIG. 1 depicts an avail-able crimped nylon-6 continuous filament (1) of the prior art, which is shown in two cross sections thereof as viewed under a microscope under polarized light. A characteristic spherulitic ring (2) is observed along the periphery o-f the cross sections.
Also seen in the cross sections are small particles (~) o-f a delustrant such as titanium dioxide. lhe spherulltlc rlng (2) is comprised of a multiplicity of individual partiaL spherulites (3), which, although not visible under orcLinary conditions, are visible under polarized light. The fllaments depicted here have a modiication ratio of between abou-t 2 and 3, i.e. 9 -the configuration thereof is commonly referred to as "trilobal".
lo determine the modification ratio as well as the presence or absence of a spherulitic ring structure, the following procedure is employed. A filament or yarn sample is placed in a suitable embedding agent. A thin section thereof is then cut with a microtome. A photomicrograph of this section is then obtained, and the modification ratio (MR) is calculated, with the use of a template, employing the following equation:
MR = Do D.l ' wherein Do Diameter of circumscribed circle to cross section, and D1 Diameter of inscribed circle into cross section.
The presence or absence of any peripheral ring is determined by visual observation of the section, under polarized lighting (phase-contrast or dark field may also be employed); a photo-micrograph can also be obtained under these conditions.
Depicted in FIG. 2 is one embodiment (5) of the crimped nylon-6 continuous filament according to the present invention, which is shown in two cross sections thereon as viewed under a microscope under polarized light. No spherulitic ring is observed along the periphery of the cross sections, as a (6).
Seen in the cross sections are small particles (4) of a delus-trant such as titanium dioxide. lhe filaments depicted here also have a modification ratio as discussed above of between about 2 and 3, i.e., the configuration thereof is commonly referred to as "trilobal".
To be sure, it is not necessary that delustrants such as titanium dioxide be present in the filaments according to the present invention. lndeed, the same advantages and benefits over the prior art- are obtained when a filament according to the present invention is substantially :Eree of any delustrant. ~loreover, although a modification ratio ox bet~e~en about 2 and 3 is advantageously employed, ~ilame!lts accordirlg to the present invention may have other cross sectional con~igu-rations as well, under which condltions the same aclvan~ages and benefits over the prior art are observed. That is to say, filaments of the present invention have a higher luster--as determined visually or by any of many standard optical methods known to the skilled artisan--when compared with other-wise equivalent filaments of the prior art which have the same level of crimp, or the same level of delustrant in an amount which is substantially below the saturation level thereof, or the same cross sectional configuration.
As is understood by those of swill in the art, filaments according to the present invention whlch are substantially free of any delustrant are considered to be very highly lustrous. lf not as much luster is desired, one of the S delustrants known to those of skill in the art may be employed.
lhese include no only the usual non-chromatic delustrant and illers such as titanium dloxide, zinc sulfide, calcium carbonate, glass particles, etc., but also delustering agents which impart color as well. Such include organic and inorganic pigments and dyes that are added to the molten nylon-6 polymer prior to or during extrusion and spinning, or to the nylon-6 polymer in chip form in a dyeing operation prior to extrusion and spinning. When titanium dioxide is employed, it is advantageously present in an amount of not greater than about 0.1 percent by weight.
The crimped nylon-6 continuous filament of the present invention advantageously has a tank bulk o-f at leas-t 8 percent and a denier of at least 5. Under these conditlons it is especially suitable for use in the fabrication of a large number ox textile structures desirable in -today's market. 'rank bulk is determined by first measuring the lengch chatlge in a skein ox fiber exposed to boiling water under two loads of appro~i-mately 0.0003 g/dte~ ~L2) and 0.09 g/clte~ (Ll), respectively.
Tank bulk is then calculated employing -the following equation:
Bulk - L -L
~loreover, especially beneficial results aTe obtained when the crimped nylon-6 continuous filament according to the present invention has a modification ratio of between about 2 and 3 and a denier of between about 5 and 25. Under these conditions, use of the filament according to the present invention results in carpets having outstanding characteristics.
- In addition to showing no spherulitic ring structure along the periphery of the cross section thereof when the cross section is viewed under polarized light, a crimped nylon-6 continuous filament according to the present invention which has a denier of at least 5 is found to have another significant morphological characteristic, viz: the ratio of -form nylon-6 to a form nylon-6 is at least 1 to 1, and often about 3/1 to 3.5/1, as measured on non-heat treated, undyed, crimped filamentary material. This compares with I- form to - form ratios of about 1/3 to 1/3.5 for available prior art products under the same conditions of treatment. However, after heat setting of the crimped filamentary material of the present invention, the Go - form is predominant. such a phenomenon clearly demon-strates that a higher proportion of the entire filamentary structure of the present invention is rearranged during heat setting, thereby increasing heat setting efficiency over that obtained with prior art products. To determine the crystallinity ratios referred to above, t-he equitorial x-ray diffraction pattern of the sample is measured and recorded continuously between 2 values of 12 and 30. The alpha crystalline form has a peak at 2 20.0 to 20.5, and another at 2 ~~
23.2 to 2~Ø llhe pseudo-gamma form has a slngle peak at about 2 21.2. By visual examination of the curve, one can determine the relative preponderance ox a particular crystalline form. Such products according to the present invention which have a ratio of I- form nylon-6 to cC - form nylon-6 are especially desirable when substan-tially free of any delustrant, or when a delustrant such as titanium dioxide is present therein in an amount not greater than about 0.1 percent by weight. Moreover, modification ratios of between `about 2 and 3 are highly advantageous, as is a tank bulk as s specified supra of at least about percent.
Any of the filaments according to the present inven-tion may be employed in a multifilament yarn--e.g., grouped together with other filaments according to the present invention--which may be interlaced and/or twisted, utilizing standard techniques well-known to those of skill in the art, to produce carpets, upholstery, and other such textile structures having outstanding characteristics.
The present invention, lncluding its object and benefits, may be better understood by reference to the following illus-trative examples:
xample 1 Nylon-6 chips having a relative viscosity of 2.69 as measured in 96-98% sulfuric acid and con-taining less than 0.01~ titaniwm dioxlde were melted in an extruder and spun at a temperature of 265 through two spinnerettes with 99 irregular shaped holes each at a thruput of 335 grams per minute per spin-nerette forming two 99 filament threadlines. The spun filaments were quenched with a crossflow of air at approximately 12C, and were lubricated with an oil spin finish comprising a poly-alko~ylated alcohol containing essentially no water. Ihe fibe-r was stretch pre-tensioned 1 1/2%, pre-hea-ted to 45C, ancl stre-tched 3.25~ to a speed of 2119 meters per minute and heated to 165C.
The stretched threadlines were crlmped in a hot air te~turizer such as tha-t in US Patent 3~908,248, and deposited onto a rotating cooling sieve through which air was moved by means of a vacuum. The sieve moved at a velocity ox 45 meters per minute.
The threadlines were unraveled from their plug form on the cool-ing sieve to a speed of 1732 meters per minute established by a cold pair of godets. The yarns were subsequen-tly interlaced in a conventional air jet and wound up under 200 pond tension on a double cup winder. lhere was no spherulitic ring structure along the periphery of the cross section of the fiber when viewed under a microscope under polarized light. Some of the fiber produced was processed in a commercial space dyeing operation and exhibited excellent uniformity and bulk/cover.
other fiber was commercially cabled, continuously heatset, tufted, and dyed into an excellent residential type carpet.
The fiber exhibited physical properties common to Bulked Continuous Filament (BCF) products including:
Luster : Excellent Dtex : 1990 Tenacity : 2.3 g/dtex Elongation at Break : 40%
'l'ank Bulk : 10.2%
Dyeability : Piece dyeable in Acid Red;
absence of noticeable streaks in Ortalon Blue G
Filament Modifica-tion Ratio : 2.5 Example 2 A procedure essentially equivalent to tha-t of Example 1 was followed, resulting in a product having the following characteristics:
Luster : Excellent Dtex : 1430 Filament Modifica-tion Ratio : 2.5 'l'ank Bulk : 11%
Ratio of form nylon-6 to Oc-form nylon-6 : 3.5/1 Dyeability : Piece dyeable in Acid Red;
absence of noticeable streaks in Ortalon Blue G
After heat setting of this giber, the OC- form nylon-6 was determined to be predominant.
In order to produce crimped nylon-6 contlnuous filaments according to the present invention, it is necessary to orient the fiber before allowing any moisture migration into the fiber. This is advantageously accomplished by employing an essentially non-aqueous spin finish, as utilized in the examples above.
Although the present invention has been described in detail with respect to certain preferred embodiments thereof, it is understood by those of skill in the art that variations and modifications in this detail may be effected , without any departure from the spirit and scope of the present invention, as defined in the hereto-appended claims.
None of the filamentary products described above is descril as having no characteristic spherulltic ring structure along the periphery of the cross section thereof when the cross section is viewed undeT polarized light. Spherulitic rings normally havea diffused transition to a non-spheruli~ic coTe. The depth of the spherulitic ring varies usually from about 10 to about l 20 .
Completely unsuggested by the prior art teachings, the crimped nylon-6 continuous filament of the present inven-tion shows a complete absence of a spherulitic ring structure when the cross section thereof is viewed under polaTized light.
The result of the absence of such a spherulitic ring structure is that the filament is more lustrous than available prior art fila-ments under otherwise identical conditions. As a consequence, the fiber producer may increase bulk and cover in a fibrous structure such as a carpet without any loss ln luster.
JO SUMMARY OF 'l'HE INVENTION
In ordeT to furnish a textile fiber whlch affords increased bulk and cover in a ibrous s~TuctuTe abricated therefrom without any sacrifice in luster there is provided a crimped nylon-6 continuous filament characterized by the absence of a spherulitic ring structuTe along the periphery of the cross section thereof when the cross section is viewed under polarized light.
In accordance with. the specific teachings, a crimped nylon-6 con$inuous filament is provided which has a denier of at least 5, a modification ratio of between about 2 and 3, a tank bulk of at least 8% and is characterized by the absence of a spherulitic ring structure along the periphery of the cross secti.on of the filament when the cross section is teed under polarized light.
Jo \
BRIEF DESCRIPTION OF THE DRAWING
.
For a more complete understanding of the present invention, including the primary object and benefits thereon - 4a -;5 which are set forth immediately above, reference should be made to the Detailed description ox the Preferred Embodiments, which is set forth below. This detailed description should be read together with the accompanying drawlng, wherein:
FIG. 1 depicts two cross sections of crimped nylon-6 continuous filaments ox the prior art, which show a characteristic spherulitic ring structure along the perlphery of the cross sections; and FIG. 2 depicts two cross sections ox crimped nylon-6 continuous filaments according to the present lnvention, which show a complete absence of the spherulitic ring structure which is characteristic of the prior art filaments shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED E~!BODIMENTS
KefeTring now to the drawlng, FIG. 1 depicts an avail-able crimped nylon-6 continuous filament (1) of the prior art, which is shown in two cross sections thereof as viewed under a microscope under polarized light. A characteristic spherulitic ring (2) is observed along the periphery o-f the cross sections.
Also seen in the cross sections are small particles (~) o-f a delustrant such as titanium dioxide. lhe spherulltlc rlng (2) is comprised of a multiplicity of individual partiaL spherulites (3), which, although not visible under orcLinary conditions, are visible under polarized light. The fllaments depicted here have a modiication ratio of between abou-t 2 and 3, i.e. 9 -the configuration thereof is commonly referred to as "trilobal".
lo determine the modification ratio as well as the presence or absence of a spherulitic ring structure, the following procedure is employed. A filament or yarn sample is placed in a suitable embedding agent. A thin section thereof is then cut with a microtome. A photomicrograph of this section is then obtained, and the modification ratio (MR) is calculated, with the use of a template, employing the following equation:
MR = Do D.l ' wherein Do Diameter of circumscribed circle to cross section, and D1 Diameter of inscribed circle into cross section.
The presence or absence of any peripheral ring is determined by visual observation of the section, under polarized lighting (phase-contrast or dark field may also be employed); a photo-micrograph can also be obtained under these conditions.
Depicted in FIG. 2 is one embodiment (5) of the crimped nylon-6 continuous filament according to the present invention, which is shown in two cross sections thereon as viewed under a microscope under polarized light. No spherulitic ring is observed along the periphery of the cross sections, as a (6).
Seen in the cross sections are small particles (4) of a delus-trant such as titanium dioxide. lhe filaments depicted here also have a modification ratio as discussed above of between about 2 and 3, i.e., the configuration thereof is commonly referred to as "trilobal".
To be sure, it is not necessary that delustrants such as titanium dioxide be present in the filaments according to the present invention. lndeed, the same advantages and benefits over the prior art- are obtained when a filament according to the present invention is substantially :Eree of any delustrant. ~loreover, although a modification ratio ox bet~e~en about 2 and 3 is advantageously employed, ~ilame!lts accordirlg to the present invention may have other cross sectional con~igu-rations as well, under which condltions the same aclvan~ages and benefits over the prior art are observed. That is to say, filaments of the present invention have a higher luster--as determined visually or by any of many standard optical methods known to the skilled artisan--when compared with other-wise equivalent filaments of the prior art which have the same level of crimp, or the same level of delustrant in an amount which is substantially below the saturation level thereof, or the same cross sectional configuration.
As is understood by those of swill in the art, filaments according to the present invention whlch are substantially free of any delustrant are considered to be very highly lustrous. lf not as much luster is desired, one of the S delustrants known to those of skill in the art may be employed.
lhese include no only the usual non-chromatic delustrant and illers such as titanium dloxide, zinc sulfide, calcium carbonate, glass particles, etc., but also delustering agents which impart color as well. Such include organic and inorganic pigments and dyes that are added to the molten nylon-6 polymer prior to or during extrusion and spinning, or to the nylon-6 polymer in chip form in a dyeing operation prior to extrusion and spinning. When titanium dioxide is employed, it is advantageously present in an amount of not greater than about 0.1 percent by weight.
The crimped nylon-6 continuous filament of the present invention advantageously has a tank bulk o-f at leas-t 8 percent and a denier of at least 5. Under these conditlons it is especially suitable for use in the fabrication of a large number ox textile structures desirable in -today's market. 'rank bulk is determined by first measuring the lengch chatlge in a skein ox fiber exposed to boiling water under two loads of appro~i-mately 0.0003 g/dte~ ~L2) and 0.09 g/clte~ (Ll), respectively.
Tank bulk is then calculated employing -the following equation:
Bulk - L -L
~loreover, especially beneficial results aTe obtained when the crimped nylon-6 continuous filament according to the present invention has a modification ratio of between about 2 and 3 and a denier of between about 5 and 25. Under these conditions, use of the filament according to the present invention results in carpets having outstanding characteristics.
- In addition to showing no spherulitic ring structure along the periphery of the cross section thereof when the cross section is viewed under polarized light, a crimped nylon-6 continuous filament according to the present invention which has a denier of at least 5 is found to have another significant morphological characteristic, viz: the ratio of -form nylon-6 to a form nylon-6 is at least 1 to 1, and often about 3/1 to 3.5/1, as measured on non-heat treated, undyed, crimped filamentary material. This compares with I- form to - form ratios of about 1/3 to 1/3.5 for available prior art products under the same conditions of treatment. However, after heat setting of the crimped filamentary material of the present invention, the Go - form is predominant. such a phenomenon clearly demon-strates that a higher proportion of the entire filamentary structure of the present invention is rearranged during heat setting, thereby increasing heat setting efficiency over that obtained with prior art products. To determine the crystallinity ratios referred to above, t-he equitorial x-ray diffraction pattern of the sample is measured and recorded continuously between 2 values of 12 and 30. The alpha crystalline form has a peak at 2 20.0 to 20.5, and another at 2 ~~
23.2 to 2~Ø llhe pseudo-gamma form has a slngle peak at about 2 21.2. By visual examination of the curve, one can determine the relative preponderance ox a particular crystalline form. Such products according to the present invention which have a ratio of I- form nylon-6 to cC - form nylon-6 are especially desirable when substan-tially free of any delustrant, or when a delustrant such as titanium dioxide is present therein in an amount not greater than about 0.1 percent by weight. Moreover, modification ratios of between `about 2 and 3 are highly advantageous, as is a tank bulk as s specified supra of at least about percent.
Any of the filaments according to the present inven-tion may be employed in a multifilament yarn--e.g., grouped together with other filaments according to the present invention--which may be interlaced and/or twisted, utilizing standard techniques well-known to those of skill in the art, to produce carpets, upholstery, and other such textile structures having outstanding characteristics.
The present invention, lncluding its object and benefits, may be better understood by reference to the following illus-trative examples:
xample 1 Nylon-6 chips having a relative viscosity of 2.69 as measured in 96-98% sulfuric acid and con-taining less than 0.01~ titaniwm dioxlde were melted in an extruder and spun at a temperature of 265 through two spinnerettes with 99 irregular shaped holes each at a thruput of 335 grams per minute per spin-nerette forming two 99 filament threadlines. The spun filaments were quenched with a crossflow of air at approximately 12C, and were lubricated with an oil spin finish comprising a poly-alko~ylated alcohol containing essentially no water. Ihe fibe-r was stretch pre-tensioned 1 1/2%, pre-hea-ted to 45C, ancl stre-tched 3.25~ to a speed of 2119 meters per minute and heated to 165C.
The stretched threadlines were crlmped in a hot air te~turizer such as tha-t in US Patent 3~908,248, and deposited onto a rotating cooling sieve through which air was moved by means of a vacuum. The sieve moved at a velocity ox 45 meters per minute.
The threadlines were unraveled from their plug form on the cool-ing sieve to a speed of 1732 meters per minute established by a cold pair of godets. The yarns were subsequen-tly interlaced in a conventional air jet and wound up under 200 pond tension on a double cup winder. lhere was no spherulitic ring structure along the periphery of the cross section of the fiber when viewed under a microscope under polarized light. Some of the fiber produced was processed in a commercial space dyeing operation and exhibited excellent uniformity and bulk/cover.
other fiber was commercially cabled, continuously heatset, tufted, and dyed into an excellent residential type carpet.
The fiber exhibited physical properties common to Bulked Continuous Filament (BCF) products including:
Luster : Excellent Dtex : 1990 Tenacity : 2.3 g/dtex Elongation at Break : 40%
'l'ank Bulk : 10.2%
Dyeability : Piece dyeable in Acid Red;
absence of noticeable streaks in Ortalon Blue G
Filament Modifica-tion Ratio : 2.5 Example 2 A procedure essentially equivalent to tha-t of Example 1 was followed, resulting in a product having the following characteristics:
Luster : Excellent Dtex : 1430 Filament Modifica-tion Ratio : 2.5 'l'ank Bulk : 11%
Ratio of form nylon-6 to Oc-form nylon-6 : 3.5/1 Dyeability : Piece dyeable in Acid Red;
absence of noticeable streaks in Ortalon Blue G
After heat setting of this giber, the OC- form nylon-6 was determined to be predominant.
In order to produce crimped nylon-6 contlnuous filaments according to the present invention, it is necessary to orient the fiber before allowing any moisture migration into the fiber. This is advantageously accomplished by employing an essentially non-aqueous spin finish, as utilized in the examples above.
Although the present invention has been described in detail with respect to certain preferred embodiments thereof, it is understood by those of skill in the art that variations and modifications in this detail may be effected , without any departure from the spirit and scope of the present invention, as defined in the hereto-appended claims.
Claims (3)
1. A crimped nylon-6 continuous filament having a denier of at least 5, a modification ratio of between about 2 and 3, a tank bulk of at least 8 percent, and characterized by the absence of a spherulitic ring structure along the periphery of the cross section of the filament when said cross section is viewed under polarized light.
2. The filament of claim 1, wherein the ratio of y-form nylon-6 to ?-form nylon-6 is at least 1 to 1, as measured on non-heat treated, undyed, crimped filamentary material.
3. The filament of claim 2, wherein the ?-form nylon-6 is predominant after heat setting of the crimped filamentary material.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US27280781A | 1981-06-11 | 1981-06-11 | |
| US272,807 | 1981-06-11 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1189265A true CA1189265A (en) | 1985-06-25 |
Family
ID=23041381
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000404869A Expired CA1189265A (en) | 1981-06-11 | 1982-06-10 | Textured nylon-6 filament |
Country Status (9)
| Country | Link |
|---|---|
| EP (1) | EP0067385B1 (en) |
| JP (1) | JPS5836213A (en) |
| KR (1) | KR880000293B1 (en) |
| AT (1) | ATE18922T1 (en) |
| BR (1) | BR8203419A (en) |
| CA (1) | CA1189265A (en) |
| DD (1) | DD206800A5 (en) |
| DE (1) | DE3270222D1 (en) |
| GR (1) | GR77197B (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100430628B1 (en) * | 2001-12-18 | 2004-05-10 | 주식회사 코오롱 | A sea island type composite fiber with excellent division of cross section |
| KR20150088244A (en) * | 2012-11-28 | 2015-07-31 | 도레이 카부시키가이샤 | Polyamide crimped yarn for clothing and woven or knitted fabric for clothing comprising same |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DD124391A5 (en) * | 1975-03-13 | 1977-02-16 | ||
| JPS5390420A (en) * | 1977-01-13 | 1978-08-09 | Teijin Ltd | Polyamide yarn |
-
1982
- 1982-06-04 DE DE8282104936T patent/DE3270222D1/en not_active Expired
- 1982-06-04 EP EP82104936A patent/EP0067385B1/en not_active Expired
- 1982-06-04 AT AT82104936T patent/ATE18922T1/en active
- 1982-06-09 BR BR8203419A patent/BR8203419A/en unknown
- 1982-06-10 CA CA000404869A patent/CA1189265A/en not_active Expired
- 1982-06-10 GR GR68396A patent/GR77197B/el unknown
- 1982-06-10 JP JP57099928A patent/JPS5836213A/en active Pending
- 1982-06-10 KR KR8202591A patent/KR880000293B1/en active
- 1982-06-10 DD DD82240628A patent/DD206800A5/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| DD206800A5 (en) | 1984-02-08 |
| EP0067385A2 (en) | 1982-12-22 |
| EP0067385A3 (en) | 1984-05-16 |
| KR880000293B1 (en) | 1988-03-19 |
| JPS5836213A (en) | 1983-03-03 |
| DE3270222D1 (en) | 1986-05-07 |
| ATE18922T1 (en) | 1986-04-15 |
| KR840000682A (en) | 1984-02-27 |
| EP0067385B1 (en) | 1986-04-02 |
| GR77197B (en) | 1984-09-11 |
| BR8203419A (en) | 1983-06-07 |
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