DE60112954T2 - EXPRESSIVE POLYMER FIBERS, SPINNING NOZZLES FOR THE PRODUCTION THEREOF, AND ARTICLES MANUFACTURED THEREFROM - Google Patents

Abstract

A stretchable synthetic polymer fiber comprising an axial core formed from an elastomeric polymer, and two or more wings attached to the core and formed from a non-elastomeric polymer, wherein preferably at least one of the wings is mechanically locked with the axial core. The fibers can be used to form garments, such as hosiery. A spinneret pack for producing such fibers is also provided.

Description

BACKGROUND THE INVENTION

AREA OF INVENTION

The The present invention relates to a stretchable synthetic polymer fiber with an axial core that is a thermoplastic, elastomeric polymer and a plurality of on the outer periphery the core attached and radially spaced wings, the a thermoplastic non-elastomeric polymer. At least one of the wing polymers or the core polymer protrudes into the other polymer for adhesion the wing to improve on the core. The invention also relates to methods for producing such fibers and one for producing the fibers usable spinneret stack. The invention also relates to articles produced from the fibers, including Yarns, garments and the same.

DESCRIPTION OF THE RELATED AREA

at many products made from synthetic fibers, such as different garments, e.g. Sportswear and knitwear to convey a stretch. As in the "prior art" of US-P-4,861,660 disclosed by Ishii, numerous methods are known, synthetic Filaments an elasticity to convey. In one of the processes, the fibers become two or three three-dimensionally curled. In another such process, stretchable filaments produced from elastic polymers, such as natural or Synthetic rubber or a synthetic elastomer, such as a polyurethane elastomer. This type of stretchable filament is disadvantageous in that elastomeric filaments made of rubber or polyurethane on its own a very bad behavior in use and processability in action as well as over bad dyeing properties features. The disadvantage of rubber or polyurethane elastomeric filaments is therefore avoided by the fact that the rubber or elastomer filament covered with a different filament type that's over has a satisfactory processability and color property.

Indeed There are disadvantages associated with such coated elastomeric filaments. Ishii tries to overcome these disadvantages by removing the filaments, which are made of two polymers, asymmetry is conferred. Nevertheless, these fibers are often serious Deficiency is exposed in that the two polymers often slightly apart from each other separate the processing. The resulting split fiber has a low tear length and can become textile fabrics to lead, the lower gloss and thermal conductivity have as intended. See also US Pat. No. 3,017,686 by Breen et al., in which fibers are disclosed which consist of two different, non-elastomeric polymers are produced and the disadvantages to have.

So is recognized in Tanner U.S. Patent 3,418,200, that when the core polymer protruding into the wing polymer, this very well causes that the section of the wing, which is made of a polymer other than the core, and the outstanding sections of the wings more easily separable from the protruding sections. On the contrary It may be desirable on occasion be the adhesion of the two different polymers in a filament as disclosed in US Pat. No. 3,458,390, where one type of mechanical locking has been applied to two polymers with high modulus and low elasticity to connect together. Like the polymers disclosed by Breen and Tanner, they have these Polymers due to their low elasticity on insufficient stretch and Recovery properties for the present desired garments with high stretch.

fibers, containing two polymers can be spun with spinnerets, as disclosed in U.S. Patent Nos. 3,418,200 and 5,344,297. The spinnerets However, these patents show a polymer migration when multiple polymer streams in feed channels essential in front of the spinneret be united. These problems have been described in "Journal of Polymer Science "(Physics Edition), Vol. 13 (5), p. 863, 1975 and have been specifically described only recently in the International Fiber Journal "(1998), Bd. 13 (5), p. 48 in the case of another spinning according to the state The technique of a trilobal fiber with tips shown to the Cleavage from the core were designed.

Thus, there is still a shortage of fibers and articles thereof which have excellent stretch and recovery and which retain their tenacity during processing and use, and a lack of easy process for producing such fibers and articles. There is also a lack of spinnerets for spinning two polymers with which the problems in the buttocks lymer migration can be eliminated if multiple polymer streams are combined in feed channels substantially in front of the spinneret orifice.

SUMMARY THE INVENTION

It it has now been found that the delamination significantly reduced inside a stretchable two-polymer fiber or can be eliminated if one of the two polymers is the other Polymer permeates, i. at least a portion of a wing polymer from one or more wings protruding into the core polymer or at least a portion of the Core polymer in a wing polymer protrudes. Such behavior was unexpected, as assumed was that the elastomeric polymer deform easily under load and from the interpenetrating compound with the non-elastomeric Pulling out the polymer, which is especially true given the teachings of Tanner, supra.

In the spirit of these findings, the present invention provides a stretchable synthetic polymer fiber including an axial core comprising a thermoplastic elastomeric polymer and a plurality of wings attached to the core and comprising a thermoplastic non-elastomeric polymer, wherein at least one of the wing polymers or core polymers is incorporated in the other polymer sticks out. In one embodiment, the axial core has an outer radius R ₁ , an inner radius R ₂ , where R ₁ / R _{2 is} greater than about 1.2.

In another embodiment granted the invention includes a stretchable synthetic polymer fiber including one axial core comprising a first polymer, and a plurality of wings attached to the core, comprising a second polymer, wherein the fiber has a delamination rating less than about 1 and at least 20% cooldown Has.

Furthermore it is with the spinneret stack the present invention possible directly multicomponent polymer streams at specific locations the back Entry of the fiber-producing nozzle in the spinneret plate to dose. This addresses the problems of polymer migration eliminated when multiple polymer streams in feed channels substantially in front of the spinneret orifice become.

In order to is further according to the present Invention a spinneret stack for the Melt extrusion of a plurality of synthetic polymers for Generation of fibers, comprising: a metering plate containing a first series of bores contains which are designed to receive a first polymer melt, and a second series of bores containing a second polymer melt are designed; a spinneret plate, which is aligned and in contact with the distributor plate, the spinneret plate has capillaries going through them and a length of Reduction of less than 60% of the length of spinneret capillaries; a spinneret carrier plate with holes larger than the capillaries are and are aligned and in contact with the spinneret plate; wherein the plates are oriented such that the plurality of polymer feeds to the dosage plate through the spinneret plate and the spinneret carrier plate pass through to produce a fiber.

SHORT DESCRIPTION THE DRAWINGS

1 Figure 3 is a cross-sectional view of a fiber of the present invention having the wing polymer projecting in the core;

2 Figure 3 is a cross-sectional view of a fiber of the present invention having the core polymer protruding in the wing;

3 Figure 3 is a cross-sectional view of an embodiment of the fiber of the present invention in which the protruding polymer, for example, the wing polymer, protrudes into the penetrated polymer, eg, the core polymer, such as the roots of a tooth;

4 Figure 4 is a cross-sectional view of an embodiment of the fiber of the invention in which the protruding polymer, eg, the core polymer, protrudes so far into the penetrated polymer, eg, the wing polymer, that the penetrating polymer is similar to a spline profile;

5 Figure 4 is a cross-sectional view of an embodiment of the fiber of the present invention in which the core polymer protrudes into the wing polymer and includes an opposite enlarged end portion and a reduced stretch portion attached to the end portion of the remainder of the core poly adjacent to form at least one stretched section therein;

6 Figure 3 is a cross-sectional view of an embodiment of the fiber of the present invention in which the core surrounds a portion of the side of one or more vanes so that a vane penetrates the core;

7 Figure 3 is the process schematic of an apparatus applicable to the production of the fibers of the present invention;

8th is an illustration of an assembly of the spinneret stacking plate in side view, which can be used to produce the fibers of the invention;

8A is a representation of a nozzle plate A in plan view at 90 ° to the in 8th shown assembly of the spinneret stack plate and transverse to the line 8A-8A of 8th ;

8B is an illustration of a nozzle plate B in plan view at 90 ° to that in 8th shown assembly of the spinneret stack plate and transverse to the line 8B-8B of 8th ;

8C is an illustration of a nozzle plate C in plan view at 90 ° to the in 8th shown assembly of the spinneret stack plate and transversely to the line 8C-8C of 8th ;

9A shows a representation in the exposed cross section of a spinneret plate of known design;

9B and 9C Figure 4 is an exploded cross-sectional view of two spinneret plates of the invention;

10 Figure 4 is a side view of the assembly of a spinneret stack plate which may be used to make an alternative embodiment of the fiber of the invention;

10A . 10B and 10C each show an alternative embodiment of a spinneret plate, distributor plate and metering plate in plan view at 90 ° to the assembly of the spinneret stacking plate of 10 , which can each be used in a spinneret stack assembly according to the invention for producing an alternative embodiment of the fiber according to the invention;

11A . 11B and 11C show in each case another alternative embodiment of a spinneret plate, distributor plate and metering plate in plan view at 90 ° to the assembly of the spinning nozzle stacking plate of 10 , which can each be used in a spinneret stack assembly according to the invention for producing an alternative embodiment of the fiber according to the invention;

12 Figure 3 is a cross-sectional view of the fiber of the present invention as exemplified in Example 6;

13 Figure 3 is a cross-sectional view of the fiber of the invention as exemplified in Example 7;

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a stretchable synthetic polymer fiber, which is generally with 10 in the 1 . 2 . 3 . 4 . 5 . 6 . 11 and 12 is pictured. The fiber of the present invention includes an axial core incorporated in the 1 and 2 With 12 is shown, as well as a plurality of wings, in the 1 and 2 With 14 to be shown. The axial core comprises a thermoplastic elastomeric polymer attached to the core. Preferably, the thermoplastic non-elastomeric polymer is permanently stretchable.

The term "fiber" as used herein is interchangeable with the term "filament". The term "yarn" includes yarns of a single filament. The term "multifilament yarn" generally refers to yarns of two or more filaments. The term "thermoplastic" refers to a polymer that can be repeatedly melt processed (for example, by melt spinning). By "elastomeric polymer" is meant a polymer which is in the form of a monocomponent fiber is of extensors, has an elongation at break of more than 100% and when stretched to 2 times its length and holding for one minute and then releasing to less than 1.5 times its original length within one minute after release contracts. The elastomeric polymers in the fiber of the present invention may have a flexural modulus of less than about 96,500 kPa (about 14,000 pounds per square inch), and more typically less than about 58,600 kPa (about 8,500 pounds per square inch) when in one Multicomponent fiber is present, which has been spun according to the standard ASTM D790, "bending properties at room temperature or 23 ° C" and under the conditions essentially as described herein. As used herein, "non-elastomeric polymer" means any polymer that is not an elastomeric polymer. These polymers may also be referred to as low elasticity, hard, and high modulus polymers. By "permanently stretchable" is meant that the polymer has a yield point and, when stretched beyond that limit, does not reassume its original length.

The Fibers of the present invention are referred to as "biconstituent fibers" as long as they are at least have two polymers which are adjacent to each other along the length of the Fiber adheres Each polymer belongs to another generic class, e.g. Polyamide, polyester or polyolefin. If the elastic properties polymers are sufficiently different, polymers can be the same generic class can be used and the resulting fiber is a "bicomponent fiber". Such bicomponent fibers are also within the scope of the invention.

According to the invention, at least one of the wing polymer and the core polymer protrude into the respective other polymer. 1 shows the wing polymer protruding into the core polymer and 2 shows the core polymer protruding into the wing polymer. Penetration of core and wing polymers can be achieved by any method suitable for reducing fiber breakdown. For example, in one embodiment, the penetrating polymer (eg, the wing polymer) may protrude into the penetrated polymer (eg, the core polymer) in the form of roots of a tooth to form a plurality of protrusions (see 3 ). In another embodiment, the penetrating polymer (eg, the core polymer) may extend so far into the penetrated polymer (eg, the wing polymer) that the penetrating polymer is similar to a spline profile (see 4 ). A spline profile has a substantially uniform diameter. In yet another embodiment, the at least one polymer may have at least one protruding portion of a single wing in the core or a core in the wing, including an opposite enlarged end portion and a reduced stretch portion adjacent to the end portion of the remainder of the at least one polymer forming at least one stretched section therein. 5 shows the projecting into the respective wing polymer core polymer, which has such an opposite enlarged end portion 16 and a reduced drafting section 18 features. Vanes and core connected to each other by means of such an enlarged end portion and a reduced stretched portion are referred to as being "mechanically interlocked". For ease of manufacture and more effective adhesion between wings and core, the latter embodiment having a reduced necked portion is often preferred. From the point of view of those skilled in the art, other methods for protrusions may be considered. For example, the core, as in 6 can be seen, a part of the page surrounded by one or more wings, so that a wing penetrates the core.

The fiber of the present invention includes an axial core having an outer radius and an inner radius (eg, "R ₁ " and "R ₂ ", respectively ₎ 1 and 2 ). The outer radius is that of a circle surrounding the outermost portions of the core, while the inner radius is that of a circle inscribing the innermost portions of the wings. In the fibers of the invention, R ₁ / R ₂ is generally greater than about 1.2. Preferably, R ₁ / R _{2 is} in the range of about 1.3 to about 2.0. At lower ratios, resistance to delamination may decrease, while at higher ratios the high levels of elastomeric polymer in the wing (or nonelastomeric polymer in the core) may reduce the stretch and recovery of the fiber. When the core forms a spline profile inside the wing, R ₁ / R ₂ approaches 2. In contrast, in a fiber where one of the wing or core polymers does not protrude into the other polymer, R ₁ approaches the value of R ₂ so that neither wing nor core will penetrate the other polymer. In cases where, among the plurality of wings, the polymer in some wings penetrates the core polymer while the polymer in other wings is penetrated by the core polymer, R ₁ and R _{2 become} only pairs corresponding to the respective wing, as in FIG 2 and each ratio R ₁ / R ₂ and R ₁ '/ R ₂ ' is typically greater than about 1.2 and is preferably in the range of 1.3 to 2.0. In another embodiment, some wings may be penetrated by the core polymer while adjacent wings are not penetrated and R ₁ and R _{2 are} determined by the relationship to the penetrated wings, while similarly R ₁ and R ₂ are related to the penetrating wings are determined when only a few parts of the core of wing polymer are penetrated. Any combination of core-in-wing, wing-in-core, and also no penetration for the wings can be used as long as at least one wing penetrates a core or is penetrated by a core.

The Fiber of the present invention does not become substantial about its longitudinal axis two- or three-dimensional curling characteristic twisted. (At such a higher-dimensional frizz takes the longitudinal axis a fiber itself a zig-zag or helical configuration and such fibers are not within the scope of the invention). The fiber of the present invention can be characterized thereby that they over a substantially spiral twist and a one-dimensional rotation line features. "Largely spiral Twisting "closes both a rotation line completely around the elastomeric core goes, as well as a rotation line, which only partially around the Kern goes, since it has been established that a complete rotation line not around 360 ° is required to achieve the desired track characteristics in the Reach fiber. The essentially spiral twist can either be almost closed peripheral or she can almost not completely be peripheral. A "one-dimensional" twist means that, although the wings the fiber can be largely spiral, the axis of the fiber itself At a low voltage substantially straight is in contrast to the fibers that over have a two- or three-dimensional crimp. Indeed lie fibers that over have a certain ripple, within the scope of the invention.

The Presence or absence of a two- or three-dimensional ripples let yourself gauge the amount of stretch required to pull the fiber substantially straight (by using all possible nonlinearities are pulled out) and is a measure of the radial symmetry of Fibers that over have a spiral twist. The fiber of the invention can be less than about 10% stretch and more typically less than about 7% elongation and, for example, about 4% to about 6% require to pull the fiber largely straight.

The fiber of the present invention has a substantially radially symmetric cross-section as shown in FIGS 1 and 2 can be removed. A "substantially radially-symmetrical cross-section" is understood to mean a cross-section in which the vanes are arranged and have dimensions such that a rotation of the fiber about its longitudinal axis by 360 / n degrees, where "n" is an integer and "n-fold" symmetry of the fibers, essentially the same cross section as before the rotation results. The cross-section is substantially symmetrical in size, in terms of polymer, and angular distance around the core. This substantially radially symmetric cross-section provides an unexpected combination of high stretch and high uniformity without significant amounts of two- or three-dimensional curl. Such uniformity is beneficial in the high performance processing of fibers, such as through guides and knitting needles, as well as in the production of smooth "non-fine" fabrics and especially in translucent fabrics such as hosiery. Fibers having a substantially radially symmetric cross-section have no self-cockling potential, that is, they have no significant two- or three-dimensional crimping properties. See "Textile Research Journal", June 1967, p. 449.

With a maximum of radial cross-sectional symmetry, the core can have a largely circular or regular polyhedron cross section, as can be seen for example in US Pat 1 and 2 sees. By "substantially circular", the ratio of the lengths of two axes crossing each other at an angle of 90 ° in the center of the fiber cross-section will not be more than about 1.2: 1. The use of a substantially circular or regular polyhedron core, unlike the cores of U.S. Patent No. 4,861,660, can protect the elastomer from contact with the rollers, guides, etc., as will be described later with reference to the number of blades. The plurality of vanes may be arranged around the core in any desired manner, for example, as shown in FIGS 1 and 2 is continuous, ie, the wing polymer does not form a continuous shell on the core, or with adjacent adjacent wing (s) meeting at the core surface, such as in the US Pat 4 and 5 U.S. Patent No. 3,418,200. The wings may be the same size or may be of different sizes provided that substantially radial symmetry is maintained. Moreover, each wing may be of a different polymer from the other wings, again as long as substantially radial symmetry is maintained and the symmetry of the polymer composition is maintained. However, for reasons of ease of manufacture and because it is easier to obtain radial symmetry, the vanes are preferably approximately the same size and are made of the same polymer or blend of polymers. It is also preferred that the wings surround the core in an interrupted form for ease of manufacture.

Although the fiber cross section in terms of size, in terms of the polymer and the bending distance around the core is largely symmetrical applies that obvious, that minor Deviations from a perfect symmetry usually at each Any spinning process as a result of factors such as non-uniform cooling or incomplete Polymer melt flow or faulty spinnerets. It goes without saying that such deviations are permissible provided that that they are not that big, that they no longer fulfill the objects of the invention, as well providing fibers of desired elongation and recovery over one one-dimensional spiral twist, while two- and three-dimensional Ripples are reduced to a minimum. That means the fiber deliberately not asymmetric design becomes as in US Pat. No. 4,861,660.

The wing protrude from the nucleus to which they are attached, to the outside and Form a plurality of spirals at least at a distance the core especially after a successful heating. The slope of such Spirals can get bigger, when the fiber is stretched. The fiber according to the invention has a Plurality of wings and preferably features she over 3 to 8 and more preferably over 5 or 6. The number of wings used can be depend on other features of the fibers and on the conditions under which they are generated and used. For example can 5 or 6 wings used, provided that a monofilament is produced, and especially at higher draw ratios and fiber tensions. In this case, the wing clearance around the core in one be sufficient sequence number that the elastomer over the Contact with rollers, guides and the like protected is less vulnerable across from Cracks, roll distortions and wear is considered when using less wings. The effect of the higher stretch ratios and fiber stresses is to make the fiber harder against rollers and guides to press and thereby the wings spread out and the elastomeric core in contact with the roller or the leadership to bring, with a preference for more as two wings at high draw ratios and fiber tensions. In monofilaments are often five or six wings for one optimal combination of easy manufacturing and reduced Core contact preferred. If a multiple yarn is desired, can be used down to two or three wings, which is due to that the probability of contact between the elastomer core and the rollers or guides is reduced by the presence of the other fibers.

There the wings because of the easier production of the core preferably in broken Surrounded by way, in the core on its outside can be a coat of one nonelastomeric polymer between the sites, where are the wings touch with the core. The jacket thickness can range from about 0.5% to about 15% of the largest radius the fiber core lie. The jacket can assist in the adhesion of the wings to the core by more contact points are provided between the core and wing polymers, which is a useful feature when the polymers in the biconstituent fiber not stick to one another without further ado. The jacket can also the abrasive contact between the core and the rollers, guides and the like, and especially when the fiber has a has low number of wings.

The core and / or the wings of the multi-leaf cross-section of the present invention may be solid or contain holes or cavities. Typically, both core and wings are solid. In addition, the wings may take any shape, such as oval, T, C, or S shapes (see, for example 4 ). Examples of useful wing shapes can be found in US Pat. No. 4,385,886. T, C or S shapes can help protect the elastomer core from contact with guides and rollers, as previously described.

The weight ratio of the entire wing polymer relative to the core polymer can be varied to the desired one Impose a mix of properties e.g. the desired elasticity from the core and other properties, such as a low Tack of the wing polymer. For example, can be a weight ratio from about 10/90 to about 70/30, and preferably about 30/70 to about 40/60 from wings apply to core. With high durability in combination with high stretchability in applications where the fiber is not accompanied by an accompanying Yarn (e.g., hosiery) is often used Wing / core weight ratio in Range from about 35/65 to about 50/50. For a best adhesion between the core and the wings can typically about 5% to about 30% by weight of the total weight fiber non-elastomeric polymer penetrating the core, or elastic core polymer that penetrates the wings.

As noted above, the core of the fiber of the present invention can be made from a thermoplastic elastomeric polymer. Examples of useful elastomers include thermoplastic polyurethanes, thermoplastic polyester elastomers, thermoplastic polyolefins, thermoplastic polyesteramide elastomers and thermoplastic polyetheresteramide elastomers.

usable thermoplastic polyurethane core elastomers include those prepared from polymeric glycol, a diisocyanate and at least one diol or diamine chain extender. Diol chain extender preferred because the polyurethanes produced therewith lower melting points than when using a diamine as a chain extender. Polymeric glycols used in the production of elastomeric polyurethanes are usable close a: polyether glycols, polyester glycols, polycarbonate glycols and Copolymers thereof. examples for close such glycols a: poly (ethylene ether) glycol, poly (tetramethylene ether) glycol, poly (tetramethylene-co-2-methyltetramethylene ether) glycol, Poly (ethylene-co-1,4-butylene adipate) glycol, poly (ethylene-co-1,2-propylene adipate) glycol, Poly (hexamethylene-co-2,2-dimethyl-1,3-propylene adipate) glycol, poly (3-methyl-1,5-pentylene adipate) glycol, Poly (3-methyl-1,5-pentylenedonanoate) glycol, poly (2,2-dimethyl-1,3-propylenedodecanoate) glycol, Poly (pentane-1,5-carbonate) glycol and poly (hexane-1,6-carbonate) glycol. Use of usable diisocyanates a: 1-isocyanato-4 - [(4-isocyanatophenyl) methyl] benzene, 1-isocyanato-2 - [(4-isocyanatophenyl) methyl] benzene, Isophorone diisocyanate, 1,6-hexane diisocyanate, 2,2-bis (4-isocyanatophenyl) propane, 1,4-bis (p-isocyanato), alpha, alpha-dimethylbenzyl) benzene, 1,1'-methylenebis (4-isocyanatocyclohexane) and 2,4-tolylene diisocyanate. Useful diol chain extenders include: Ethylene glycol, 1,3-propanediol, 1,4-butanediol, 2,2-dimethyl-1,3-propylenediol, Diethylene glycol and mixtures thereof. Preferred polymeric glycols are: poly (tetramethylene ether) glycol, poly (tetramethylene-co-2-methyltetramethylene ether) glycol, Poly (ethylene-co-1,4-butylene adipate) glycol and poly (2,2-dimethyl-1,3-propylene dodecanoate) glycol. A preferred diisocyanate is 1-isocyanato-4 - [(4-isocyanatophenyl) methyl] benzene. Preferred diol chain extenders are 1,3-propanediol and 1,4-butanediol. To control the molecular weight of the polymer, monofunctional ones can be used Add chain terminators, such as 1-butanol and the like.

usable thermoplastic polyester elastomers include the polyetheresters, by the reaction of a polyether glycol with a low molecular weight Diol can be prepared, e.g. with a molecular weight of less than about 250; and dicarboxylic acid or a diester thereof, e.g. Terephthalic acid or dimethyl terephthalate. Useful polyether glycols include: poly (ethylene ether) glycol, Poly (tetramethylene ether) glycol, poly (tetramethylene-co-2-methyltetramethylene ether) glycol (derived from the copolymerization of tetrahydrofuran and 3-methyltetrahydrofuran) and poly (ethylene-co-tetramethylene ether) glycol. Usable low molecular weight Close Diols ethylene glycol, 1,3-propanediol, 1,4-butanediol, 2,2-dimethyl-1,3-propylenediol and mixtures thereof; 1,3-Propanediol and 1,4-butanediol are included prefers. Usable dicarboxylic acids shut down terephthalic acid optionally with minor amounts of isophthalic acid and diesters thereof (e.g., <20 mol%).

usable thermoplastic polyesteramide elastomers used in the manufacture the core of the fibers of the invention can be used shut down those described in U.S. Patent No. 3,468,975. For example can such elastomers are prepared with polyester segments, the produced by the reaction of ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 2,2-dimethyl-1,3-propanediol, 1,5-pentanediol, 1,6-hexanediol, 1,10-decanediol, 1,4-di (methylol) cyclohexane, Diethylene glycol or triethylene glycol with malonic acid, succinic acid, glutaric acid, adipic acid, 2-methyladipic acid, 3-methyladipic acid, 3,4-dimethyladipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid or dodecanedioic acid or Esters of it. Examples of polyamide segments in such polyester amides include those which are prepared by reaction of hexamethylenediamine or dodecamethylenediamine with terephthalic acid, oxalic acid, adipic acid or sebacic as well as by the ring-opening polymerization of caprolactam.

thermoplastic Polyetheresteramide elastomers are those as described in US Pat 230 838, which can also be used to make the fiber core. Such elastomers may be, for example be prepared by a dicarboxylic acid-terminated polyamide prepolymer of a low molecular weight (e.g., about 300 to about 15,000) polycaprolactam, Polyoenantholactam, polydodecanolactam, polyundecanolactam, poly (11-aminoundecanoic acid), poly (12-aminododecanoic acid), poly (hexamethyelnadipate), Poly (hexamethylene azelate), poly (hexamethylene sebacate), poly (hexamethylene undecanoate), Poly (hexamethylene dodecanoate), poly (nonamethylene adipate) or dg. and succinic acid, adipic acid, suberic, azelaic acid, sebacic, undecanedioic, terephthalic acid, dodecanedioic or the like. The prepolymer can be subsequently reacting with a hydroxy-terminated polyether such as e.g. Poly (tetramethylene ether) glycol, Poly (tetramethylene-co-2-methyltetramethyleneether) glycol, Poly (propylene ether) glycol, poly (ethylene ether) glycol or the like.

As stated above, the wings may be made of any non-elastomeric or har th polymer are generated. Examples of such polymers include non-elastomeric polyesters, polyamides and polyolefins.

usable thermoplastic non-elastomeric wing polyesters include: Poly (ethylene terephthalate) ("2G-T") and copolymers thereof, poly (trimethylene terephthalate) ("3G-T"), Polybutylene terephthalate ("4G-T") and polyethylene-2,6-naphthalate), Poly (1,4-cyclohexylene dimethylene terephthalate), Poly (lactide), poly (ethylene azelate), polyethylene-2,7-naphthalate), Poly (glycolic acid), Poly (ethylene succinate), poly (alpha, alpha-dimethylpropiolactone), poly (p-hydroxybenzoate), Poly (ethyleneoxybenzoate), poly (ethylene isophthalate), poly (tetramethylene terephthalate), Poly (hexamethylene terephthalate), poly (decamethylene terephthalate), Poly (1,4-cyclohexanedimethylene terephthalate) (trans), Polyethylene-1,5-naphthalate), polyethylene-2,6-naphthalate), poly (1,4-cyclohexylidenedimethylene terephthalate) (cis) and poly (1,4-cyclohexylidene dimethylene terephthalate) (trans).

preferred non-elastomeric polyesters include: poly (ethylene terephthalate), Poly (trimethylene terephthalate) and poly (1,4-butylene terephthalate) and copolymers thereof. If relatively high melting polyester, such as poly (ethylene terephthalate) may be used in the polyester a comonomer can be incorporated so that it can be spun at reduced temperatures. such Comonomers can linear, cyclic and branched aliphatic dicarboxylic acids with 4 to 12 carbon atoms (e.g., pentanedioic acid); aromatic dicarboxylic acids except terephthalic acid having 8 to 12 carbon atoms (e.g., isophthalic acid); linear, cyclic and branched aliphatic diols having 3 to 8 carbon atoms (e.g. 1,3-propanediol, 1,2-propanediol, 1,4-butanediol and 2,2-dimethyl-1,3-propanediol) and aliphatic and araliphatic ether glycols having 4 to 10 carbon atoms (e.g. Hydroquinone-bis (2-hydroxyethyl) ether). The comonomer can be found in the Polyester in an amount ranging from about 0.5% to 15 mole%. Because of their easy commercial availability and because they are inexpensive, are preferred comonomers for Poly (ethylene terephthalate) isophthalic acid, pentanedioic acid, hexanedioic acid, 1,3-propanediol and 1,4-butanediol.

Of / wing polyester can also contain small amounts of other comonomers, provided that that these comonomers have no adverse effect on the fiber properties to have. Such other comonomers include 5-sodiosulfoisophthalate a, for example, in an amount ranging from about 0.2% to 5 mol%. Very small amounts of, for example, about 0.1% by weight to about 0.5% by weight based on the total ingredients of trifunctional Comonomers, e.g. trimellitic acid, can for controlling the viscosity be incorporated.

usable thermoplastic non-elastomeric wing polyamides include: Poly (hexamethylene adipamide) (nylon 6,6); Polycaprolactam (nylon 6); Polyene antidote (nylon 7); Nylon 10; Poly (12-dodecanolactam) (nylon 12); Polytetramethylene adipamide (nylon 4,6); polyhexamethylene (Nylon 6,10); Poly (hexamethylenedodecanamide) (nylon 6,12); the polyamide of dodecamethylenediamine and n-dodecanedioic acid (nylon 12,12), PACM-12 polyamide, derived from bis (4-aminocyclohexyl) methane and dodecanedioic acid, the copolyamide from 30% hexamethylenediammonium isophthalate and 70% hexamethylenediammonium adipate, the copolyamide of up to 30% of bis (p-amidocyclohexyl) methylene and terephthalic acid and caprolactam, poly (4-aminobutyric acid) (nylon 4), poly (8-aminooctanoic acid) (Nylon 8), poly (heptamethylenepimelamide) (nylon 7,7), poly (octamethylene suberamide) (Nylon 8,8), poly (nonamethyleneazelamide) (nylon 9,9), poly (decamethyleneazelamide) (Nylon 10,9), poly (decamethylene sebacamide) (nylon 10,10), poly [bis (4-aminocyclohexyl) methane-1,10-decanedicarboxamide], Poly (m-xylene adipamide), poly (p-xylene sebacamide), poly (2,2,2-trimethylhexamethylene pimelamide), Poly (piperazine sebacamide), poly (11-aminoundecanoic acid) (nylon 11), polyhexamethylene isophthalamide, Polyhexamethylene terephthalamide and poly (9-aminononanoic acid) (nylon 9), polycaproamide. copolyamides can also be used, such as poly (hexamethylene-co-2-methylpentamethylenadipamid), in which the hexamethylene part with up to about 75% to 90 mole% of the total diamine derived Parts may be present.

usable Close polyolefins a: polypropylene, polyethylene, polymethylpentane and copolymers and terpolymers of one or more of ethylene or propylene with other unsaturated Monomers. For example, there are fibers, the non-elastomeric polypropylene wings and have an elastomeric polypropylene core, within the scope of the present invention, wherein these fibers are bicomponent fibers are.

Combinations of elastomeric and non-elastomeric polymers may include: a polyetheramide, eg, a polyetheresteramide, a polyamide-winged elastomer core, and a polyester-fluorinated polyetherester elastomer core. For example, a wing polymer may include nylon 6,6, as well as copolymers thereof, eg, poly (hexamethylene-co-2-methylpentamethylene adipamide) wherein the hexamethylene moiety is about 80 Mole% optionally blended with about 1% to about 15% by weight nylon-12, and wherein a core polymer may comprise an elastomeric segmented polyetheresteramide. "Segmented polyetheresteramide" means a polymer that has soft segments (long chain polyether) covalently bonded (via the ester groups) to hard segments (short chain polyamides). Similar definitions correspond to the segmented polyetherester, segmented polyurethane and the like. The nylon 12 can improve the adhesion of the wing to the core and especially if the core is based on PEBAX ^™ 3533SN from Atofina. Another preferred wing polymer may comprise a non-elastomeric polyester selected from the group of poly (ethylene terephthalate) and copolymers thereof, poly (trimethylene terephthalate) and poly (tetramethylene terephthalate); an elastomeric core suitable for use therewith may comprise a polyetherester comprising the reaction product of a polyether glycol (selected from the group of poly (tetramethylene ether) glycol and poly (tetramethylene-co-2-methyltetramethylene ether) glycol with terephthalic acid or dimethyl terephthalate and a low molecular weight diol selected from the group of 1,3-propanediol and 1,4-butanediol.

One elastomeric polyetherester core may also be non-elastomeric Polyamide wings be used and especially if an adhesion promoting Additive is used as described elsewhere herein becomes. For example, you can the wings selected from such a fiber from the group of: (a) poly (hexamethylene adipamide) and copolymers thereof with 2-methylpentamethylenediamine and (b) polycaprolactam; and the core of such a fiber may be selected from the group of (a) polyetheresteramide and (b) the reaction products of poly (tetramethylene ether) glycol or poly (tetramethylene-co-2-methyltetramethylene ether) glycol with terephthalic acid or dimethyl terephthalate, and a diol selected from the group of 1,3-propanediol and 1,4-butanediol.

method for the preparation of the polymers described above are on Specialization known and can the use of catalysts, cocatalysts and agents for Include chain branching, as known in the art.

The high elasticity of the core allows it to absorb compressive and tensile forces when twisting through the attached wings as the fiber is stretched and relaxed. These forces can cause delamination of the two polymers if their adhesion is too weak. Optionally, in the present invention, mechanical blocking of the wing and core polymers is employed to enhance adhesion and further minimize delamination in processing and use. Bonding between the core and wings can be increased even further by selecting wing and core compositions and / or by using adhesion promoting additives to one or both polymers. An adhesion promoter can be used in any or only some of the wings. For example, individual wings may have different degrees of lamination to the core, eg, some of the wings may be deliberately created to delaminate. One example of such additive is nylon 12, for example, 5 wt .-% based on the total wing polymer, that is, poly (12-dodecanelactam), also known as "12" or "N12", commercially available as Rilsan ^® "AMNO" from Atofina. In addition, maleic anhydride derivatives may be used (eg Bynel ^® CXA, a registered trademark of EI du Pont de Nemours and Company, or Lotader ^® ethylene / acrylate / maleic anhydride terpolymers from Atofina), a polyether elastomer to improve its adhesion to modify on a polyamide.

When another example may be a thermoplastic novolak resin, e.g. HRJ12700 (Schenectady International) with a number-average molecular weight in the range of about 400 to about 5,000 an elastomeric (co) polyetherester core be added to its adhesion to (co) polyamide wings to improve. The amount of novolak resin should be in the range of 1% to 20% by weight with a more preferred range of 2% to 10% by weight lie. examples for Novolak resins useful herein include the following, without limited to these phenol-formaldehyde, resorcinol-formaldehyde, p-butylphenol-formaldehyde, p-ethylphenol-formaldehyde, p-hexylphenol-formaldehyde, p-propylphenol-formaldehyde, p-pentylphenol-formaldehyde, p-octylphenol-formaldehyde, p-heptylphenol-formaldehyde, p-nonylphenol-formaldehyde, Bisphenol A formaldehyde, hydroxynaphthalene formaldehyde and alkyl (e.g. tert-butyl) phenol-modified ester (e.g., pentaerythritol ester) of rosin (especially partially maleated rosin). Please refer in this regard the granted US patent application with file number 09/384 605, filed August 27, 1999, for examples of methods for granting improved adhesion between copolyester elastomers and Polyamide.

Maleic anhydride ("MA") functionalized with polyesters may also be used as adhesion promoting additives. For example, poly (butylene terephthalate) ("PBT") may be functionalized with MA on radical grafting in a twin screw extruder according to JM Bhattacharya, "Polymer International" (August, 2000), 49: 8, pp. 860-866, which also report that a few weight percent of the resulting PBT gMA acts as a compatibilizer for binary blends of poly (butylene terephthalate) with nylon 66 and poly (ethylene terephthalate) with nylon 66 were used. For example, such an additive could be used to more strongly adhere (co) polyamide vanes to a (co) polyetherester core of the fiber of the present invention.

The Polymers and resulting fibers, yarns and articles used in the can be used in the present invention, conventional additives include that during the polymerization process or to the polymer produced or Article can be added and to improve the properties of the polymer or fibers can contribute. examples for close these additives a: antistatic agents, antioxidants, antimicrobials, flame retardants, Dyes, light stabilizers, polymerization catalysts and Additives, adhesion promoters, de-glazing agents, such as titanium dioxide, Matting agents and organic phosphates.

Other Additives, for example, during the processes of spinning and / or drawing on the fibers can be applied shut down Antistatic agents, smoothing agents, Adhesion improvers, Hydrophilizers, Antioxidants, Antimicrobial Substances, flame retardants, lubricants and combinations thereof. About that In addition, these additional Additives during of the various process steps as they are in the field are known.

• (a) die streckbare synthetische Polymerfaser eine Delaminierungsbewertung von mindestens etwa 1 hat und eine Abkochschwindung von mindestens etwa 20%;
• (b) die streckbare synthetische Polymerfaser eine Abkochschwindung von mindestens etwa 20% hat und eine Streckung von mindestens etwa 10% erfordert, um die Faser im Wesentlichen gerade zu ziehen;
• (c) die streckbare synthetische Polymerfaser einen axialen Kern aufweist, der ein elastomeres Polymer und eine Mehrzahl von Flügeln hat, die ein nichtelastomeres Polymer angefügt an den Kern aufweisen, worin der Kern auf seiner Außenseite einen Mantel aus einem nichtelastomeren Polymer zwischen den Stelle hat, wo die Flügel den Kern berühren;
• (d) die streckbare synthetische Polymerfaser einen axialen Kern hat, der ein elastomeres Polymer aufweist und eine Mehrzahl von Flügeln, die ein nichtelastomeres Polymer angefügt an den Kern haben, worin der Kern einen weitgehend kreisrunden Querschnitt oder einen Querschnitt eines regelmäßigen Polyeders hat; oder
• (e) die streckbare synthetische Polymerfaser einen axialen Kern hat, der ein elastomeres Polymer aufweist und eine Mehrzahl von Flügeln, die ein nichtelastomeres Polymer angefügt an den Kern aufweisen, worin mindestens einer der Flügel eine T-, C- oder S-Form hat.

While the foregoing description focuses on advantages when the fiber has a substantially radially symmetric cross-section, such symmetry, while often desired, is not required for the embodiments of the invention, wherein:

• (a) the extensible synthetic polymer fiber has a delamination rating of at least about 1 and a boil off shrinkage of at least about 20%;
• (b) the stretchable synthetic polymer fiber has a boil-off shrinkage of at least about 20% and requires a stretch of at least about 10% to stretch the fiber substantially straight;
• (c) the extensible synthetic polymer fiber has an axial core comprising an elastomeric polymer and a plurality of wings comprising a non-elastomeric polymer attached to the core, wherein the core has on its outside a shell of a non-elastomeric polymer between the site, where the wings touch the core;
• (d) the extensible synthetic polymer fiber has an axial core comprising an elastomeric polymer and a plurality of leaflets having a nonelastomeric polymer attached to the core, wherein the core has a substantially circular cross section or cross section of a regular polyhedron; or
• (e) the stretchable synthetic polymer fiber has an axial core comprising an elastomeric polymer and a plurality of leaflets comprising a non-elastomeric polymer attached to the core, wherein at least one of the leaflets has a T, C or S shape.

The fibers of the invention can in the form of an endless filament (either as a multifilament yarn or a monofilament) or as a staple fiber (including, for example Tow or spun yarn). The stretched fibers of the invention can have a denier per fiber of about 1.5 to about 60 (about 1.7 to 67 dtex). Completely Elongated fibers of the invention with polyamide wings typically have fineness-related tear strengths of about 1.5 up to 3.0 g / dtex and fibers with polyester wings about 1 to 2.5 g / dtex, what about the wing / core relationships dependent is. The resulting fibers of the invention may undergo a decoction shrinkage of at least about 20%. For a larger stretch and recovery in textile fabrics, from the fibers of the invention can be made the fibers have a Abkochschwindung of at least about 45%.

If a yarn is produced which has a plurality of fibers, the Fibers any desired Fineness number and any desired dpf value, the ratios from elastomeric to non-elastomeric polymers from fiber to fiber can differ. The multifilament yarn may be a plurality of different fibers contained, e.g. from 2 to 100 fibers. In addition, yarns, comprising the fibers of the present invention, an area have linear densities per fiber and may also not according to the invention fibers contain.

The synthetic polymer fibers of the present invention may be used to form fabrics using known techniques, including weaving, warp knitting, wefting (including circular knitting) or socketing. Such textile fabrics have a her excellent stretch and recovery. The fibers may be useful in textiles and fabrics, such as furnishing fabrics and apparel (including underwear and hosiery) to make all or part of the garment, and including in tight garments. Clothing such as hosiery and fabrics made from the fibers and yarns of the present invention have been found to be smooth, lightweight and very even ("non-fine") with good stretch and recovery properties.

In addition, the present invention provides a melt spinning process for spinning polymeric continuous fibers and this process with reference to 7 which is a schematic representation of an apparatus that can be used to produce the fibers of the present invention. However, it goes without saying that other apparatus can be used. The method of the present invention comprises passing a melt comprising an elastomeric polymer through a spinneret to produce a plurality of stretchable synthetic polymer fibers having an axial core comprising the elastomeric polymer and a plurality of wings on the core attached, which has the non-elastomeric polymer. Referring to 7 For example, a feed of thermoplastic hard polymer, not shown, is included 20 in an assembly of the spinneret stacking plate 35 and a thermoplastic elastomeric polymer feed, not shown, at 22 in a spinneret group in stack construction 30 introduced. Spinneret groups can be used before or after coalescing. The two polymers can be considered undrawn filaments 40 from the spinneret group 35 be extruded in the stack construction, which has nozzles sized to provide the desired cross-section. The method of the present invention further includes quenching the filaments after they exit the capillary of the spinneret to cool the fibers in any known manner, such as by the use of cooling air 50 in 7 , Any suitable method of quenching may be used, such as cross-flow or radially-flowing air.

The filaments are optionally treated with a finish, such as silicone oil, and optionally with magnesium stearate using any known method with an applicator for finish 60 as he is in 7 is shown. These filaments are then stretched after quenching to show a boil off shrinkage of at least about 20%. The filaments may be stretched in at least one step, such as between a feed roll 80 (which can be operated at 150 to 1,000 meters per minute) and a draw roll 90 be stretched, the schematic in 7 shown to be a stretched filament 100 to create. The stretching step may be coupled with spinning to produce a fully stretched yarn or, if a partially oriented yarn is desired, in a split process where there is a delay between spinning and stretching. The stretching may also be carried out during the winding of the filaments as a warp of yarn, which is referred to in the art as "warp shears". Any stretch ratio (whose defect interferes with processing by breaking the filament) can be imparted to the filament so that, for example, a fully oriented yarn can be produced by means of a draw ratio of about 3.0 to 4.5 times and a partially oriented yarn having a draw ratio of about 1.2 to 3.0 times can be produced. Herein, the stretch ratio is the revolution speed of the stretch roller 90 divided by the rotational speed of the feed roller 80 , The stretching may be carried out at about 15 ° to 100 ° C, and typically about 15 ° to 40 ° C.

The stretched filament 100 can optionally be relaxed in part, eg with steam at 110 in 7 , In the course of spinning, a heat relaxation can be performed with any amount. The greater the relaxation, the more elastic the filament, and the lower the shrinkage that occurs in downstream process steps. The stretched finished filament may have at least about 20% coold-melt after relaxation as described below. Preferably, heat relaxation of the as-spun filament is about 1 to 35% based on the length of the drawn filaments before being wound up, so that they can be handled as a typical hard yarn.

The quenched, stretched and optionally relaxed filaments can then be wound on a rewinder at a speed of 200 to about 3500 meters per minute and up to 4,000 meters per minute 130 in 7 be recorded. Or, a plurality of fibers may be spun and quenched, with the fibers converging, optionally interwoven, and then, for example, up to 4,000 meters per minute on the rewinder 130 and wound, for example, in the range of about 200 to about 3500 meters per minute. There may be monofilament or multifilament yarns on a rewinder 130 in 7 be wound up in the same way. If multifilaments The filaments can be combined and optionally intertwined prior to winding, as is conventional in the art.

To at any time after stretching, the biconstituent filament may dry or wet a heat treatment be subjected while it completely is relaxed to the desired stretching and recovery properties to develop. Such relaxation may occur during the production of the filament for example during of the relaxation step described above or after the filament is in a yarn or fabric has been incorporated, for example, during washing, dyeing and like. The heat treatment in the form of the fiber or yarn may be on hot rollers or a "hot chest" or in a padding step executed with steam jet become. Preferably, such a relaxed heat treatment becomes executed after the fiber is in a yarn or textile fabric so it's like a nonelastomer up to that point Fiber can be treated. However, it may be required heat treated and completely be relaxed before being wound up as a fiber with high elongation becomes. The fiber can for a higher one Measure uniformity in the finished textile fabric heat treated and be relaxed. The temperature of the heat treatment / relaxation can in the range of about 80 ° to about 120 ° C lie when the medium for heating is dry air, and about in the Range of 75 ° to about 100 ° C lie when the medium for heating is hot water, and in the area from about 101 ° to about 115 ° C lie when the medium for heating water vapor at overpressure is (e.g., in an autoclave). Lower temperatures can too too little or no heat treatment to lead and higher Temperatures can melt the elastomeric core polymer. The step of Heat Treatment / Relaxation let yourself generally within a few seconds.

As stated above, has the spinneret capillary a dimensioning according to the desired cross-section of the fibers the present invention as described above, or for producing other biconstituent or bicomponent fibers. Leave the capillaries or spinneret holes to intersect with any method that is suitable, such as for example, by laser cutting according to the description in US Pat. No. 5,168,143, by drilling, with the help of electrical discharge Machining (EDM) and with the help of punching, which is in the professional world is known. The capillary nozzle Can be done using a laser beam for proper control of the Cross-sectional symmetry of the fiber of the invention are cut. The openings the spinneret capillary can have any suitable dimensions and can be cut throughout (pre-coalescence) or be interrupted (Postkoaleszens). A non-continuous capillary Can be done by drilling small holes can be obtained in a pattern that the polymer a converge allowed below the front of the spinneret and the multi-bladed Cross section of the present invention forms.

For example, the filaments of the present invention can be made with a pre-coalescing spinneret stack as described in U.S. Pat 8th . 8A and 8B and 8C is illustrated. In 8th , which is a side view of the assembly of the spinneret stacking plate, which in 7 As shown, the polymer flows in the direction of arrow F. The first plate in the spinneret assembly is plate D, which contains the polymer melt pool and has a conventional construction. Plate D rests on the dosing plate (shown in cross-sectional view in FIG 8C ), which in turn rests on an optional distributor plate B (shown in cross-sectional view in FIG 8B ) resting on the spinneret plate A (shown in cross-sectional view in FIG 8A ), and which is held by the spinneret support plate E. The metering plate C is aligned with and in contact with the distributor plate B below the metering plate, the distributor plate being located above and aligned with the spinneret plate A and contacting the capillaries passing therethrough but having substantially no depressions wherein the spinneret plate (s) is aligned with and in contact with a spinneret support plate (E) having larger holes larger than the capillaries. The orientations are such that a polymer feed to the metering plate C can pass through the distributor plate B, spinneret plate A and spinneret carrier plate E to produce a fiber. Melt pool plate D, which is a conventional plate, is used to feed the dosing plate. The polymer melt pool plate D and the spinneret assembly support plate E are sufficiently thick and rigid that they can be pressed firmly together and thereby prevent the polymer from leaking between the stacked plates of the spinneret assembly. The plates A, B and C are sufficiently thin so that the nozzles can be cut by the laser methods. Preferably, the holes in the Spinndüsenträgerplatte (E) are widened, for example at an angle of about 45 ° to 60 °, so that the just spun fiber does not touch the edges of the holes. Also preferably, the polymers do not touch each other (pre-coalescing) in a distance of less than about 0.30 cm, and usually less than 0.15 cm, before the fiber is formed, so that the cross-sectional shape provided by FIG Dosing plate C, the optional distributor plate D and Be measurement of the spinneret plate E in the fiber is shown in more detail. A more precise definition of the fiber cross section may also be obtained by cutting the holes through the plates as described in US Pat. No. 5,168,143, after which a multimode beam from a solid state laser to a predominantly single mode beam (eg TM ₀₀ -Mode) is reduced and focused on a spot with a diameter of less than 100 microns and 0.2 to 0.3 mm above the metal sheet. The resulting molten metal is ejected from the lower surface of the metal sheet by pressurized fluid and flows coaxially with the laser beam. The distance from the top of the topmost distributor plate of the front of the spinnerette can be reduced to less than about 0.30 cm.

To produce filaments having any number of symmetrically arranged sections of wing polymer, the same number of symmetrically located nozzles are used in each of the plates. For example, in 8A the spinneret plate A in a plan view at an angle of 90 ° oriented to the assembly of the spinneret stacking plate of 7 shown. The plate A in 8A consists of 6 symmetrically arranged wing spinneret openings 140 with a central round spinneret opening 142 keep in touch. Each of the spinneret openings 140 can have different widths 144 and 146 to have. In 8B the complementary distributor plate B is shown, via distributor nozzles 150 which is on the open side 152 to an optional slot 154 tapered, the distributor nozzles with a central round hole 156 combines. In 8C is the nozzle plate C with Dosierkapillaren 160 for the wing polymer and with a central dosing capillary 162 for the core polymer. The polymer melt pool plate D can be of any conventional design known in the art. The Spinndüsenträgerplatte E has a sufficiently large, through hole and is diverging from the way the newly spun filament expanded (eg 45 ° to 60 °), so that the filament does not touch the side surfaces of the bore, as in the 7 and 8th is shown in side view. The plates A to D of the spinneret stack plate assembly are oriented such that the core polymer from the polymer melt pool plate D passes through the central metering orifice 162 the dosing plate C and through the six small capillaries 164 flows through the central circular capillary 156 the distributor plate B, through the central circular capillary 142 the spinneret plate A and through the large expanded hole in the Spinndüsenträgerplatte E emerges. At the same time, the wing polymer flows from the polymer melt pool plate D through the metering capillaries 160 the dosing plate C for wing polymer, through the distributor nozzles 150 the distributor plate B (which, with optional presence of slot 154 the two polymers first come into contact with each other) through the nozzles 140 the spinneret plate A for wing polymer and finally out through the bore of Spinndüsenträgerplatte E.

The spinneret stack of the invention can be used to melt-extrude a plurality of synthetic polymers to produce a fiber. In the spinneret stack of the present invention, the polymers can be fed directly into the spinneret capillaries because the spinneret plate has no significant sink. By "no substantial dip" is meant that the length of any existing dip (including any gaps connecting the inputs of the plurality of capillaries) is less than about 60% and preferably less than about 40% of the length of the spinneret capillary. See also 9A which shows a cross-sectional view of a spinneret plate of the prior art, and see 9B and C, which shows a cross section of spinneret plates of the present invention. The direct metering of multicomponent polymer streams to specific locations on the rear entrance of the fiber producing nozzle in the spinneret plate eliminates the problems of polymer migration when multiple polymer streams are combined in the feed channels substantially in front of the spinneret orifice, which is the norm.

It can be useful be the function of the two plates to one through the use recessed grooves on one or both sides of the single plate with appropriate holes through the plate unite to connect the grooves. For example, you can Recesses, grooves and depressions in the upstream Side of the spinneret plate cut (for example, with the help of electrical discharge machining) and can Function of distribution channels or -mulden in pronounced Take over sinks.

A plurality of fibers comprising two or more polymers can be produced by means of the spinneret stack of the present invention. For example, other biconstituent fibers and bicomponent fibers not disclosed and / or claimed herein can be produced in this manner, including the cross-sectional profiles disclosed in U.S. Patent Nos. 4,861,660, 3,458,390, and 3,671,379. The resulting fiber cross-section may be, for example, a side-by-side cross-section, an eccentric sheath-core cross-section, a concentric sheath-core cross-section, a wing-and-core cross-section, a wing-and-sheath and core Cross section and the like. In addition, the Spinneret stacks according to the invention are used for spinning splittable and non-split fibers.

The spinneret stack of the present invention can be modified to achieve different multi-bladed fibers, for example, by changing the number of capillary webs for a different desired number of blades by changing the slot dimensions to vary the geometrical parameters required to produce a different denier per Filament or yarn count, or as needed for use with various synthetic polymers. For example, in the embodiment of FIG 10 a relatively thin spin stack as used to produce a three-blade fiber and as exemplified in Example 7 below. In 10A For example, the spinnerette plate was 0.038 cm (0.015 inch) thick and had throughgoing nozzles of full thickness stainless steel thereon by the laser techniques disclosed herein, in the form of three straight wings 140 in two widths (with lengths 144 respectively. 146 ) and arranged symmetrically at 120 ° about the center of symmetry; with no sink above the capillary nozzle. Every wing 140 had a length of 0.102 cm (0.040 inches) from its tip to the circumference of a central round spinneret bore 142 with a diameter of 0.030 cm (0.012 inches), whose center coincided with the center of symmetry. Referring next to 10B the distributor plate B is 0.025 cm (0.010 inch) thick coaxially aligned over the spinneret plate A so that every other vane nozzle 150 the distributor plate B with a wing 140 the spinneret plate A was aligned; every wing nozzle 150 the distributor plate B had a length of 0.349 cm (0.1375 inches) from its tip to the center of symmetry. The metering plate C ( 10C ) had a thickness of 0.010 inches and had holes 160 with a diameter of 0.064 cm (0.025 inch), holes 162 with a diameter of 0.015 inches (0.038 cm) and a central bore 164 with a diameter of 0.025 cm (0.010 inches). The plate C was aligned with the distributor plate B, so that in use the supply of wing polymer to the melt pool plate D (see 10 ) to the holes 160 and feeding core polymer to the bores 162 and 164 from distributor plate C from plate B to plate A so as to produce a fiber in which the wings penetrate the core. There was no dip in the spinneret plate A and the combined thicknesses of plates A, B and C were only about 0.089 inches (0.035 inches).

In another embodiment of the spinneret group, no spinneret support plate E was used (see 8th ). This is exemplified in Example 8 below. In 11A For example, spinneret plate A was 0.794 cm (0.3125 inches) thick and each spinneret orifice had a diameter of 0.254 cm (0.100 inches) and a sink and capillary 0.038 cm (0.015 inches) in length at the bottom of the sink. As in 11A is shown, each spinneret orifice in the spinneret plate A had six straight vane nozzles 170 each of which had a long axis centerline passing through the center of symmetry and a length of 0.089 cm (0.035 inches) from its tip to the perimeter of the central circular bore 172 would have. The length 174 had a 0.010 cm (0.004 inch) width from the tip of each blade to 0.038 inches (0.038 cm); the length 176 had a length of 0,051 cm (0.020 inch) and a width of 0,007 cm (0,0028 inch). The tip of each wing was rounded at one half the width of the top. The distributor plate B (see 11B ) had a thickness of 0.015 inches and had six vane openings, each of which was centered over a corresponding valley in the spinneret plate A and oriented so that each vane nozzle in plate B was aligned with a vane nozzle of plate A. Every wing nozzle 150 in plate B had a length of 0.152 cm (0.060 inches) and a width of 0.051 cm (0.020 inches) with its tip rounded to a radius of 0.025 cm (0.010 inches). The central hole 152 in the plate B had a diameter of 0.254 cm (0.100 inches). The dosing plate C (see 11C ) also had a thickness of 0.015 inches. In the plate C had the holes 160 0.020 cm (.008 inches) in diameter and were 0.254 cm (0.100 inches) from the center of the central bore 162 plates B and A and formed the core of the fiber. The non-elastomeric wing polymer was inserted into the holes 160 fed to plate C and passed through the vane nozzles of plates B and A to produce the wings of the fiber. Wing and core polymers first contacted the top of the distributor plate B, which is 0.833 cm (0.328 inch) above the front of the spinneret plate A, from which the 0.203 cm (0.080 inch) diameter fiber was extruded. Plate C was aligned with plate B, leaving the six holes 160 the plate C is above the center lines of the vane nozzles 150 from plate B. The plates were aligned so that into the hole 162 The core C introduced elastomeric core polymer passed through the center.

The The invention will be apparent from the following non-limiting Examples illustrated. There were the following test methods applied.

TEST METHODS

Of the Term "Abkochstreckung" is interchangeable with the following terms used in the art: "percent stretch", "recoverable stretch", "recoverable shrinkage" and "curling potential". The term "unrecoverable shrinkage" becomes interchangeable used with the following terms: "percent shrinkage", "apparent shrinkage" and "absolute shrinkage".

The stretch properties (cooldown, boil-off shrinkage, and recovery after boiling) of the fibers prepared in Examples 1A, B, C, and D were determined as follows. A 5,000 denier (5,550 dtex) strand was wound onto a 54 inch (54 cm) package. Both sides of the looped strand were included in denier totals. The initial strand lengths weighing 2g (CB length) and weighing 1000g (0.2g / denier) (LB length) were measured. The strand was placed in water at 95 ° C ("boil off") for 30 minutes and the initial lengths (after boiling) measured at 2 g (CA _initial length) and 1000 g (LA _initial length). G by the measurement with the weight of 1000 were more lengths with a 2 gram weight after 30 seconds (length CA _30s) and after 2 hours (length CA _2h) measured. The boil off shrinkage was calculated as 100X (LB-LA) / LB. The percent cook-off stretch was calculated as 100x (LA-CA @ 30 s) / CA @ 30 s. Recovery after boiling was calculated to be 100x (LA-CA _2h ) / (LA-CA _initial ).

Of the Test for relieving force at 20% and 35% of available stretch was like follows. It became a biconstituent fiber strand with a denier total of 5,000 (5,550 dtex) after boiling. Both sides of the strand stranded were included in denier totals. It became an Instron tensile testing machine (Canton, MA) at 21 ° C and 65% relative humidity used. The strand became into the clamping jaws of the testing machine between which there was a gap of 76 mm (3 inches). The testing machine was characterized by three stretching and relaxation cycles (load-unloading) driven, each load cycle a maximum of a force of 0.2 g per denier had (500 gf) and then the force at the third Relief cycle was determined. The effective denier number (i.e. the actual linear density at the test stretch) was determined for 20% and 35% available Extension in the third unloading cycle. "20% and 35% available stretch" means that the Strand by 20% and 35% by the force of 0.2 g per denier (500 gf) was relaxed at the third cycle. The relief force at 20% and 35% available stretch was recorded in milligrams per effective denier number (mg / denier).

The delamination of the wings from the core of a fiber was determined by first winding a 5,000 denier (5,550 dtex) strand on a 1.25 m spool (the strand size included both sides of the resulting loop). The strand was exposed to 102 ° C steam in an autoclave for 30 minutes. A length of 20 cm of a single fiber was selected from the strand and folded in half. The open end of the resulting loop was wrapped at the bottom and the wrapped loop hung vertically on a hook. A 1 gram per denier (50 grams for a 25 denier loop) was attached to the lower (wrapped) end of the loop. The weight was raised to the point where the loop sagged, then slowly lowered to stretch the loop and full weight applied. After 10 such cycles, the loop was examined for delamination under magnification and evaluated. Three samples were evaluated as follows:
0 = no wing / core delamination visible along the fiber
1 = slight delamination visible at one or more of the circulation nodes
2 = a delamination visible where the fiber was scrubbed against the hook from which it hung
3 = a slight delamination (in small loops and only in a few places)
4 = small loops show delamination along the entire fiber
5 = strong delamination (big loops all along the fiber)

The Results from the three samples were averaged.

R ₁ and R ₂ were measured by superimposing two circles on a photomicrograph of a cross-section of the fiber such that one circle (R ₁ ) circumscribes approximately the outermost polymer core and the other circle (R ₂ ) inscribes approximately the innermost circumference of the wing polymer ,

EXAMPLES

EXAMPLE 1

each Fiber had a linear density of 26 denier (28.6 dtex) and was largely radially symmetrical. The properties after boiling are summarized in Table 1.

EXAMPLE 1A (COMPARISON)

Using the in 7 illustrated apparatus and the assembly of the spinneret stacking plate in 8th Biconstituent fibers spun. First, a polymer which produced the cores of the fibers was included 20 for spinning the filter plate 30 in 7 introduced. The core polymer was a polyetheresteramide (PEBAX ^™ 3533SN, ex Atofina) and was volumetrically metered to produce a core that constituted 51% by weight of each fiber. at 22 in 7 A molten nylon copolymer was introduced to filter plate 30 to spin. The nylon copolymer which produced the six wings was poly (hexamethylene-co-2-methylpentamethylene adipamide) wherein the hexamethylene moiety was present with 80 mole% diamine derived parts. There was no significant penetration of the wing through the core or vice versa (R ₁ / R ₂ = 1.09).

The pre-coalescent spinnerette assembly consisted of stacked plates labeled A through E and is shown in side view in FIG 8th shown. The nozzles were cut through 0.015 inch (0.038 cm) thick stainless steel spinneret plate A as six symmetrically centered squares at 60 ° about a center of symmetry using the method described in US Pat. No. 5,168,143. As in 8A Illustrated was each wing nozzle 140 rectilinear with a long axis centerline passing through the center of symmetry and 0.244 cm (0.049 inch) in length from the tip to the perimeter of a central circular spinneret bore 142 (Diameter 0.030 cm (0.012 inches)) having the radius origin which was the same as that of the center of symmetry. There was no sink at the entrance to the spinneret capillary. The wing length 144 from the tip to 0.027 cm (0.027 inches) had a width of 0.0107 cm (0.0042 inches); the remaining length 146 0.052 inches (0.056 cm) was 0.0032 inches (0.0081 cm) wide. The tip of each wing was cut to half the width of the top rounded. The distributor plate B ( 8B ) with a thickness of 0.015 inches was with the spinneret plate A (FIG. 8A ) were aligned so that their distributor nozzles were congruent with the spinnerets in the spinneret plate A. The six wing nozzles 150 Plate B was 0.399 cm (0.094 inches) in length and 0.051 cm (0.020 inches) wide, and its wing tips were rounded to a radius of half its width. As in 8B Illustrated was each of the six vane nozzles 150 The distributor plate B was conically shaped into a rounded (0.015 cm (0.006 inch) diameter) open end and then ran as a slot 154 0.013 cm (0.013 inch) long and 0.0046 cm (0.0018 inch) in length to the center bore 156 , The central hole 156 in this plate was 0.032 cm (0.0125 inches) in diameter. A slot 154 connected the central bore to the end of each wing distribution nozzle. The metering plate C had a thickness of 0.025 cm (0.010 inches) (see 8C ). Each of the metering orifices was centered above a centerline of the long axis of the blade or above the center of symmetry in the distributor plate B. The central dosing opening 162 and one hole per wing 160 had a diameter of 0.025 cm (0.010 inches); the centers of the holes 160 were from the middle of the hole 162 0.305 cm (0.120 inch) away. The central metering orifice was filled with filtered, molten elastomeric polymer from a conventional melt pool plate D (see 7 ) and created the core element inside the terminating fiber. The outer six metering holes 160 of the plate C were charged with a non-elastomeric polymer from the melt pool plate D to become the polymer wings. Large holes (typically 0.4763 cm (0.1875 inch) diameter) in spinneret support plate E (see again 8th ) were aligned with the spinnerets in the spinneret plate A and were expanded at an angle of 45 °. The spinneret plate A, distributor plate B and metering plate C were sandwiched by the melt pool plate D and the spinneret support plate E as shown in FIG 8th locked in. Typically, the plate E had a thickness of 0.4 to 1.3 cm (0.2 to 0.5 inches) and the plate D had a thickness of 0.05 to 0.08 cm (0.02 to 0, 03 inch).

In the spinneret plate A there was no sink and the united thickness of plates A, B and C was only about 0.102 cm (0.040 inches). The wing and For the first time, core polymers were directly above each other Distributor plate B in contact so that they together for about 0.076 cm (0.038 cm distribution plate + 0.038 cm spinneret plate) coalesced before the fiber was formed.

It was freshly spun fiber 40 (please refer 7 ) until it solidifies with the help of flowing air 50 cooled and 5 wt .-% (based on the fiber weight) of a finish of silicone oil and a metal stearate at 60 applied. The fiber was stretched to the draw zone between the feed roll 80 and the stretch roller 90 moved forward and added several revolutions around each roll. The speed of the stretch roller 90 was four times (4 times) the feed roller 80 (the latter at 350 meters per minute) at a draw ratio of 4.0. Then, the filament was 6 pounds per square inch (0.87 kPa) in a chamber 110 treated with steam and the rewinder 130 at a speed of 20% less than that of the stretch roller pair 90 so that the fiber was partially relaxed (20%) to reduce shrinkage in the finished fiber. The stretched and partially relaxed fiber 120 was on the rewinder 130 wound and had a linear density of 26 denier (29 dtex).

EXAMPLE 1B (COMPARISON)

A six-blade fiber of poly (hexamethylene-co-2-methylpentamethylene adipamide) in which the hexamethylene part was 80 mol% and a core of PEBAX ^™ 3533SN was spun substantially as in Example 1A except that that 5 wt .-% based on the total weight of the wing polymer nylon 12 [poly (dodecane), "N12"] (Rilsan® AMNO ^® from Atofina) was added to the wing polymer to promote the wing / core cohesion. The wing / core ratio was 48/52 and R ₁ / R ₂ was 1.05.

Example 1C (Invention)

A six-blade fiber of poly (hexamethylene-co-2-methylpentamethylene adipamide) (20 mole% of 2-methylpentamethylene portions based on the diamine derived portions) and a PEBAX ^™ 3533SN core (flexural modulus 19.300 kPa (2.800 psi)) is largely made as in Example 1A except that the metering plate C has a different set of holes 164 (as shown in 8C Each had a diameter of 0.013 cm (0.005 inches) and a distance from the center of symmetry of the holes of 0.141 inches (0.04175 inches). These additional holes and the central hole were fed with molten polymer from a common melt pool to create the core and the core elements projecting into the wings. As a result, there was a wing penetration through the core polymer (R ₁ / R ₂ = 1.6, estimated from the ratio of similarly prepared fibers) to allow the wings to better adhere to the core. The fiber cross section was essentially as in 2 illustrated.

EXAMPLE 1D (INVENTIVE)

There was a fiber spun substantially as in Example 1C, but with 5 wt .-% Nylon 12 [poly (dodecane)] (Rilsan ^® AMNO) as a cohesion additive in the wings. The fibers had a wing portion penetration through the core polymer (R ₁ / R ₂ = 1.5) to better adhere the wings to the core. The fiber cross section was essentially as in 2 shown.

TABLE 1

These data show that the fibers were very good for hosiery and apparel applications. The superior behavior of the fibers with wings attached to the core is shown by the delamination data. The fibers of the invention may have a delamination score of less than about 1.0. In addition, the data show that the use of an additive for adhesion, such as N12, is advantageous in the wing polymer.

EXAMPLE 2A

A three-filament biconstituent yarn of the present invention was spun substantially as in Example 1D with the following differences. Each panel had five holes for the wing polymer symmetrically spaced 72 ° so that each fiber had five wings. The polymer in the five wings consisted of 95% by weight of polycaprolactam (3.14 IV, manufactured conventionally and obtained from DuPont do Brasil) with 5% by weight of nylon 12 as an additive. The wing / core ratio varied as shown in Table 2A. The finish was a mixture of coconut fat, quaternary amine, water and nonionic surfactant applied at 2% by weight of the fiber. The feed roll speed was 420 meters per minute and the drawn fiber was subjected to a relaxation of 15% before being wound up. The cross section was essentially the one in 2 shown; R ₁ / R ₂ was about 1.4 and the drawn fiber was 23 denier (25 dtex).

The percent Abkochstreckung for Yarns with varying wings / core ratio became as determined above.

TABLE 2A

The Results in Table 2A show that a higher cook-off stretch was obtained when the wing / core weight ratio becomes smaller is about 50/50 in the fiber of the example, which is preferred if no accompanying fiber is used with the fiber according to the invention. often are even lower wing / core ratios preferably (for example, about 20/80 to about 40/60) when with the fiber according to the invention to increase the power of restoration in the combination yarn accompanying fibers be used.

EXAMPLE 2B

The durability of hosiery, show through, and stretch were evaluated as a function of the total wing density (denier, decitex). The fibers of Example 2A were knit into hosiery fabrics. No other fiber was used. The total fiber denier and wing / core volume ratio were varied. A panel of examiners subjectively evaluated the hosiery on a) durability based on longevity, b) aesthetic translucent appearance (in reference to a reference standard for hosiery fabric similarly composed of 10 denier LYCRA ^™ spandex spun at 7 denier (8 dtex) Nylon 6-6 was knitted from 5 fibers), and c) percent cook-off stretch. The shelf life was considered acceptable if it exceeded 7 days; the translucent appearance was considered acceptable if it was the same as the reference standard, and the percent stretch was considered acceptable if it was between 40 and 120% and bulking and "sagging" of the sock knit were avoided. The numbers marked with (*) and the bold numbers in Table 2B show the decitex number and the vane / core ratios, which are qualitatively preferable based on the three evaluation ranges. The numbers in the table are summed on decitex of the wings for each fiber.

TABLE 2B

If the decitex total over increased about 33 out was reduced, the translucent appearance of hosiery fabric was reduced. When the total decitex number decreases below about 22 was and the sum of the wing decitex number fell below about 11, durability began to suffer. If the wing-core weight ratios to about about 50/50, the percent elongation began to fall (as previously shown in Example 2A).

When Result of this test was concluded that a preferred Biconstituentenfaser the invention has a total linear density in Range of about 22 to 33 dtex, a summed decitex number for the wing section of at least about 11 and a wing / core weight ratio between 35/65 and 50/50 can have.

EXAMPLE 3A

A biconstituent fiber of the invention was spun substantially as described in Example 2A, except that 4% by weight (by weight of the fiber) of a polysiloxane-based finish (as described in U.S. Patent 4,999,120 ) was applied instead of the finish of Example 2A, the fiber was relaxed 20% before being wound up, and the steam used in the relaxation step had 20.7 kPa (3 psi). The wing / core / outstanding core weight ratio was 38/53/9 and R ₁ / R ₂ was about 1.4. 5 Figure 4 is a cross-sectional photomicrograph of the fiber having 32 denier (36 dtex stretched) and 108% cooldown, 24% cooldown and 92% recovery after boiling.

EXAMPLE 3B

Out The fibers of Example 3A were on a commercial machine Stocking crocheted, typically for each run mechanically on double wound spandex leg constructions was set. The machine was a MATEC HSE 4.5, with about 700 rpm in the thigh area and 800 rpm in the heel area worked and set to size F. was. It was worked in about 2 min a leg blanks. The legs were fed to the machine in the normal way for hard yarns and no electronic tensioner used. The tights blanks were aged by tumble steaming at atmospheric pressure for 30 minutes. The clothes were subsequently using an automatic plant of a stocking autoclave, as it is standard in the industry, fixed at 102 ° for four seconds from drying at 95 ° C for 30 Seconds. The piece length for the stocking shaping was as small as possible selected while the piece kept in a wrinkle-free state. The pieces were under Use of standard acid dyes at 98 ° C for 45 dyed min and postfixed using the same shape size and condition.

The resulting sheet had an unexpectedly high thermal conductivity of 3.38 × 10 ^-4 watts / cm.-C.

EXAMPLE 4

Using an apparatus as in 7 have been illustrated, according to the invention were three filament biconstituent yarns made with polyester wings and polyetherester cores. The core polymer fiber 4A was HYTREL ^® 3078, a polyether-ester elastomer (a registered trademark of EI du Pont de Nemours and Company; flexural modulus of 27,600 kPa (4,000 psi)). The core polymer for the fibers of Examples 4B and 4C was a polyetherester elastomer having a soft segment of poly (tetramethylene-co-2-methyltetramethylene ether) glycol and a hard segment of butylene terephthalate (4G-T), prepared substantially as described in U.S. Pat U.S. Patent 4,906,721. The amount of 3-methyltetrahydrofuran incorporated into the copolyether glycol was 9 mole%, the number average molecular weight was 2750, and the molar ratio of 4G-T to copolyether glycol was 4, 6: 1. In Table 4, this polymer is referred to as "2MePO4G: 4G-T". The wing polymer in the fibers of Examples 4A and 4B was poly (butylene terephthalate) (4G-T, Crastin® ^® 6129, a registered trademark of EI du Pont de Nemours and Company; flexural modulus 2,400,000 kPa (350,000 psi)) and fiber 4C was poly (trimethylene terephthalate) (3G-T). The 3G-T was prepared (a registered trademark of EI du Pont de Nemours and Company) at 60 ppm based on the polymer of 1,3-propanediol and dimethylterephthalate in a two-vessel process using tetraisopropyl titanate as a catalyst, Tyzor ^® TPT. Molten DMT and catalyst were added to the 3G at 185 ° C in a transesterification kettle, and the temperature was increased to 210 ° C during which time methanol was driven off. The resulting intermediate was transferred to a polycondensation kettle where the pressure was reduced to 10.2 kg / cm ² (1 millibar) and the temperature increased to 255 ° C. Once the desired melt viscosity was achieved, the pressure was increased and the polymer extruded, cooled and cut into pellets. The pellets were polymerized in the solid phase to an intrinsic viscosity of 1.04 dl / g in a tumble dryer operated at 212 ° C. The spinneret stack and spinning conditions for the respective fibers of this example were essentially the same as in Example 2A, except that there was no polymer additive in the wings, the wings accounted for 40% by weight of the total fiber, 4% by weight ( based on the fiber) of the finish described in Example 3A, and the fiber was relaxed by 20% before being wound with steam at 20,7 kPa (3 pounds per square inch). The fibers had the properties given in Table 4.

TABLE 4

The Delamination rating for the fiber 4B was 0.0. The translucent appearance of sock blanks, which were knitted from fibers of Examples 4A, 4B and 4C was after steam fixing, dyeing and finish uniformly and have a good stretch and recovery.

EXAMPLE 5A

A biconstituent fiber of the present invention was blended with the polymers and the finish of Example 1D using the apparatus of 7 and the spinneret stack and spinning conditions of Example 3A, except that 13% by weight of the finish was used based on the weight of the fiber. The wing and core polymers first came into contact with each other about 0.076 cm before spinning into fibers.

The core penetrated the wing such that the wing / core / core outstanding weight ratio was 39/51/10 (R ₁ / R _{2 was} about 1.5). The fiber had a linear density of 20 denier (22 dtex), a percent coker draw of 100%, a boil off shrink of 23%, and a post-cook recovery of 94%.

EXAMPLE 5B

Four ends of the fiber of Example 5A were entangled with an air jet to form a biconstituent yarn. The fabric was placed on a SULZER RUTI 5100 (air jet loom) in a 3/1 construction using air-entangled biconstituent yarn as weft at 38 yarns per centimeter (96 wefts / inch) and 44 denier (48 dtex / 34 filaments) TACTEL ^™ (a registered trademark of the EI du Pont de Nemours and Company) type 6342 nylon was woven as the warp at 48 ends per centimeter (121 per inch) .The fabric was steamed and relaxed at 115 ° C, MCF jet scrubbing at 70 ° C; MCF jet staining was completed at 100 ° C for 60 minutes using standard acid dyes for nylon and heat set at 190 ° C for 30 seconds.These fabrics were swell-free and smooth with no creases on air-drying and exhibited good Stretch and recovery and excellent hard-fiber grip and aesthetic appearance The relaxed finished fabric had the following characteristics:

One Fabric of width 5 cm × 10 cm length let himself go hand by 40%, after which it recovered more than 95%.

EXAMPLE 6

This example illustrates the use of a full thickness spinnerette to make the fiber of the present invention. The same precoalescent spinneret stack was used as in Example 1C, except that carrier plate E was passed through a spinneret ( 11A 0.794 cm (0.3125 inch) thick with a spinneret capillary (0.038 cm (0.015 inch) in length) of the same pattern, size, axial repeat, and radial orientation as the nozzle of the spinneret plate A (FIG. 8A ) and exchanged with a 0.377 cm (0.1406 inch) diameter round sink. The wing and core polymer first contacted each other for about 0.87 cm (0.794 cm spinneret + 0.038 cm plate A + 0.038 cm plate B) prior to generation of the fiber. A 25 denier (28 dtex) biconstituent fiber was made having six wings of poly (hexamethylene-co-2-methylpentamethylene adipamide) wherein the hexamethylene part was present with 80 mole% of the diamine derived parts (conventionally made, relative viscosity 90) and a core of PEBAX 3533SN, polyetheresteramide prepared using the apparatus of 7 was spun at a draw ratio of 4 times and wound at 1400 m / min. The wing / core / outstanding core weight ratio was 45/48/7 and R ₁ / R ₂ was about 1.4. In the fiber spun in this manner, the core penetrated the wing, but without the often preferred reduced stretch section as found in Figs 3 is shown.

EXAMPLE 7

This example illustrates a three winged biconstituent fiber in which the wings penetrate the core and also illustrates the use of a thin spinneret stack to make the fiber. The wing polymer was poly (hexamethylene dodecanoamide) (intrinsic viscosity 1.18, Zytel ^® 158, a registered trademark of EI du Pont de Nemours and Company) and the core polymer was Pebax ^® 3533SA, polyetheresteramide. A ten-filament yarn of 70 denier (78 dtex) with a void-to-core volume ratio of 40/60 was spun at a spinneret temperature of 265 ° C. It was the general in 10 used, but the individual plates differed from those in the previous examples. In the 10A Stainless steel spinnerette plate A shown was 0.038 cm (0.015 inch) in thickness and had three straight-vane nozzles cut therethrough by the method of Example 1A 1 for every other width and arranged symmetrically at intervals of 120 ° about a center of symmetry; there was none Valley above the capillary nozzle. Every wing 140 was 0.102 cm (0.040 inches) long (length 144 plus length 146 in 10A ) from its tip to the circumference of a central round spinneret bore 142 with a diameter of 0.030 cm (0.012 inches), whose center coincided with the center of symmetry. Referring next to FIG 10B the distributor plate B is 0.025 cm (0.010 inch) thick coaxially aligned over the spinneret plate A so that every other vane nozzle 150 the distributor plate B with a wing 140 the spinneret plate A was aligned; every wing nozzle 150 the distributor plate B was 0.349 cm (0.1375 inches) long from its tip to the center of symmetry. The metering plate C ( 10C ) had a thickness of 0.010 inches and had holes 160 with a diameter of 0.064 in (0.025 inch), holes 162 with a diameter of 0.03 cm (0.015 inches) and the central bore 164 with a diameter of 0.025 cm (0.010 inches). Plate C was aligned with the distributor plate B so that in use the wing polymer would be melted using the melt pool plate D (see 10 ) to the holes 160 and core polymer to the holes 162 and 164 was supplied to the distributor plate C and distributed through the plate B to the plate A to produce a filament wherein the wings penetrated the core. There was no dip in the spinneret plate A and the combined thickness of plates A, B and C was only 0.089 cm (0.035 inch). The yarn was drawn 3.5 times at a speed of the draw roll of 1225 meters per minute and relaxed in a steam jet at atmospheric pressure at a windup speed of 1045 meters per minute. The yarn wrapped a spiral twist when steamed in a relaxed state and had a high elongation and recovery. A photomicrograph of the cross section of a fiber produced according to this example is in FIG 13 shown.

EXAMPLE 8

This Example illustrates the use of a spinneret plate with conventional thickness for the Production of the fiber according to the invention.

Example 1A was repeated with the following differences. No spinneret plate E was used (see 8th ). The spinneret plate A had a thickness of 0.794 cm (0.3125 inches) and each spinnerette had a 0.254 cm (0.100 inch) diameter sink and a 0.038 cm (0.015 inch) long capillary at the bottom of the sink. As in 11A is shown, each spinneret in the spinneret plate A had six straight nozzle orifices 170 each having a centerline along the long axis passing through a center of symmetry and a length of 0.089 cm (0.035 inches) from its tip to the perimeter of the central circular bore 172 would have. The length 174 0.015 cm (0.038 cm) from the tip of each blade to 0.038 cm (0.004 inch); the length 176 was 0.052 cm (0.020 inches) long and 0.007 cm (0.0028 inches) wide. The tip of each wing was cut to half the width of the top rounded. The distributor plate B (see 11B ) had a thickness of 0.015 inches and had six vane nozzles 150 , which were each centered over a corresponding sink in the spinneret plate A and were oriented so that each vane nozzle 150 in plate B was aligned with a wing nozzle 170 from plate A. Each wing nozzle 150 in plate B was 0.152 cm (0.060 inch) long and 0.051 cm (0.020 inch) wide and had a tip rounded to a radius of 0.025 cm (0.010 inch). A central hole 152 in plate B had a diameter of 0.254 cm (0.100 inches). The dosing plate C (see 11C ) was also 0.038 cm (0.015 inch) thick. In plate C had the holes 160 0.020 cm (0.008 inches) in diameter and was 0.254 cm (0.100 inches) from the center of a central bore 162 which was 0,203 cm (0.080 inch) in diameter. Plate C was aligned with plate B, leaving the six holes 160 from plate C above the centerlines of the vane nozzles 150 from plate B. The plates were aligned to the bore 162 elastomeric core polymer fed from plate C, flowed through the middle of plates B and A and formed the core of the fiber. It became non-elastomeric wing polymer holes 160 fed into plate C and flowed through the vane nozzles of plates B and A to produce the wings of the fiber. The wing and core polymers first contacted the top of the distributor plate B, which was 0.833 cm (0.328 inches) above the front of the spinneret plate A, from which the fiber is extruded.

The spinneret temperature was 247 ° C. A 14-filament yarn was spun, 5 wt.% Of a polyetherester-based finish substituted for the previously used finish, and the yarn relaxed by 15% (in terms of the stretched length of yarn) before being wound up. The drawn and partially relaxed yarn had a linear density of 75 denier (83 dtex) and R ₁ / R ₂ was 1.20. A microphotograph of the cross section of the fiber is in 6 shown.

Although the invention has been described in conjunction with the detailed description thereof, it is to be understood that the foregoing description is exemplary and exemplary in nature and intended to illustrate the invention and its preferred embodiments is.

Claims (20)

Stretchable synthetic polymer fiber including one axial core comprising a thermoplastic elastomeric polymer and a plurality of wings attached to the core and comprising a thermoplastic, non-elastomeric polymer, wherein at least one of the wing polymers or core polymers protrudes into the other polymer. The fiber of claim 1, wherein the core has an outer radius R ₁ and an inner radius R ₂ and R ₁ / R _{2 is} greater than 1.2. The fiber of claim 2 wherein R ₁ / R _{2 is} in the range of 1.3 to 2.0 and the weight ratio of non-elastomeric wing polymer to elastomeric core polymer is in the range of 10:90 to 70:30 and the coker draw is at least 20%. The fiber of claim 1, wherein the protruding polymer an opposite enlarged end portion includes and a reduced drawing portion attached to the end portion of the remainder of the protruding polymer adjacent to at least one to form a stretched section therein. The fiber of claim 1 wherein the wings are broad are of the same dimension and largely symmetrical about the axial Core are arranged. The fiber of claim 1, wherein said non-elastomeric Polymer selected is selected from the group consisting of polyamides, nonelastomeric polyolefins and polyesters, and wherein the elastomeric polymer is selected from the group consisting of thermoplastic polyurethanes, thermoplastic Polyester elastomers, thermoplastic polyolefins, thermoplastic Polyesteramide elastomers and thermoplastic polyetheresteramide elastomers. The fiber of claim 1, further comprising an additive, that the wing polymer added to improve the adhesion of the wings to the core, wherein the fiber has a delamination rating below 2.5. A fiber according to claim 7, wherein the non-elastomeric Polymer selected is selected from the group consisting of (a) poly (hexamethylene adipamide) and copolymers thereof with 2-methylpentamethylenediamine and (b) polycaprolactam, and wherein the elastomeric polymer is polyetheresteramide is. Clothing, which comprises the fiber according to claim 1. Stretchable synthetic polymer fiber including one axial core comprising a thermoplastic elastomeric polymer and a plurality of wings, which comprise at least one thermoplastic, non-elastomeric polymer and protrude into the core, wherein the fiber is a delamination rating of less than 1 and has a cooldown of at least 20%. Process for melt spinning for spinning polymers Continuous fibers, comprising: passing a melt that is a non-elastomeric Polymer has, through a spinneret, stretchable synthetic To produce polymer fibers that over have a plurality of wings attached to the core, wherein at least one the wing polymers or core polymers protrude into the other polymer; Scare off the fibers after exiting the spinneret to cool the fibers; and Picking up the fibers. The method of claim 11 comprising after quenching An additional Step of heat relaxation of the fiber, so that this shows at least 20% Abkochstreckung. The method of claim 12, wherein the step the heat relaxation with a heating medium of dry air, hot water or steam at overpressure is carried out at a temperature in the range of 80 ° to 120 ° C, if it is at The heating medium is the dry air, at 75 ° to 100 ° C, if it is in the heating medium to the hot Water acts, and at 101 ° to 115 ° C is carried out, if the heating medium is the vapor at overpressure is. A method according to claim 11, comprising, after quenching, an additional step of Rela xierens the fiber based on the fiber length before relaxation in the range of 1 to 35%. Spinneret pack for the Melt extrusion of a first and second synthetic polymer, to produce fiber, comprising: a dosing plate, the one contains first row of holes, which are designed to receive a first polymer melt, and a second series of bores containing a second polymer melt are designed; a spinneret plate, which is aligned and in contact with the distributor plate, the spinneret plate capillaries passing therethrough and having a length of Reduction of less than 60% of the length of the spinneret capillary Has; and a spinneret carrier plate with holes larger than the capillaries are and are aligned and in contact with the spinneret plate; wherein the plates are aligned so that the first and second polymer feeds to the dosing plate through the distributor plate, the spinneret plate and the first spinneret carrier plate pass through to produce a fiber. Spinneret pack according to claim 15, wherein the length the lowering of the spinneret plate less than 40% of the length the spinneret capillary. Spinneret pack according to claim 15, wherein the bores of the spinneret support plate are widened. Spinneret pack according to claim 15, wherein the bores and capillaries with the aid of a Lasers have been cut. Spinneret pack according to claim 15, further including a distributor plate. Spinneret pack according to claim 19, wherein the maximum combined thickness of the distributor plate and the spinneret plate smaller than 0.3 cm.