CA2107777A1 - Soil resistant fibers - Google Patents

Soil resistant fibers

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Publication number
CA2107777A1
CA2107777A1 CA 2107777 CA2107777A CA2107777A1 CA 2107777 A1 CA2107777 A1 CA 2107777A1 CA 2107777 CA2107777 CA 2107777 CA 2107777 A CA2107777 A CA 2107777A CA 2107777 A1 CA2107777 A1 CA 2107777A1
Authority
CA
Canada
Prior art keywords
fluorochemical
core
inner core
polypropylene
outer core
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.)
Abandoned
Application number
CA 2107777
Other languages
French (fr)
Inventor
Ralph Richard Sargent
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.)
Peach State Labs Inc
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of CA2107777A1 publication Critical patent/CA2107777A1/en
Abandoned legal-status Critical Current

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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
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/02Halogenated hydrocarbons
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/04Oxygen-containing compounds
    • C08K5/10Esters; Ether-esters
    • C08K5/101Esters; Ether-esters of monocarboxylic acids
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/02Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L77/00Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
    • 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
    • D01F1/00General methods for the manufacture of artificial filaments or the like
    • D01F1/02Addition of substances to the spinning solution or to the melt
    • D01F1/10Other agents for modifying properties

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • General Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Artificial Filaments (AREA)
  • Multicomponent Fibers (AREA)
  • Glass Compositions (AREA)
  • Road Paving Structures (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

Permanently soil resistant polymeric compositions that have fluorochemical dispersed throughout the polymer are prepared by melt extrusion of the fluorochemical with the desired polymer.
Preferred polymers for extrusion with the fluorochemical are polyester, polypropylene, polyethylene, and polyamide.

Description

WO 92/1856g 2 1 0 7 7 7 7 PCI/US92/028Z6 SOIL RESISTANT FIBERS

This invention is in the area of fiber technology, and in particular -~
relates to carpet and textile fibrous compositions prepared by melt cxtrusion of a polymer with a fluorochcmical.
Also described are polymeric àrticles, including thin film and molded ~ ;
objects prepared from polymeric compositions that have a fluorochemical dispcrsed throughout a polymcr.
'.:
Ba~ound of the Imrention C;upct and tcxtile fibers arc easily soiled and stained in everyday use. Thc problem of fibcr soiling has becomc morc dfflicult with thc advent of synthetic fibcrs such as polypropylene, polya~de, polycthylene, and polycstcr, that a~C substantially more olcophilic ~oil-loving) than traditional natural fibers such as cotton and wool.
A u~de variie~ of matcrials are known to cause soiling. Soil found on fibers can include a variety of solid particles, such as fly ash or other inorganic particulatcs; liquids, such as oils and greases; mixturcs of solids and liquids, such as soot (that contain ~articles mixed with oily components); and biological matter such as skin cells and sebum.
Soil ~pically adheres to the fiber surface by Van der Waals forces, that arc effective only over very shon distances. The strength of the bond depends on the forces of interaction per unit interfacial area, the area of contact, and whether a liquid is present on the fiber surface. Oily films on the fiber increase soiling. In general, the higher the viscosity of the liquid, the greater the adhesion of the liquid to the fiber. Soil particles can even adhere to initially smooth surfaces, such as polyester and polyethylene film. Soil is not commonly mechanically entrapped in the fiber.
Staining of a fiber can occur in a wide variety of ways, including through the ionic or covalent binding of an exogenous colored substance to the fiber. For example, nylon fibers are polyamides with terminal amino . , .

wo 92/18S69 Pcr/us92/02~26 and carboxyl end groups. Nylon is commonly stained by acid dyes, which are eolored, negatively charged molecules that ionieally bind to the protonated ~ienninal amine. Examples of staining aeid dyes inelude liquids containing FD&C Red Dye No. 4, wine, and mustard. For many years, soil (as opposed to stain) resistanee has been i nparted to carpet and textile fibers by applying a finish that repels oil and water. Perhaps the first soil rcs;ist agent for fibers was starch, that was removed along with the soil WheD tl# fiber was washed. Other water soluble polymerie stain resist finishes have ineluded methylcellulose, hydroxypropyl stareh, polyvinyl alcohol, alginie aeid, hydroxyethyl eellulose and sodium earboxymethyl eellulose. As with stareh, the strong disadvan~age of these proteetive finishes is that their meehanism of aetion is saedfieial; they eontain the ~ -soil but arc rcmoved along with it when the fiber is eleaned.
Vinyl polymers ineluding aerylies, methaerylies and polymers of maleie aeid have also been used as soil release agents. One of the first patents in this area was U.S. Patent No. 3,377,249, issued in 1969 and assigned to Deering Millilcen, diselosing and elaiming emulsions of eopolymers of ethyl aerylate with at least 20% aerylic, methaerylic, or itaeonie aeid in eombination with N-methylol aerylamide.
More reeently, fluoroehemieal soil release agents have beeome very popular. The fluoroehemieal agents are eoated onto the fiber to prevent wetting of the surface by minimizing ehemical contaet between the surface and substances that can soil the carpet, making the substance easier to remove.
The first fluorochemical finishes focused on reducing the surface energy of the fiber to prevent the spreading of oily soils. More recently developed fluorochemical finishes have attempted to combine reduction in surfaee energy with hydrophilicîty, as described in U.S. Patent No.
3.728,151. Increased hydrophilicity facilitates the removal of the soil or W092/18S6g rcr/uss2/02s26 staining material during washing. Hydrophilic moieties in soil resist finishes include a number of hydrogen bonding groups, including polyalkylene glycols.
A number of patents describe fluorinated polymers for use as soil resist coatings for fibers, including U.S. PatentNo. 3,759,874 (describing polyurethanes that consist of a combination of an oleophilic fluorine-cont~ining block and a hydrophilic polyethyleneoxide block) and U.S.
Patent No. 4,046,944 (dcscribing a fluorinated condensation block copolymer, that include oleophilic fluorinated blocks and hydrophilic polyethyleneoxide blocks connected by urea linkages).
Fluorochemical coatings havc been used extensively on carpet fibers, either alone (Antron PlusT~ ca pet manufactured by E. I. DuPont Nemours and Company), or in combination with an acid dye slain resistant polymeric formulation that includes a sulfonated aromatic formaldehyde condcnsation polymer. Examples of commercially available fluorochemical coatings for carpet fibers include Scotchgard~ 358 and 352 (Minnesota Mining & Mfg. Co.), ZonylTM 5180 Fluorochemical dispersion, and Teflon Tuft Coat Anionic (E.I. Du Pont de Nemours and Company, Inc.). ZonyllM 5180 is an aqueous fluorochemical dispersion containing a 1-10% polyfunctional perfluoroaLtcyl ester mixture, 10-20%
polymethylmethacrylate, and 70-75% water. Teflon Tuftcoat Anionic contains 5-10% perfluoroalkyl substituted urethanes, 1-5% polyfunctional perfluoroalkyl esters, and 85-90% water~
Although fluorinated finishing coats on fibers do impart an arnount of soil resistance to the fiber, they all suffer from the distinct disadvanta~e that they are removed by routine maintenance of the fiber. None of the fluorochemical finishes available to date provides permanent protection from soiling and staining. This is a particular problem for polypropylene. ~-wo 92/18569 Pcr/us92/02826 2107~77 4 that is very oleophilic, and that has begun to compete witn nylon as a fiber for usc in residential carpcts.
Therefore, it is an object of the present invention to provide carpet and textilc fiber ~at has permanent soil resistance.
It is another object of the present invention to provide a method of manufacture of permanently soil resistant fibers.
It is a fur~cr object of the present invention to providc a polypropykne fibcr dlat has supcrior soil ~esistancc.

Sun~ of the Invention Pcrmancntly soil resistant polymeric compositions are preparod by cxtruding an appropriate polymer, copolymer, or polymer mixture, in combination wi~ a fhlorochemical, to produce a fibcr that has thc fluorochemical dispcrsçd throughout thc filament. Fibcrs producod in this manner havc a decrcased surfacc cnergy and thus decreased tendcncy to adhcre to soiling agcnts. Tl;e fluorochemical is intricately bound with the polymer, imparting to it permanent soil rcsisting properties. --Any polymer, copolymer, or polymer mixture that can h extruded with the desired fluorochemical can be used to prepare the soil resistant fibcr. Preferred polymers for melt extrusion are polypropylene, nylon 6, polyester, and polyethylene, or mixtures of these. A preferred ;~
fluorochemical îs Zonyl FIS Pluorotelomer 5822APP marketed by E. I.
Du Pont Nemours and Company.
ln one embodiment, in a first step of manufacture, the polymer chip and fluorochemical are blended in a rotary drum dry blender. The blended chips are then poured into a feed hopper, and extruded through a heated temperature chamber and spinneret to form monofilament that is chipped or flaked to an appropriate size. The chips or flakes are then shaped as desired, or extruded into fiber. ln an optional second step, the WO 92/1856g Pcr/US92/02826 polymer fluorochemical chips are blended with other polymer chips that do not contain fluorochemical, and the blend is then extluded to fonn ob~ects or fibcrs of a desired size. The polymer in the chip or flake can be the samc as or diff~rent tharl the polymer that is later mixcd with the chip or fl~. .:
The polymerlfluorochcmical chips can also be uscd to coat a polymcr fiber to improve its propcrties. For cxamplc, nylon 6 (such as polycaprolactarn) can be coatcd with a polyestcr or polypropylene that has a fluorochcnucal dispersed in it to impart soil rcsisting properlies t~ the nylon.
Thin films of polymcr with fluorochemical dispcrsed in the film can also bc prepared that havc supcrior antiwetting proper~cs. These films can be coated with an adhesive shor~y after prcparation without the nced to extensively dry thc film. Polypropylenc fibers prcpared as dcscribcd }#rcin can bc used in residcntial or con~nercial ca~pct to provide a long lasting, durablc carpet with pcrmanent soil rcsistance and low flammability.

Detailed Description of the ln~ention Polymeric compositions that are permanently soil resistant are prepared that have fluorochemical dispersed throughout the polymer.
Carpet and textile fibers prepared in this way have reduced surface energy and low static properties relative to the fiber without the fluorochemical.
The fibers represent a significant advance in fiber and textile technology, in that the fluorochemical is dispersed throughout the polymer instead of coated onto the fiber, and is not removed from the fiber on washing.
The dispersion of the fluorochemical in the polymer improves characteristics of the polymer other than soil resistance. For example, polypropylene fibers that are extruded without a fluorochemical are highly 2107~7~ `

static. Antistatic agents must be applied to the fiber after extrusion to keep the fiber from breaking or static clinging during later processing steps. However, the anistaic agents must be removed from the fiber by scouring after the fiber is tufted because they can increase the ~endency of the fiber to soil on use. This process is cumbersome and increascs the cost of the fiber. Polymers, and in parlicular polypropylene fibers, extruded with a fluorochemical do not require antistatic agents to facilitate handling, because they have inhercntly low static cnergy.
Pluorochcmicals also impart antiwetting charactcristics to polymers that arc uscful for a number of applications. For ex~nple, the fluorochemical can bc cxtruded with a polymer into a thin film that rcpcls water. This is paricularly useful for certain manufacturing procedures ~at requirc a dry film for the application, for example, addition of an ~ -adhcsive to a rccendy extruded film. Dispersion of the fluorochemical -into the polymer also decreases the flammability and alters the combustion charactcristics of ~e polymer. ;```

I. Polymers Suitable for the Preparation of Soil and Stain Resistant Compositions The term "copolymer" as used herein includes polymers formed by the polymerization of at least two different monomers; a monomer and a polymer; or two or more polymers or oligomers. For simplicity, the term polymer as used herein includes copolymers and mixtures of polymers.
Any polymer~ copolymer~ or mixture of polymers is suitable for use in the soil resistant fiber tnat can be melt extruded and that is compatible with the desired fluorochemical. Common polymers that are typically melt extruded include nylon 6, polyester, polypropylene~ and polyethylene.

WO 92/18569 2 1 0 7 7 7 7 PCr/USg2/02826 A polymer should be selected that, when combined with the fluorochemical, has an appropriate viscosity and shear rate on extrusion.
It should solidify within a reasonable time to a filament with appropriate characteristics for the desired function, including tensile strength (strain), elongation (stress), modulus, crystaUinity, glass transition temperature, and melt temperature. Thcse characterisdcs can be measured by known thods. ~ ~

. Fluorochemicsls ~ ~ -The t~rm fluorochcmical, as used herein, refers to an organic nonpolymeric compound in which more than two of the hydrogens atoms attached direcdy to carbon have been replaced with fluorine, or an organic polymeric compound in which at least one hydrogen attached to a carbon in a monomer used to prepare the polymer or copolymer is replaced with fluorine. Fluorochemicals are sometimes also called fluorocarbons or ~
fluoroca~on polymers. Fluorochemicals can include other halogen atoms `
bound to carbon, notably chlorine.
The presence of the fluorine atoms impart stability, inertness, nonflallunability, and oleophobic characteristics to the molecule.
Fluorochemicals are typically more dense and more volatile than the corresponding hydroca~bons and have lower refractive indices, lower dielectric constants, lower solubilities, and lower surface tensions than the comsponding nonfluorinated compound or polymer.
The fluorochemical selected for extr~sion with the polymer can be perfluorinated. wherein all of the hydrogens are replaced with fluorine atoms, or semifluorinated, wherein two or more, but not all~ of the hydrogens are replaced with fluorine. Suitable fluorochemicals for use in preparation of the soil resistant fibers are small molecules, oligomers, or wo 92/18569 P~tUS92~02826 210777~ -8-polymers, or muttures of these. The fluorochemical can be added to the mechanical blender in a solid or liquid form.
The fluorochemical or mixture of fluorochemicals that is selected should not includc any moiety that reacts adversely or degrades on extrusion. The fluorochemical must also be compatible with, and not adversely react with, functional or functionaLized moieties in the polymer extruded with the fluorochemical. The fluorochemical extruded with the ~;
polymer can be homogeneous or can include a mixture of semifluorinatcd compounds, pcrfluorinated compounds, or both semifluonnated and perfluorinated compounds. The types of functional groups that can be included in the fluorochemical will-depend on the temperature of ex~usion, length of time that the material is heated in the extruder, and prescncc of other components in the extruded material. Nonlimiting ~ .
examples of functional or functionalized moieties that may be included in the fluorochemical for use under the proper conditions include alcohols, glycols, ketones, aldchydes, ethers, esters, amides, acids, acrylates, urethanes, urcas, alkanes, alkenes, aLkynes, aromatics, heteroaromatics, and nitriles.
A wide range of fluorocarbon hydrocarbon polymers are known, including poly.e~afluoroethylene, polymers of chlorotrifluoroe~ylene, fluorinated e~ylene-propylene polymers, polyvinylidene fluoride, and poly(hexafluoropropylene). A variety of suitable fluorochemicals are available commercial1y, many from E.I. Du Pone Nemours and Company, Wilmington, Delawaire. A preferred fluorochemical markeeed by Du Pont is Zonyl FTS Fluorotelomer 5823APP, ehat includes 85-90%
perfluoroaL~cylstearate ((~-fluoro-w-12-1( 1 -oxooctadecyl )oxy~ethyl]-poly(difluoromethylene) CAS 65530-65-6); 1-5 % fluorinated alcohol mixture (CAS 112-61-~), aind 5-10% methyl stearate. Zonyl ~:TS is a waxy, light brown solid with a melting point between 30 and 4SC.

WO g2/1856g Pcr/us92/02826 g Other fluorochem cals that can be used include those that are now used colrunercially in fluorochemicals coatings, including Scotchgard~ 358 and 352 (Minnesota Mining & Mfg. Co.~, ZonylTM 5180 Pluorochemical dispersion, and Teflon Tuft Coat Anionic (E.I. Du Pont de Nemours a~nd Company, Inc.). ZonylT~ 5180 is an aqueous fluorochem cal dispersion containing a 1-10% polyfunctional perfluoroalkyl ester mixture, 10-20%
polymcthylmcthacrylate, and 7~75% water. Teflon Tuftcoat Anionic contains 5-10% perfluoroalkyl substituted urethanes, 1-5% polyfunctional perfluoroalkyl esters, and 85-90% water.
If the fluorochemical is obtained as a water based emulsion, the -cmulsifiers and water should bc removcd before the fluorochemical is added to the blender with the polymer.

m. Extrusion of the Desired Polymer with the ~luorochemical Extn~ion is a process for making continuous-filament synthetic polymcric forms by forcing a polymer through minute holos of a spinneret with a rotating screw. The polymeric composition can be extnlded in a thick form and cut into chips or flakes, or extruded in a thin form for use as carpet or textile fiber. Fiber extrusion is often referred to as "spinning"
in the industry.
ln a preferred embodiment, the fiber is prepared in a melt spin process, wherein the fiber-forrning substance is melted and then extruded through the spinneret into a gas (such as air), or a liquid, to cool and solidify the fiber. Polypropylene, polyethylene, polyamide ~nylon), and polyester (for example. Dacron~ Terylene, and Vycron) fibers are prepared in this way. ln this process the fluorochemical can be extruded neat with the melted polymer. lt is important in using this process to choose a polymer that has a melting temperature below that at which the fluorochemical that is extruded with it de~rades or reacts. Polypropylene -WO 92/1856g PCI`/US92/02826 2107777 -lo-used for continuous filament fiber typically melts at approximately 300F.
Nylon is typically extruded at a temperature of approximately 490F. The melt or degradation temperature of the fluorochemical to be used can be dctermined easily by known methods.
In one embodiment, in a first step of manufacture using melt :;
extrusion, chips or flakes of a desired poiymer and fluorochemical are initially prepared by known methods, typicaUy in a dual screw (such as a Farrell) or singb screw (such as a Mackic, Barmag, Filtecho, Plantex, Hills Reacher, or Neumag) device. Thc chips can be used as an additive in a manufac~urc of wide varicty of polymcric ar~cles, including thin film, and ~ermoplas~c or thcrmoset objects. Alternativdy, the chips can be extruded into fiber. The polymcr/fluorochcmical chip should be prepared in appropriatc sizc to bc used in thc desired extrusion, molding, or othcr equipmcnt. ' In a second optional step, the polymer fluorochemical chips are used in a polymer cxtrusion feedstock along with chips or flalces of the same or a different polymer to produce a soil resistant fiber. For example, chips can be prepared from nylon and a fluorochemical, and then extruded in combination with polypropylene chips.
Soil resislant fibers can also be prepared by thin core coextrusion, that involves the extrusion of an inner core of a polymer with an outer core of a polymer that has fluorochemical embedded in it. Machinery appropriate for thin-core coextrusion is available from Hills Research Corporation in Florida. For durability, an inner polymer core should be chosen that adheres sufficiently to the outer soil resistan~ polymeric composition. Thin core coextrusion can be used to prepare a wide variety of fibers for varying applications at varying costs. For example, a less expensive polymer can be used as an inner core of the fiber, and the desired polymer with fluorochemical soil protection as the outer core.

WO 92~18569 PCr/US92/02826 1 1 - .

Alternatively, a soil resistant fiber can be strengthened with a strong inner polyrner core. Nonlimiting examples include fibers prepared by coextruding a polypropylene inner core with a polyarnide/fluorochemical outer core, a polyamide inner core with a polypropylene/fluorochernical outer core, a polyethylene inner core with a polypropyleneMuorochcm~cal ^
outcr core, a polypropylene inner core with a polyethylene/fluorochemical outer core, a polyethylcnc inner core with a po~yamide/fluorochernical outcr core, a polyarnidc inncr core with a polycthylenelfluorochernical outcr core, a polyester inner core with a polyamide/fluorochernical outer ;~
core, a polyamide inner co~e with a polyester/fluorochemical outer core, a polycthylene umer corc and a polyester/fluorochemical outer core, a polypropylene inner core and a polyester/fluorochemical outer core, a polyester inncr core and a polyethylcnelfluorochernical outer core, a polyester inner core and a polypropylene/fluorochemical outer core, and v~nations of these.
The ratio of polymer to fluorochemical in the chip will vary based on the end use of the chip. In general, if the chip is to be extruded into fiber or made into an article without addition of other polymer chip in the final feedstock, less fluorochemical will be used than if the fluorochemical chip is later diluted with other polymer in the fiber or article formation.
A ratio of fluorochemical to polymer should be used that produces a chip with the desired characteristics of melting temperature, strength, processability, soil resistance, and antistatic properties. These characteristics can be measured easily by one skilled in the art of polymer technology. ln a preferred embodiment, the ratio of polymer to fluorochemical in the chip ranges from 1:1 to 1000:1, and more preferably from 20:1 to 1:1, for melt extrusion. As an example of one embodiment of this invention, a feeder chip is prepared with approximately I part by weight of fluorochemical to 9 parts by weight of polymer. The 9:1 wo 92~18569 Pcr/us92/o2826 polymer/fluorochemical chip is then coextruded with polymer chip in a 1:1 weight:weight ratio to form a final product with the desired characteristics.
The temperature of extrusion will vary depending on the polymer and fluorochemical ussd in the process. Typical extrusion temperatures vary from 100F to 800F, however, extrusion temperatures outside this range may be requir~d in cerlain processes. The fiber denier will also vary depending on the product being prepared, and are typically within the range of 1 to 50,000. Carpet fibcrs typically range from 900 denicr to ;
8000 denier.
A ~,vidc variety of textile treatment chemicals can be addcd to the cx~usion proccss to improve the propcrties of the product. Examples include antioxidants, flame retardants, ultra-violet absorbers, dyes or coloring agents, and nicrobiocidal agents, including sntibacterial sgents, antifungals, and antialgals. Any commercially available textile treatment chemical that does not degrade or adversely react in the extrusion process is appropriate. Commercially available flame retardants indude alumina trihydrate, calcium carbonate, magnesium carbonate, barium carbonate, metal oxides, borates, sulfonates, and phosphates.

Example 1 Preparation of Polypropylene Zonyl FIS Chip 12 Melt flow polypropylene ~:~A 3661) provided by Fina Oil and Chemical Corporation, Dear Park, Texas, was mechanically blended with Zonyl FTS Telomer Stearate 2967 (E.I. Du Pont Nemours and Company) in a weight ratio of 9 parts by weight of polypropylene to 1 part by weight of Zonyl FTS. The blended material was poured into a feed hopper, and forced through a single screw extrusion apparatus with temperature chambers of 490F, 505F, 510F, S20F, and 500F. The extruded monofilament was cooled in a cold water quenching bath, and then passed through a chipper to provide soil resistant polypropylene wo 92/1850 PCr/US92/02826 chips. These chips can be used as a polymer additive or remelted and cxerudcd into fiber.

Exunpk 2 Preparation of Nylon Zonyl FI'S Chip Thc procedure of Examplc 1 is repcated using nylon 6 in place of polypropylcne.

Ex~npke 3 Preparation of Polypropylene Zonyl FIS r~ber Polypropylcne Zonyl FIS chips prcparcd as in Example 1 are fed into a singlc scrcw cxtrusion apparatus, passed through a cooling chambcr and around hcatcd rollcrs. Thc fibcr is thcn passcd through forced air and wound onto a cone.

Exampk 4 Prep~ration of Nylon Polypropylene Zonyl FIS Flber Tl# prooedure of Example 3 is followcd with the cxccption that nylon chips and polypropylcne Zonyl FTS chips arc used as the fecd stock in a 1:1 by weight ratio.

Example 5 Preparation of Fiber by Coextrusion of Nylon/Zonyl FIS with chips of polypropylene.
Polypropylene chips are fed into a single screw extrusion apparatus manufactured by Hills Research Colporation, and then passed through a solution chamber that includes nylon 6 and Zonyl FTS. The coated fiber is then quenched in a cooling chamber and pulled around heated rollers. The fiber is then passed through forced air and wound onto a cone.
This invention has been described with reference to its preferred embodiments. Variations and modifications of the process for the preparation of soil resistant materials will be obvious to those skilled in the art from the foregoin~ detailed description of the invention. lt is intended WO92/18S69 PCI/US92/02826 :::
2107777 ` ~

~at all of these variations and modifications be inciuded within the scope of thc appcnded claims.

Claims (22)

I claim.
1. A polymeric composition that comprises a material prepared by melt extrusion of a polymer selected from the group consisting of polypropylene, polyethylene, polyamide, and polyester with a nonpolymeric fluorochemical.
2. The polymeric composition of claim 1 wherein the fluorochemical comprises a perfluoroalkylstearate.
3. The polymeric composition of claim 1 that is a fiber.
4. The polymeric composition of claim 1 that is a chip.
5. The polymeric composition of claim 1 that is a film.
6. The polymeric composition of claim 1 that is a molded article.
7. The polymeric composition of claim 1 that is prepared by thin core coextrusion.
8. The polymeric composition of claim 7 wherein the composition comprises a material selected from the group consisting of a polypropylene inner core with a polyamide/fluorochemical outer core, a polyamide inner core with a polypropylene/fluorochemical outer core, a polyethylene inner core with a polypropylene/fluorochemical outer core, a polypropylene inner core with a polyethylene/fluorochemical outer core, a polyethylene inner core with a polyamide/fluorochemical outer core, a polyamide inner core with a polyethylene/fluorochemical outer core, a polyester inner core with a polyamide/fluorochemical outer core, a polyamide inner core with a polyester/fluorochemical outer core, a polyethylene inner core and a polyester/fluorochemical outer core, a polypropylene inner core and a polyester/fluorochemical outer core, a polyester inner core and a polyethylene/fluorochemical outer core, and a polyester inner core and a polypropylene/fluorochemical outer core.
9. The polymeric composition of claim 1 wherein the ratio of polymer to fluorochemical in the material ranges from 1:1 to 1000:1.
10. The polymeric composition of claim I wherein the ratio of polymer to fluorochemical in the material ranges from 20:1 to 1:1.
11. The polymeric composition of claim 1 that includes a compound selected from the group consisting of an antioxidant, an ultraviolet light absorbing agent; a flame retardant, a dye or coloring agent, an antibacterial agent, an antifungal agent, and an anitalgal agent.
12. A method for preparing a polymeric composition comprising melt extruding a polymer selected from the group consisting of polypropylene, polyethylene, polyamide and polyester with a nonpolymeric fluorochemical.
13. The method of claim 12, wherein the fluorochemical is perfluoroalkylstearate.
14. The method of claim 12, wherein the composition is a fiber.
15. The method of claim 12, wherein the composition is a chip.
16. The method of claim 12, wherein the composition is a film.
17. The method of claim 12, wherein the composition is a molded article.
18. The method of claim 12, further comprising extruding the composition by thin core coextrusion.
19. The method of claim 18 wherein the composition extruded is selected from the group consisting of a polypropylene inner core with a polyamide/fluorochemical outer core, a polyamide inner core with a polypropylene/fluorochemical outer core, a polyethylene inner core with a polypropylene/fluorochemical outer core, a polypropylene inner core with a polyethylene/fluorochemical outer core, a polyethylene inner core with a polyamide/fluorochemical outer core, a polyamide inner core with a polyethylene/fluorochemical outer core, a polyester inner core with a polyamide/fluorochemical outer core, a polyamide inner core with a polyester/fluorochemical outer core, a polyethylene inner core and a polyester/fluorochemical outer core, a polypropylene inner core and a polyester/fluorochemical outer core, a polyester inner core and a polyethylene/fluorochemical outer core, and a polyester inner core and a polypropylene/fluorochemical outer core.
20. The method of claim 12 wherein the ratio of polymer to fluorochemical in the composition ranges from 1:1 to 1000:1.
21. The method of claim 12 wherein the ratio of polymer to fluorochemical in the material ranges from 20:1 to 1:1.
22. The method of claim 12 further comprising extruding the composition with a compound selected from the group consisting of an antioxidant, an ultraviolet light absorbing agent, a flame retardant, a dye or coloring agent, an antibacterial agent, antifungal agent, and an antialgal agent.
CA 2107777 1991-04-11 1992-04-07 Soil resistant fibers Abandoned CA2107777A1 (en)

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JPH06506714A (en) 1994-07-28
WO1992018569A1 (en) 1992-10-29

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