CN1349571A

CN1349571A - Tow and process of making same

Info

Publication number: CN1349571A
Application number: CN00807169A
Authority: CN
Inventors: J·S·阿恩; D·S·奎因
Original assignee: EI Du Pont de Nemours and Co
Current assignee: EIDP Inc
Priority date: 1999-05-10
Filing date: 2000-05-09
Publication date: 2002-05-15
Also published as: DE60029441D1; EP1183410B1; DE60029441T2; KR20010112483A; JP2002544398A; WO2000068476A1; EP1183410A1; AU4708200A

Abstract

A three-dimensionally crimped spreadable continuous filament tow band is made by extruding polymers through a capillary, spinning the extruded polymers into filaments to form fibers, quenching the fibers, grouping the quenched fibers together to form one or two separate ropes, drawing the separate ropes simultaneously to form flat ribbons, stacking the flat ribbons on top of each other to form a single uniform tow band, and removing tension from the band. The batting produced by deregistering and spreading the tow band uniformly is useful, for example, to make filled articles, such as sleeping bags, duvets, and pillows.

Description

Tow and manufacture method thereof

Related application

The application requires the priority of the provisional application 60/133,394 of 1999.5.10 submission, it is introduced in full being made for reference.

Invention field

The present invention relates to tow and with the cotton-wool and the goods of its production, and the method for making these tow, cotton-wool or goods.

Background of invention

Manufacturing and the employed method of uniform spreading long filament with the continuous filament yarn sprawled tow of machine crimp have seen for example to be set forth in the US Patent No 3,730,824 and 3,952,134.In addition, known crimped tow bar through spreader.This class tow strip is used to make cotton-wool, and described cotton-wool can be as the fiberfill such as goods such as pillow, sleeping bags.The superior especially part of this tow of sprawling with machine crimp is: the technological requirement of making useful article obtains simplifying, and the relative intensity that is comparable to traditional cotton-wool of making from machine crimp, carded staple from the relative intensity of the cotton-wool of this tow manufacturing.Yet, machine crimp tow and be: can only obtain limited flexibility, bulkiness and other aesthetic property from the shortcoming of the cotton-wool of its manufacturing.

In addition, the application of three-dimensional crimp staple fibre is also well-known in the art.Give three-dimensional structure several method is arranged, comprise unsymmetrical quenching technology, expanded continuous filament yarn (BCF) processing, two kinds of conjugate spinnings of different polymer aspect molecular chain length only, bi-component spinning with two kinds of different polymer or copolymer, be disclosed in for example US Patent No 5,723,215, US Patent No 3,671,379 and Japan Patent JP 61-32404 (B2) in.

With respect to machine crimp staple fibre and tow, known three-dimensional crimp staple fibre and provide tangible advantage from the goods of its manufacturing, is shelved outward appearance and compressibility preferably at the crimp recovery of for example higher bulkiness, flexibility, improvement.But the processing of this class three-dimensional crimp staple fibre usually is difficult to carry out, because the flexibility and the silkiness of giving from coiled structure partly.Cotton-wool from this fiber manufacturing has shortcoming equally, that is, they usually are low intensive, and are destroyed easily.

Therefore, this area need obtain a kind of the manufacturing and the method for machining 3 D crimped fibre in tow is produced, and this tow can be sprawled with manufacturing and be used for cotton-wool such as goods such as sleeping bag, lid quilt, duvet and pillows.

Summary of the invention

According to these demands, the invention provides a kind of three-dimensional crimp and can sprawl the continuous filament yarn tow strip.In a preferred embodiment, tow strip is made up of the bicomponent fiber that comprises two kinds of polymer in every fiber.Can sprawl cotton-wool and the goods that the continuous filament yarn tow strip forms by three-dimensional crimp is another aspect of the present invention.

In another embodiment of the invention, a kind of method that three-dimensional crimp can be sprawled continuous tow of making is provided, this method comprises: extrude at least two component polymer through a capillary, the polymer of extruding is spun into silk forms doughnut, the quenching doughnut, with quenching fiber concentrate in together independently rope of at least two of formation, stretching independently simultaneously, rope forms bandlet, overlapping these bandlets form single tow strip on every other bandlet top, remove tension force from the gained tow strip, form spirality crimping removing on the tow strip of tension force.

In yet another embodiment, a kind of method that three-dimensional crimp can be sprawled the continuous tow bar of making is provided, this method comprises: make polymer fiber, the gained fiber gathered together form many independently ropes, the gained that stretches is simultaneously independently restricted and is formed on bandlet under the tension force, the gained bandlet is overlapped on the top of every other bandlet and forms single tow strip, compresses the tow strip of gained, with remove tension force from the gained tow strip, form spirality crimping removing on the tow strip of tension force.

In another embodiment, the method for making cotton-wool comprises that the uniform spreading three-dimensional crimp can sprawl the continuous tow bar.

From obviously other purpose of the present invention, characteristics and advantage hereinafter are described in detail in detail.

The accompanying drawing summary

Fig. 1 is the schematic diagram of explanation according to bi-component tow of the present invention spinning and drawing process.

Fig. 2 is the schematic diagram of explanation according to tow spreading methods of the present invention.

Detailed Description Of The Invention

The present invention is by adopting low cohesive force tow manufacture method and the overlapping legal system of tow bar to make three-dimensional crimp Tow has overcome the problem that has earlier technology to exist, and these methods are given each and become low between sub-tow bar Therefore cohesive force makes the as a whole unit of tow row culture further processing through sprawling of mixing. This The tow of sample manufacturing can be separated at overlapping thickness it and become in the sub-tow bar. In addition, tow also Can process through feeding device, seem that it is a filament tow long fibre. Therefore, each tow Bar all can be in the spreader width range uniform spreading.

Term " curling " as used in this specification, refers to the ripple of fiber or bulk The property. Therefore, " three-dimensional crimp " refer to, and for example from the two-dimentional saw tooth crimp phase of machine crimp Relatively, fiber is at bulkiness or the ripple of three-dimensional. Adopt in the art various terms such as helix-coil, ω is curling, three-dimensional random coil etc. described three-dimensional crimp. The three-dimensional crimp fiber also exists to a great extent Describe in the field relevant with expanded continuous long filament technology with the fiber cluster. Also narrated and obtained three-dimensional Curling method. For example, United States Patent (USP) No 4,618,531 is hereby incorporated by, and has narrated A kind ofly make method cluster or random arrangement, that tangle, helix-coil polyester fiber filler. United States Patent (USP) No 5,723,215 is hereby incorporated by, and has narrated a kind of manufacturing and has had the spiral volume The method of bent bicomponent polyester fiber.

" tow bar ", " tow " or " rope bar " refer to big strand the loose rope form that is concentrated into The long filament of making continuously. It is long that tow bar of the present invention preferably comprises the bi-component that contains at least two kinds of polymer Silk. The melting that tow bar illustration polymer of the present invention includes, but not limited to form any type spins Homopolymers, copolymer and the terpolymer of the monomer of silk polymer. This kind melt-spinnable polymer Comprise polyester such as PET (PET), polybutylene terephthalate (PBT or 4GT), polytrimethylene terephthalate (PTT or 3GT), polytrimethylene terephthalate and PEN (PEN) and polyolefin such as polypropylene and polyethylene (PE), and Its combination comprises the bicomponent polyester fiber from PET and PTT preparation. Make and make in the present invention With the method for homopolymers, copolymer and terpolymer, be well known in the art, can wrap Draw together, applications catalyst, co-catalyst and/or chain branching agent form copolymer and terpolymer, As known in the art.

The polymer and the gained fiber that use in the present invention can comprise habitual additive, and it is in polymerization Add in the process or join in the polymer of making, it can help to improve polymer or fiber Performance. The example of these additives comprises antistatic additive, antioxidant, antiseptic, fire retardant, dyes Material, light stabilizer, polymerization catalyst and auxiliary ingredient, tackifier, matting agent such as titanium dioxide, Delustering agent, organic phosphoric acid ester, and combination. Can impose on other additive of fiber, for example, Apply in spinning and/or the drawing process, comprise antistatic additive, level and smooth agent, tackifier, antioxidant, Antiseptic, fire retardant, lubricant and its combination. And, as known in the art, these additional adding Adding agent can add in each step of this method.

As known in the art, using level and smooth agent is that valency is arranged especially in making synthetic fibers filler goods Value. Level and smooth agent provides silk taste sample, that spin the eider down feel for fiber or cotton-wool, and makes Fiber in the whole manufactured goods can move freely and not delustring during use each other. Can use Any suitable level and smooth agent, for example various silicone oil, preferably poly-amino silicone. Be applied on the fiber Antistatic additive and lubricant also are particular importances, because they can be helped during fiber processing Help. Antistatic additive can be used in and prevents from producing static at the tow spreader, and can be in stretching Before or be applied on the fiber afterwards.

The fiber that the present invention uses can also have any suitable shape of cross section.Shape of cross section for example, can comprise circle, ellipse, trilobal, more symmetry or asymmetric leaf, dumb-bell shape, and the doughnut with many holes or space, and preferred about 1～about 10 holes are as known in the art.In one embodiment of the invention, fiber has the circular cross section in three spaces.

In a preferred embodiment, fiber in tow strip comprises first polymer of being made by polyethylene terephthalate homopolymer, with second polymer of making by the approximate copolymer that comprises the polyethylene terephthalate of 7,000 ppm (by weight) tri trimellitate hydroxyl ethyl ester.

In second preferred embodiment, fiber in tow strip can comprise bicomponent fiber, wherein, first component is selected from polyethylene terephthalate and copolymer thereof, second component is selected from polytrimethylene terephthalate and copolymer thereof, there were preferred about 70: 30 to about 30: 70 in about 95: 5 to about 5: 95 in two components with weight ratio.The cross section of bicomponent fiber can be shape arranged side by side or concentric core-skin shape.When using the copolymer of polyethylene terephthalate or polytrimethylene terephthalate, comonomer can be selected from linear, ring-type and the branching aliphatic dicarboxylic acid (for example: succinic acid, glutaric acid, adipic acid, dodecanedioic acid and 1,4-cyclohexane dicarboxylic acid) that contains 4～12 carbon atoms; Aromatic dicarboxylic acid outside the terephthalic acid (TPA), that contain 8～12 carbon atoms (for example M-phthalic acid and 2,6-naphthalenedicarboxylic acid); Contain 3～8 carbon atoms linearity, ring-type and branched aliphatic glycol (for example, 1, ammediol, 1,2-propylene glycol, 1,4-butanediol, 3-methyl isophthalic acid, 5-pentanediol, 2,2-dimethyl-1, ammediol, 2-methyl isophthalic acid, ammediol and 1,4-cyclohexane diol); With aliphatic series that contains 4～10 carbon atoms and araliphatic ether glycol (for example, two (2-ethoxy) ethers of quinhydrones or molecular weight are about poly-ether glycol below 460, comprise diethylidene ether glycol).Preferred M-phthalic acid, glutaric acid, adipic acid, 1, ammediol and 1, the 4-butanediol is because their commercially available are easy to get and not expensive.More preferably M-phthalic acid is because the copolyesters of deriving from it lacks than the copolyesters variable color of adopting some other comonomers to make.When using the copolymer of polytrimethylene terephthalate, preferred comonomers is a M-phthalic acid.In each polyester composition, can use a small amount of 5-sodium-sulfoisophthalate (5-sodium-sulfoisophthalate) and make dyestuff position comonomer.

Tow strip of the present invention can be used for making cotton-wool." cotton-wool " used herein refer to the tow spreader be spread to about 4 or more be multiple times than its original width, cross lapping forms the continuous filament yarn tow strip of many layers.Preferably, cotton-wool contains one to five layer of continuous filament yarn tow strip.Use cotton-wool as fiberfill then such as pillow, sleeping bag, mat, bed clothes and goods such as warm-up or goods.

Make three-dimensional crimp continuous filament yarn of the present invention and sprawl the method for tow, comprising: at first make fiber with formation three-dimensional crimp structural capacity.This can adopt any any means known to carry out, and includes, but not limited to unsymmetrical quenching, expanded continuous filament yarn (BCF) processing, the only bi-component spinning of the conjugate spinning of two kinds of polymer that strand length is different and two kinds of different polymer or copolymer.Preferably, spin and have the silk that forms the three-dimensional crimp ability and obtain molecularly oriented, form curling or cause and curls into after-drawing.

The example that preparation has the three-dimensional crimp structural fibers comprises following method, that is: two component polymer are extruded through capillary; The polymer of being extruded is spun into silk, and formation has two kinds of visibly different fibers of spun orientation degree; And drawing of fiber and releasing tension force form three-dimensional crimp.

Second method making 3-D crimped fiber comprises: make polymer carry out spinning through capillary, with polymer flow is contacted with cooling fluid immediately form silk, make the silk that forms like this, because the speed difference of in fiber, cooling off, and have spun orientation gradient everywhere along its diameter.So-called should " unsymmetrical quenching " can being undertaken by known method.For example, unsymmetrical quenching can comprise capillary of one air flow directive.Perhaps, silk is contacted at the moisture film of a side with constantly new formation, produce desired three-dimensional crimp.After unsymmetrical quenching, silk is stretched and removes tension force forms three-dimensional crimp.

In addition, the method for making three-dimensional crimp can be carried out with other method known in the art.Can also use the combination of two or more above-mentioned technology.For example, use fiber to help to introduce one or more spaces or have non-circular perimeter edge with varying cross-section.Then, can provide like this or the three-dimensional crimp structure of fortifying fibre, and other useful performance is provided.

Other method of making three-dimensional crimp is well known in the art, and/or is described in the list of references, for example polyester fiber-chemistry and technology, Hermann Ludwig, Wiley-Interscience, 1964.Any of these technology can be as the method for giving the fibre three-dimensional coiled structure.

In case obtain having the fiber that forms the three-dimensional crimp structural capacity, just the gained fiber collection formed many independently ropes.Independently restricting of any number can be by having the fibrous of three-dimensional crimp.At least 2 ropes should be arranged, preferred 2～20 ropes, most preferably 2～10 ropes.Make these ropes through low obvolvent tow production process then.

" low obvolvent " tow production process comprises: under heating, stretch simultaneously each independently rope form bandlet, cooling gained band is in case further stretch, continuously overlapping each band and tow strip compressed on another top.Described tow strip can adopt any suitable compression apparatus to compress.Preferably, the gained tow strip compresses through a pair of jaw that rotates roller in the same way.The overlapping slight obvolvent that band and band are provided like this, and band is linked together each other inseparablely.This overlapping can carrying out in the mode of any requirement, and preferred, and the width of the lamination that is built up is substantially equal to each previous independently width of tow strip.Compress except slight obvolvent level is provided, also removed excessive water from tow strip.Specifically, can be after compaction step and/or before apply smooth agent.

The bandlet drawn, overlapping and compress and/or dewater after, three-dimensional crimp forms or strengthens.For example: for bi-component silk and asymmetric crimped filament, in a single day the tension force of tow strip reduce or remove, with regard to spontaneous formation three-dimensional crimp.On the other hand, in the tow manufacture process, can form three-dimensional crimp earlier, for example, for the BCF fiber, and reduce tension force or remove tension force the three-dimensional crimp that formed is strengthened.

After curling into, can handle silk so that crimp fixing.For example, for the tow strip of spontaneous formation three-dimensional crimp, silk generally in continuous baking oven heating removing shrink tension, if curl and suitably, to finish the curing reaction of smooth agent with heat setting.Then, tow strip is cooled to make curling permanence and be bundled under the glass transition temperature of polymer and is transported to tow dividing sinker operation in transportation/hold-up vessel.Other method of curling permanent set known in the art, and can use it.

Therefore, according to the present invention, " low obvolvent tow working system " is following a kind of method, promptly, the tow strip integrality that can pack and enter as the tow spreader of next processing step is provided, and making tow strip be easy to disintegrate on the tow spreader simultaneously becomes the method for individual thread.Refer to the opening of the tow of continuous crisping silk at this paper employed " disintegration ", make the coiled structure of every rhizoid and the asynchronous appearance of coiled structure of contiguous silk.In general, carry out the dividing sinker operation after disintegrating, in the dividing sinker operation, along with tow strip passes through feeding device, long to sprawling substantially equably on the spreader width along it, the width of tow strip is increased to 4～10 times of feeding tow strip width.

Can sprawl in the process of continuous tow in manufacturing three-dimensional crimp of the present invention, can adopt any above-mentioned finishing agent to handle silk or fiber.In a preferred embodiment, on stretching-machine, adopt smooth agent coating silk, make a flexible smooth.Preferred smooth agent is a silicone oil.In another preferred embodiment, on stretching-machine, handle described silk, to eliminate the static that produces at the tow spreader with antistatic finishing agent.

Preferably after stretching, still before heat setting, apply smooth agent.Carry out heat setting then, it can make smooth agent solidify and be bonded on the fiber.Then, after this step, can apply antistatic additive.

Further recognize, can easily increase other processing step, will be understood that these operations are among the scope of the invention.From this product manufactured also in the scope of the invention.

Hereinafter relate to accompanying drawing, as how implementing to make the example that three-dimensional crimp of the present invention can be sprawled the method for continuous filament yarn tow strip.

In Fig. 1, described and made the only minimum basic operational steps that bi-component can be sprawled tow, comprising: spinning of bi-component tow and drawing process.

In Fig. 1, by means known in the art make two kinds independently polymer simultaneously through each spinneret capillary spinning, make bicomponent fiber, its method comprises at first makes polymer pass through equipment 1, and designing apparatus 1 makes every kind of polymer distribution in spinnerets 2 each capillary inlet.

Then polymer being extruded through spinnerets, adopted the appropriate medium quenching, generally is the air of regulating, and walks around one or more rollers 3 and 4 again and stretches.The fiber collecting of then will be so making from one or more spinneretss and is transported to independently in the stretching step in suitable collection container 5.

In stretching step, the ropes that will be spun from many thigh of autonomous container 6,7,8,9 merge, and are divided into many at least two ropes independently on demand, preferred 2～20,2～10 ropes independently most preferably.In the most preferred embodiment, make 4 or more independently ropes.Then, these ropes are stretched between the 1st group of roller 10 and the 2nd group of roller 11 independently of one another simultaneously, the 2nd group of roller is with 2.5～5 times of the 1st group superficial velocity, and preferred 3.0～3.5 times superficial velocity is operated.Draft temperature or adopt hot-rolling shown in Figure 1 to control, perhaps adopt spray liquid equipment 12 to control, wherein the 1st series is sprayed at about 90 ℃～about 99 ℃ (194～210) operations down of temperature of control, and be sprayed at about 15 ℃～about 70 ℃ (59～about 158) operation down at last, preferably in about 20 ℃～40 ℃ (68～104) operation down.Perhaps feeding roller 10 can be controlled at higher temperature, and draw roll 11 is controlled at lower temperature.

After draw roll, a pair of reverse rollers 14 hauls independently tow strip, by being used for the equipment of overlapping tow strip, the angled bar 13 of paintings in Fig. 1.This overlapping can carrying out in the mode of any needs, the preferred overlapping width of the lamination of finishing that makes that carries out is substantially equal to each previous independently width of tow strip.

Overlapping then tow strip is placed under low-tension and is with on 15, makes fiber pass through baking oven 16.Baking oven is used for removing the contraction of fiber and is used for making any silication finishing agent to solidify, and described finishing agent can be before fiber is placed on the baking oven belt be applied on the fiber with any method of several known methods.In general, oven temperature is about 100 ℃～about 200 ℃ (212 °F～about 392 °F), preferred about 140 ℃～about 180 ℃ (284 °F～356 °F).The time of staying in the baking oven for heating district is generally 5～20min, preferred 7～15min.1～5min is gone through in the cooling zone that makes fiber pass through to operate at ambient temperature then, preferred 1～3min.After baking oven, fiber is placed in suitable storage/cask 17 to be transported to the tow spreader.

Below narration relates to Fig. 2, and it has described the example of a tow dividing sinker operation among the scope of the invention.In Fig. 2, will take out from storage/cask 19 by the tow strip 18 that coiled-coil fiber is formed, and through anti-stacked roller 20 pullings, described roller is used for removing tow strip twisting and folding.

Then, Fig. 2 tow enters by driven a pair of reverse cylinder roller 24 and 25 jaws that constituted then through a series of

rollers

21,22 and 23 pullings.First roller 24 of this pair roller is a metal, and spiral flute profile surface is arranged.Second roller is made up of the material of rubber like, and it has smooth surface.From this pair roller, tow strip enters by second pair of reverse rollers 26 and 27 jaws that constituted, and the structure of these rollers is identical with roller 24 and 25 respectively basically, and they are driven with the speed that is higher than first pair roller.The different speed on the flute profile of accompanying roller surface makes silk be subjected to different pullings and gripping, plays a part to make tow to disintegrate.Can change this different roller surface and it is formed, condition is to obtain the difference gripping effect stated this area, is described in for example US Patent No 3,423,795, is hereby incorporated by.

Then, the tow that makes disintegration is by by driven a pair of reverse flat roll 28 and 29 jaws that produce, and it plays a part that high-tension is separated body technology and low-tension subsequently, and to sprawl technology isolated.

Tow self-isolation roller can be by the section of sprawling.For example, the section of sprawling can comprise with Watson in US Patent No 3,423, similar air described in 795 is sprawled nozzle 30 and one group of reverse driven metallic roll 31 and 32.Flowing through the air of sprawling nozzle forces the silk in tow strip to move outside the alignment of center.By second section of sprawling, the latter comprises air and sprawls nozzle 33 and tension force

isolation roller

34 and 35 tow from the 1st section of sprawling.The section of sprawling 2 is identical with section 1 basically, and just air is sprawled nozzle and tension force to isolate roller all longer.The length of this increase make tow strip with sprawl by machine broad.After tow was by second section of sprawling, by the 3rd section of sprawling, it comprises, and air was sprawled nozzle 36 and tension force is isolated roller 37 and 38.This Duan Zaiyu is aforementioned sprawl segment base this similar the time, its width is wideer, and tow is further sprawled.Tow enters the 4th section of sprawling from the 3rd section of sprawling, and the latter sprawls case 39 and

roller

40,41 expressions by air, and it is similar to former parts, but width is also wideer than aforementioned section.

From this section of sprawling, tow can be by the jaws that produced by pair of

cross lapping roller

42 and 43, and it is from roller 41 tow that pulling spread out simultaneously, simultaneously motion with 44 above vertical oscillation so form the stratiform cotton-wool 45 that continuous filament yarn constitutes.The cross lapping cotton-wool can stretch by one or more groups draw roll again, so that further reduce and control weight per unit area better.So the cotton-wool that forms can focus on the roller at this moment, is rolled into bolster or carries out any for other common procedure of processing of fibrous cotton-wadding manufacturer through the resin-bonding feeding again.

Three-dimensional crimp of the present invention can be sprawled the continuous filament yarn tow and be can be used for making the cotton-wool with good bulkiness.Particularly pass through bulkiness, be better than the bulkiness of known two-dimentional machinery crimped tow from the three-dimensional crimp generation of bi-component tow of the present invention.The three-dimensional crimp tow also has the characteristic of other hope, for example compressibility, flexibility preferably, the thermal property of the filling capacity of increase, intensity and increase.

In addition, most of three-dimensional crimp structures generally are difficult to sprawl and are difficult to make fiber and other fiber separation because in every fiber curl and other fiber has many random contact points.As a result, comprise the gap that causes by following sprawling the intrafascicular defective of typical bi-component silk, that is, when the silk from a tow strip part adheres to contiguous silk when tow strip is sprawled, in the contiguous fibre web of bound fibers, just produce a hole.But, three-dimensional crimp of the present invention can be sprawled tow and overcome these difficulties, and its reason is: overlapping many little tow strips, reduced the cohesive force of fiber in the tow strip, the overlapping covering that provides simultaneously makes the defective of any one tow strip be covered by other tow strip.In addition, by the tow that stretch and independently restrict from many, overlapping then these tow strips, thus make tow strip laterally have enough cohesive forces, sprawled uniformly.So three-dimensional crimp of the present invention can be sprawled tow and can be sprawled equably, produce and have high loft, better compressibility, flexibility, the cotton-wool of the filling capacity of increase, intensity and warmth retention property.And, the effect of this structure be make that obstruction well sprawls fold, break and the horizontal stripe silk reduces to minimum.

Again by following non-limiting example explanation the present invention.

Embodiment 1

Bicomponent fiber of the present invention is two kinds of different component polymer of 0.66 from inherent viscosity (IV) and makes, and wherein two components are vertically arranged side by side along the whole length of every fiber.A component polymer (A) is poly-to dioctyl phthalate second two ester homopolymers, and second component polymer (B) is the copolymer that contains the polyethylene terephthalate of 3500 ppm (by weight) trimellitate chain branching agent (analyze by trimethyl trimellitate, but add with the form of tri trimellitate hydroxyl ethyl ester).Every kind of polymer is that 210 lbs/hr (95.5 kg/hr) process through separately single screw extrusion machine with the mixed polymer throughput individually simultaneously all, hole inlet with being metered into each spinneret orifice with 1176 spinneret holes contacts with each other in the ratio of these two kinds of polymer with 86.5% (A) and 13.5% (B).

Above-mentioned polymer is extruded in conjunction with capillary after separately, and is spun into silk with the speed of 0.1786 lb/hr/ capillary (0.081kg/hr/ capillary) and 770 ypm (704 mpm).The gained doughnut adopts 55 (18 ℃) air to carry out quenching in the mode of lateral blowing.The fiber that is spun then gathers together, and forms two independently 137,500 d (152,778 dtex) rope of (after processing), and keeping 95 ℃ damp and hot sprinkling drawing zone to stretch simultaneously, the draw ratio that adopts is 3.24 X, is cooled to 25 ℃ then immediately.The independently rope of the bandlet form that during stretching, obtains, overlapping on a top at the tensile stress next one, form the uniform single tow strip of thickness.Remove tension force from tow strip then, this moment, visible silk formed its intrinsic three-dimensional structure, and tow strip keeps even banded structure simultaneously.

Then, with the silk of poly-amino silicone smooth agent coating gained, after this low obvolvent tow strip of gained is placed on the conveyer belt, and it carries fiber and enters among 175 ℃ of baking ovens.Make fiber be cooled to it below 55 ℃ subsequently, adopt antistatic finishing agent again in 0.33% (is benchmark with the fibre weight) coated fiber.The tow nominal fiber number that will relax then is 270, and (305, tow strip 556dtex) is placed on and is suitable for the container that transport fiber is used for further processing 000d.

Tow takes out from storage/cask, and pulling is through anti-stacked roller and predraft bar system, and its design can be prevented twisting and/or the folding tow spreader that enters.Tow strip enters the jaw that is produced by a pair of reverse cylinder roller from thread-carrier, and for example Dunlap, is hereby incorporated by described in 016 in US Patent No 3,156.The 1st roller of these rollers is metals, and has screw thread flute profile surface, and another roller has smooth surface and rubber covering layer is arranged.Then tow strip first roller to and second roller identical with it between stretch, wherein, the right superficial velocity of first roller is 36.75m/min, second roller is to superficial velocity 58.34m/min rotation, perhaps superficial velocity is first pair 1.59 times of superficial velocity.The stretching of silk and the synergy of the different clampings that caused by the flute profile surface are vertically being disintegrated the silk that constitutes tow strip.

From then on, the jaw of the tow of disintegration by contacting by two reverse flat rolls and producing, it plays a part to isolate the tension force and the technology remainder of disintegration roller.Then, tow is three sections of sprawling by subsequently under low-tension, these sections are made up of air spreader and dragging roller, for example as Watson in US Patent No 3, described in 423,795, be hereby incorporated by, its constituted mode makes tow all widely sprawl at every section, and final one section width is about 70in (178cm).The superficial velocity of dragging roller reduces to and prevents the needed minimum speed of fiber curling round the roll in each section.The superficial velocity of final one section dragging roller is 34.25m/min (37.46yd/min).

Then, the tow pleat of sprawling is on the dermatotome conveyer belt perpendicular to the motion of tow direction, and its mode of operation is to produce 2～4 cross lapping layers continuously, so forms bulk continuous filament yarn cotton-wool.Then, the acrylic resin that will in cotton-wool is made, generally use, Rhoplex TR-407, Rohm ﹠amp; Haas company is commercially available, is applied in the gained cotton-wool with 8wt%～10wt%, and adds in the heat bonding baking oven at 180 ℃ and to solidify, so that increase cotton-wool for further handling necessary intensity.Then resin processed cotton-wool is focused on the roller, so that further be processed into filled articles, as sleeping bag.

Embodiment 2

Bicomponent fiber of the present invention is that total thruput drops to 186lb/hr (84.4kg/hr) with the method manufacturing of embodiment 1, and wherein each capillary thruput is 0.1582lb/hr/ capillary (a 0.0718kg/hr/ capillary).The ratio of polymer becomes 88% polymer A and 12% polymer B.In addition, spinning speed is increased to 950yd/min (868.7m/min).As described in embodiment 1, the fiber that so forms is concentrated in together, form 4 independently rope and the stretchings simultaneously of 77,500 d (86,111 dtex).

Then, the overlapping rope that stretches, the formation width equals single bandwidth, thickness is the single band of 4 times of initial tape thickness.

The gained tow is taken out from storage/cask, and disintegrate/sprawl/cross lapping, form bulk continuous filament yarn cotton-wool according to embodiment 1 described method.

Embodiment 3

Bicomponent fiber of the present invention is made with the method for embodiment 2.With the stretching that so makes rope disintegrate according to embodiment 2 described methods, tow just that disintegrate and that sprawl rolls immediately and inserts among the pillowcase.The bulk softness of Zhi pillow like this.

Technical staff this area, that have benefited from the invention described above content can carry out many improvement.These improvement are interpreted as all being included among as claimed in claim the scope of the invention.

Claims

1. a three-dimensional crimp can be sprawled the continuous filament yarn tow strip.

2. the tow strip of claim 1, wherein tow strip comprises the helix-coil long filament.

3. the tow strip of claim 1, wherein tow strip comprises the bicomponent fiber of making from two kinds of different component polymer.

4. the tow strip of claim 2, wherein silk comprises polyethylene terephthalate homopolymer and polyethylene terephthalate copolymer.

5. the tow strip of claim 3, wherein bicomponent fiber comprises first component that is selected from polyethylene terephthalate and its copolymer and is selected from polytrimethylene terephthalate and second component of its copolymer, and two kinds of components are existence in about 95: 5 to about 5: 95 with weight ratio.

6. the tow strip of claim 5, wherein two kinds of components are to exist in about 70: 30 to about 30: 70 with weight ratio.

7. the tow strip of claim 5, wherein first component is the copolymer of polyethylene terephthalate, wherein prepares the used comonomer of copolymer and is selected from M-phthalic acid, glutaric acid, adipic acid, 1, ammediol and 1,4-butanediol.

8. one kind comprises the cotton-wool that three-dimensional crimp can be sprawled the continuous filament yarn tow.

9. one kind comprises the filled articles that three-dimensional crimp can be sprawled tow.

10. make the method that three-dimensional crimp can be sprawled continuous tow for one kind, it comprises:

(a) extrude two kinds of component polymer through capillary;

(b) polymer of being extruded is spun into silk, forms doughnut;

(c) quenching doughnut;

(d) together, form at least two independently ropes with the fiber collection of quenching;

(e) the gained formation bandlet of independently restricting that stretches simultaneously;

(f) overlapping bandlet on the top of each other bandlet forms single tow strip; With

(g) remove the tension force of tow strip.

11. the method for claim 10, it also comprises: after the described rope that stretches, with smooth agent coating silk.

12. the method for claim 10, it also comprises: cooling silk after forming bandlet.

13. the method for claim 11, it also comprises: after stretching, with antistatic finishing agent coating silk.

14. make the method that three-dimensional crimp can be sprawled the continuous tow bar for one kind, it comprises:

(a) make at least a polymer form fiber;

(b) fiber collection is formed together a plurality of independently ropes;

(c) the gained formation bandlet of independently restricting that stretches simultaneously;

(d) overlapping bandlet on each other bandlet top forms single tow strip;

(e) compress tow strip and

(f) remove tow strip tension force, on tow strip, form three-dimensional crimp.

15. the method for claim 14 wherein after removing tension force, is given tow strip with additional machine crimp.

16. the method for claim 14, it also comprises: after the described rope that stretches, with smooth agent coating gained silk.

17. the three-dimensional crimp with the preparation of the method for claim 10 can be sprawled the continuous tow bar.

18. the three-dimensional crimp with the preparation of the method for claim 14 can be sprawled the continuous tow bar.

19. a method of making cotton-wool, it comprises: the three-dimensional crimp of uniform spreading claim 17 can be sprawled the continuous tow bar.

20. a method of making cotton-wool, it comprises: the three-dimensional crimp of uniform spreading claim 18 can be sprawled the continuous tow bar.

21. a cotton-wool, its three-dimensional crimp that comprises claim 17 can be sprawled the continuous tow bar.

22. a cotton-wool, its three-dimensional crimp that comprises claim 18 can be sprawled the continuous tow bar.

23. the filled articles of claim 6, wherein said filled articles are selected from pillow, lid quilt, duvet and sleeping bag.