CA1281865C - Nylon yarn for brushed fabrics - Google Patents

Nylon yarn for brushed fabrics

Info

Publication number
CA1281865C
CA1281865C CA000514699A CA514699A CA1281865C CA 1281865 C CA1281865 C CA 1281865C CA 000514699 A CA000514699 A CA 000514699A CA 514699 A CA514699 A CA 514699A CA 1281865 C CA1281865 C CA 1281865C
Authority
CA
Canada
Prior art keywords
yarn
less
elongation
grams per
filaments
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 - Lifetime
Application number
CA000514699A
Other languages
French (fr)
Inventor
John D. Forster
John H. Southern
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Monsanto Co
Original Assignee
Monsanto Co
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Monsanto Co filed Critical Monsanto Co
Application granted granted Critical
Publication of CA1281865C publication Critical patent/CA1281865C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/60Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01DMECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00Formation of filaments, threads, or the like
    • D01D5/08Melt spinning methods

Abstract

NYLON YARN FOR BRUSHED FABRICS
ABSTRACT OF DISCLOSURE
Nylon yarn for use in brushed fabrics is made by melt spinning at high speed, snubbing the yarn at a snubbing tension between 0.57 and 0.86 grams per denier, and winding the yarn at low tension to provide a stable package. Preferably the yarn is not heated after quenching. The yarn has an elongation less than 52%, a Kanebo maximum shrinkage force at a temperature less than 150 degrees C., a SAXS discrete scattering equatorial halfwidth of at least 3.6 degrees, and a tenacity less than the lesser of 5 grams per denier and (6.8 - [0.06 X elongation %]).

Description

~2~L8~5 -l~ 14-54(8288)A
NYLON YARN FOR ~UUSHED FABRICS
SPECIFICATION

The invention relates to the art of making napped fabrics, and more particularly to the making of polyamide yarns suitable f'or use in napped fabrics.
~ rushed or napped fabrics have long been known, particul~rly in fabrics made f'rom staple yarns. Such fabrics are typically rnade by abrading the fabric surface by contact with wire cardine cloth (see textbook "Textile Finishing" by Hall, published 196~, American Elsevier, pages 105-10~). When a very short pile or nap is to be raised, the cloth surf'ace may be subjected to abrasion by contact with emery or other similar material (page 107 of the Hall text). Fabrics made of continuous filament nylon have not been used extensively for many types of brushed fabrics, since conventional nylon yarns give poor results in the napping operation when using conventional brushing equipment.
It has been discovered that the napping operation can be successful with fabrics containing continuous filament nylon yarns if the properties of the nylon yarns are properly selected as disclosed below.
Broadly, the yarns of the invention are characterized by having elongations less than 52% and tenacities less 25 than the lesser of 5 grams per denier and [7 - (0.06 X
elongation %)] grams per denier.
According to a f'irst principal aspect of the invention there i6 provided a process for making a polyamide yarn for use in brushed fabrics, comprising metering a plurali-ty of molten streams of polyamide polymer through ~pinneret orifices into a quench zone, quenching the streams into filaments in the quenoh zone, merging the filarnents into a yarn, contacting the yarn 36~ii -2- 14-5~(8288)A

with a snubbing device, withdrawing the yarn from the snubbing device at a speed of at least 2500 MPM, and winding the yarn on a bobbin. The metering rate, the forwarding speed, the elevated tension, the winding tension, and the construction and arrangement of the snubbing device, are selected and correlated such that the yarn ~ound on the bobbin forms a stable package and has an elongation less than 52~ and a -tenacity less than the lesser of 5 Krams per denier and [7 - (0.06 X
elongation ~0)] erams per denier.
According to other specific aspects in practicing the process, the polymer is preferably nylon 66. The snubbing device is preferably constructed and arranged such that the yarn wound on the bobbin has a tenacity less than the lesser of 5 grams per denier and [6.8 - (0.06 times elongation ~)] grams per denier. The filaments preferably have breaking strengths less than 12 grams. The polymer metering rate advantageously selected such that the filaments have deniers greater than 1.4. The snubbing device is preferably located more than 2 meters below the spinneret. The winding tension is preferably between 0.05 and about 0.35 grams per denier.
According to a second principal aspect of the invention, there is provided a polyamide flat yarn wound on a bobbin, the yarn being suitable for forming into brushed fabrics. The yarn haa filaments having individual deniers le~s than 10, an elongation le~s than 52%; a Kanebo maximum shrinkage force at a temperature less than 150 degrees C., a SAXS discrete scattering halfwidth of at least 3.6 degrees, and a tenacity less -3- 14-54(8288)A

than the lesser of 5 grams per denier and [6.8 - (0.06 X
elongation ~0)] grams per denier. The preferred tenacity range is between 1.5 and 4 grams per denier, and the filaments preferably have deniers greater than 1.4.
According to other preferred aspect~ in accordance with the second principal aspect, the yarn is nylon 66, preferably with no twist. The yarn preferably has an elongation less than 50%. A yarn tenaci-ty less than H4 grams per denier and an elongation less than 50 are particularly desirable, and advantageously the filaments have deniers between 2 and 4.5. The yarn preferably has a density less than 1.14.
Other aspects of the invention will appear in the following detailed description.
Example 1 This is an example of attempts to brush f~brics made of conventional nylon apparel yarns. A
conventional apparel 34 filament nylon 66 yarn is spun at 1400 MPM, steamed in a conventional interfloor tube, and wound, the spun denier being selected such that the drawn yarn will have 70 denier. The spun yarn is cold drawn to an elongation of 40~c, yielding a drawn yarn having a tenacity of 5.6 grams per denier. A warp knit fabric is formed from the yarn. Attempts to brush the fabric using a Gessner knit goods napping apparatus are unsuccessful due to rapid dulling of the wires on the napping apparatus and failure of the filaments to cleanly break.
The spinning and drawing operations are modified to provide a 70 denier drawn yarn having an elongation of 60/S, resulting in a tenacity of ~.2 grams per denier, and a 70 denier drawn yarn having an elongation of ~0~0, resulting in a -tenaci-ty of 6.5 grams per denier. Similar unsuccessful resul-ts are obtained -4- ' 14-54(8288)A

when it is attempted to brush warp knit fabrics formed from either of the drawn yarns of this paragraph.
Example 2 This is an example according to the invention.
A 34 filament yarn is spun f'rom ~0 RV nylon 66 at a melt temperature of 285 degrees C., the molten streams being conventionally quenched and converged into a yarn 52 inches (132 C~i) below the face of' the spinneret. The yarn next passes downwardly through an unheated interfloor tube to a metered finish applicator located 3.3 meters below the spinneret face, then in a partial wrap about each of two ceramic snubbing pins prior to being forwarded by contact with a feed roll running a-t a surface speed of 3800 MPM. Each of the pins has a surface roughness of 80 RMS, and the pins are adjustably mounted such that the wrap anEle or degree of wrap of the yarn on each pin may be selected. The snubbing pins constitute an adjustable snubbing device for controlling the yarn tension. After passing in a partial wrap about the f'eed roll, the yarn passes in a partial wrap about a delivery roll running at a surface speed of 3710 MPM, then is wound at a winding tension of about 7 grams.
The snubbing pins are adjusted and arranBed such that the yarn tension between the snubbing pins and the feed roll (the "snubbing tension") is 55 grams.
The resulting 70 denier yarn has an elongation of 44~ and a tenacity of 3.9 grams per denier. When examined by X-ray, the yarn has a SAXS scattering half-width of 4.79 degrees. The yarn has a ~anebo maximum shrinkage force at a temperature of about 100 degrees C. and a densi-ty less than 1.14. A warp knit f'abric formed from the yarn is brushed with excellent 2~6~
-5- 14-54(8288)A

processability, and the resulting napped fabric is of excellent quali-ty.
If the snubbing pins are adjusted to provide a snubbing tension below about 0.57 grams/denier, the yarn would elongate on the packaee, thus preventing formation of a stable package. Conversely, a snubbing tension ereater than about 0.~6 grams/denier causes the yarn to crush the bobbin, again preventing forrnation of a stable package.
Test Methods and Defirlitions For the tests in this paragraph, -the yarn packages to be tested are conditioned at 21 degrees C.
and 65% relative humidity for one day prior to testing.
Fifty yards of yarn are stripped from the bobbin and discarded. Elongation-to-break is determined using an Instron tensile testing instrument. The gage length (initial length of yarn sample between clamps on the instrument) is 25 CM, and the crosshead speed is 30 CM
per minute. The yarn is extended until it breaks.
Elongation-to-break is defined as the increase in sample length at the time of maximum load or force (stress) applied, expressed as a percentage of the original length (25 CM). Tenacity is the maximum load in grams divided by the yarn denier.
Relative viscosity (R.V.) is determined by ASTM
D789-~1, using 90~ formic acid.
Kanebo maximum shrinkage force is measured using a Type KE-2 Thermal Stress Tester manufactured by Kanebo Engineering, Ltd. A 10 CM loop of yarn is pretensioned at 5 milligrams/denier and heated from room temperature to 300 degrees C. at a constant heating rate of 1.67 degrees C. per second. The shrinkage force response is measured with a stress transducer and plot-ted with a dual channel X-Y recorder.

3L281~
6- l4-54(8288)A

X-Ray Techniques The X-ray diffraction pat-terns (small angle X-ray scattering, or SAXS) are recorded on NS54T Kodak no-screen medical X-ray film using evacuated fi~lat plate Laue cameras (Statton type). Specimen to film distance is 32.0 C~; incident beam collimator length is 3.0 inches (7.62 C~) and exposure time i5 16 hours. Interchangeable S-tatton type yarn holdsrs with 0.5 i~ diaMeter pinholes and 0.5 l~M yarn sheath thickness are used throughout as well as 0.5 MM entrance pinholes. The filamentE of each sheath of yarn are aligned parallel to one another and perpendicular to the X-ray bearn. A copper fine focus X-ray tube (~ = 1.5~18 Angstrom units) is used with nickel filter at 40 KV and 26.26 I~A ~ 85~o of their rated load. For each X-ray exposure a single film is used in the film cassette. This film is evaluated on a scanning P-1000 Obtronics Densitometer for information concerning scattering intensity and discrete scattering distribution characteristics in the equatorial and meridional directions. A curve fitting procedure, using Pearson VII
functions [see H. M. Heuvel and R. Huisman, J.Appl.Poly.Sci., 22, 2229-2243 (1978)] together with a second order polynomial background function, is used to fit the experimental data prior to calculation. A
meridional scan is performed, the discrete scattering fitted, equatorial scans are performed through each discrete scattering maxima and then again the data is fitted via a parameter fit procedure.
The SAXS discrete scattering equatorial half-wid-ths (degrees) are used to de-termine the average lamellar dimensions. In the equatorial direction this is taken here to be proportional to the average size of the lamellae scattered in a direction perpendicular to the ~:8~5 -7- 14-54(8288)A

fiber direction. These sizes are measured from the reciprocal breadth of the SAXS diffraction maxima (degrees 1), taken in the equatorial direction at a point in which the SAXS intensity has fallen to one-half its peak intensity value.

Claims (16)

1. A process for making a polyamide yarn for use in brushed fabrics, comprising:
a. metering at a given rate a plurality of molten streams of polyamide polymer through spinneret orifices into a quench zone;
b. quenching said streams into filaments in said quench zone;
c. merging said filaments in-to a yarn;
d. contacting said yarn with a snubbing device;
e. forwarding said yarn from said snubbing device at a forwarding speed of at least 2500 MPM whereby said yarn is subjected to an elevated snubbing tension and becomes oriented;
and f. winding said yarn on a bobbin at a winding tension between about 0.05 and about 0.35 grams per denier;
g. said metering rate, said forwarding speed, said elevated tension, said winding tension, and the construction and arrangement of said snubbing device, being selected and correlated such that said yarn wound on said bobbin forms a stable package and has a plurality of filaments with individual deniers less than 10, an elongation less than 52%, and a tenacity less than the lesser of 5 grams per denier and [7 - (0.06 X elongation%)] grams per denier.

-9- 14-54(8288)A
2. The process defined in claim 1, wherein said polymer is nylon 66.
3. The process defined in claim 2, wherein said metering rate, said forwarding speed, said elevated tension, said winding tension, and the construction and arrangement of said snubbing device being selected and correlated such that said yarn wound on said bobbin has a tenacity less than [6.8 - (0.06 X elongation%)] grams per denier and an elongation less than 50%.
4. The process defined in claim 2, wherein said metering rate is selected such that said filaments have deniers greater than 1.4.
5. The process defined in claim 2, wherein said snubbing device is located more than 2 meters below said spinneret.
6. The process defined in claim 2, wherein said yarn is not heated after being quenched and prior to being wound.
7. The process defined in claim 2, wherein said snubbing tension is between 0.57 and 0.86 grams per
8. A polyamide flat yarn wound as a stable package on a bobbin, said yarn being suitable for forming into brushed fabrics, said yarn comprising filaments having individual deniers less than 10, said yarn having:
a. an elongation less than 52%;
b. a Kanebo maximum shrinkage force at a temperature less than 150 degrees C., c. a SAXS discrete scattering equatorial halfwidth of at least 3.6 degrees; and d. a tenacity less than the lesser of:
(1) 5 grams per denier, and (2) [6.8 - (0.06 X elongation%)]
grams per denier.

-10- 14-54(8288)A
9. The yarn defined in claim 8, wherein said yarn is nylon 66.
10. The yarn defined in claim 9, wherein said yarn has no twist.
11. The yarn defined in claim 9, wherein said yarn has an elongation less than 50%.
12. The yarn defined in claim 9, wherein said yarn has a density less than 1.14.
13. The yarn defined in claim 9, wherein said yarn has a tenacity less than 4 grams per denier and an elongation less than
14. The yarn defined in claim 9, wherein said filaments have deniers greater than 1.4.
15. The yarn defined in claim 9, wherein said filaments have deniers between 2 and 4.
16. The yarn defined in claim 9, wherein said filaments have breaking strengths less than 12 grams.
CA000514699A 1985-07-26 1986-07-25 Nylon yarn for brushed fabrics Expired - Lifetime CA1281865C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US75956585A 1985-07-26 1985-07-26
US759,565 1985-07-26

Publications (1)

Publication Number Publication Date
CA1281865C true CA1281865C (en) 1991-03-26

Family

ID=25056132

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000514699A Expired - Lifetime CA1281865C (en) 1985-07-26 1986-07-25 Nylon yarn for brushed fabrics

Country Status (2)

Country Link
CA (1) CA1281865C (en)
FR (1) FR2585374B1 (en)

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1150761A (en) * 1966-03-14 1969-04-30 Ici Ltd Continuous Filament Bundles and processes for their Formation
FR1575351A (en) * 1967-08-02 1969-07-18

Also Published As

Publication number Publication date
FR2585374A1 (en) 1987-01-30
FR2585374B1 (en) 1989-08-11

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Effective date: 19930928