EP0041820B1 - Process for production of self-crimping polyester yarn - Google Patents

Process for production of self-crimping polyester yarn Download PDF

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Publication number
EP0041820B1
EP0041820B1 EP81302448A EP81302448A EP0041820B1 EP 0041820 B1 EP0041820 B1 EP 0041820B1 EP 81302448 A EP81302448 A EP 81302448A EP 81302448 A EP81302448 A EP 81302448A EP 0041820 B1 EP0041820 B1 EP 0041820B1
Authority
EP
European Patent Office
Prior art keywords
stream
filament
streams
yarn
shrinkage
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
EP81302448A
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German (de)
English (en)
French (fr)
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EP0041820A1 (en
Inventor
William Bruce Black
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Celanese Corp
Original Assignee
Celanese Corp
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Filing date
Publication date
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Application filed by Celanese Corp filed Critical Celanese Corp
Publication of EP0041820A1 publication Critical patent/EP0041820A1/en
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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/32—Side-by-side structure; Spinnerette packs therefor

Definitions

  • the invention relates to the art of producing a polyester filament with high and low shrinkage regions along its length, such that a yarn including a number of these filaments spontaneously develops crimp when relaxed.
  • Japanese patent publication number 42-22339 discloses extruding at low spinning speeds various polymers through combined orifices, each combined orifice including a large diameter central capillary and two or more small diameter satellite capillaries, the lengths of the various capillaries being unspecified.
  • the spun yarns are then drawn under unspecified conditions to yield drawn filaments having cross-sectional shapes which vary continuously and cyclically along the length of each filament.
  • yarn drawn at normal draw ratios and relaxed while being heated exhibited a small amount of crimp, but not to a useful degree.
  • the draw ratio is reduced experimentally to an unusual ratio, the crimp level in the relaxed yarn increases to a marginally useful level.
  • fabrics made from either of these yarns have a harsh hand.
  • Japanese patent publication 42-415/1979 discloses spinning two polyester streams through a spinneret with converging capillaries wherein the streams intersect in midair (below the spinneret) to form a combined stream.
  • One of the streams has a higher speed than the other, and an oscillation occurs in the molten stream such that the combined stream, when quenched into a filament, exhibits thick and thin regions along its length.
  • a highly useful degree of crimp is obtained, and fabrics made from the yarn have an unusual soft, luxuriant hand.
  • reproducibly manufacturing the spinnerets with converging capillaries is quite difficult.
  • Polymers as used herein means those polymers of fiber-forming molecular weight composed of at least 85% by weight of an ester or esters of one or more dihydric alcohols and terephthalic acid.
  • the shrinkage profile (and 5 cm shrinkages) are determined by separating from the yarn bundle a single filament 2.5 meters long, care being taken not to stretch the filament.
  • the filament is then cut into consecutive serially numbered 5 cm samples or segments, which are then placed while unrestrained in boiling water for 30 seconds.
  • the length of each segment is then measured, and its shrinkage as a percentage of the original 5 cm length is calculated. For example, if a segment has a length of 4.2 cm after the treatment with boiling water, its shrinkage would be 16%.
  • the percentage shrinkages when plotted in serial number order provides a profile of shrinkage variation along the filament.
  • yarn properties are determined in the following manner.
  • the yarn is conditioned for at least one hour in an atmosphere of 22°C and 65% relative humidity. If the yarn is wound on a package, at least 100 meters are stripped off and discarded.
  • the yarn is skeined under a tension of 0.035 grams per denier on a Suter denier reel or equivalent device having a perimeter of 1.125 meters per revolution to a total skein denier of approximately (but not to exceed) 8000, and the ends are tied.
  • 23 revolutions would give a skein denier of 8160. In this instance, 23 revolutions would be used.
  • the skein is removed from the denier reel and suspended from a 1.27 cm diameter round bar.
  • a 1000 gram weight is gently lowered until the weight is suspended from the bottom of the skein by a bent no. 1 paper clip or equivalent piece of wire weighing less than 1 gram.
  • the skein length is measured to the nearest 0.1 cm, the measured length being recorded as L n .
  • the 1000 gm weight is then replaced with a 20 gm weight, and the rod with the suspended skein and 20 gm weight are placed in a 120°C oven for 5 minutes.
  • the rod with the suspended skein and 20 gm weight is removed from the oven and conditioned for 1 minute at 22°C and 65% relative humidity, after which the skein length L 1 is determined to the nearest 0.1 cm.
  • the 20 gm weight is then carefully replaced by the 1000 gm weight.
  • the skein length L 2 is determined to the nearest 0.1 cm.
  • the percentage crimp is then calculated as while the percentage yarn shrinkage is calculated as
  • the filaments in a skein will be so highly entangled that, when the 20 gm weight is replaced by the 1000 gm weight, the length L 2 is about the same as L 1 , even though the skein obviously has not had its crimp pulled out. In such a case, the 1000 gm weight may be gently jarred until the weight falls and removes the crimp.
  • a process for forming a self-crimping yarn comprising melt spinning a plurality of polyester filaments having shrinkage peaks and valleys out of phase from filament to filament, wherein one or more of the plurality of filaments is generated by the steps comprising extruding from substantially parallel spinneret capillaries at least first and second molten streams of polyester polymer of fiber-forming molecular weight, the first stream having a greater velocity than the second stream and being spaced laterally from the second stream a small distance selected such that the first and second streams unite into a combined stream having thick and thin regional attenuating and quenching the combined stream into the one filament; and withdrawing the one filament from the combined stream at a spinning speed of at least 1500 metres per minute, the spinning speed and the velocities and lateral spacing upon extrusion of the first and second streams being selected such that the shrinkage peaks and valleys along the one filament are substantially regularly spaced.
  • the one filament has an average fully drawn denier less than 6.
  • the first stream is larger than the second stream.
  • the first stream has a velocity between 2 and 7 times as fast as the second stream.
  • the spinning speed and the velocities and lateral spacing upon extrusion of the first and second streams are selected such that the one filament has per 5 meters along its length an average of at least two regions possessing shrinkage peaks having at least two consecutive 5 cm shrinkages above 40%, and regions possessing shrinkage valleys between the peaks, the valleys having at least two consecutive 5 cm shrinkages below 20%.
  • the spinning speed and the velocities and lateral spacing upon extrusion of the first and second sub-streams are selected such that the yarn has a crimp-to-shrinkage ratio above 0.25.
  • the spinning speed and the velocities and lateral spacing upon extrusion of the first and second streams are selected such that the yarn has a crimp of at least 2.5%.
  • the yarn has a crimp of at least 5%.
  • polyester polymer is melt spun through substantially parallel capillaries 20 and 22 in spinneret 24 to provide at least two molten sub-streams, one of which has a higher velocity than the other.
  • the capillaries are spaced laterally a small distance selected such that the sub-streams unite below the spinneret into a combined stream having thick and thin regions.
  • capillary 20 may have a diameter of 0.305 mm while satellite capillaries 22 have diameters of 0.203 mm the centers of capillaries 22 being 0.356 mm from the center of and located on opposite sides of capillary 20, all capillaries being 0.305 mm in length.
  • Capillary 20 and its associated satellite capillaries 22 cooperate as a combined orifice for spinning a single filament, schematically shown in Figure 2.
  • a plurality of combined orifices will be provided in a single spinneret so that the resulting multifilament yarn comprises more than one of the filaments according to the invention.
  • FIG. 2 illustrates qualitatively the resulting action of the molten sub-streams immediately below the spinneret specifically described above. Since all the capillaries in this instance are the same length, the sub-stream issuing from capillary 20 has a higher velocity upon extrusion than the sub-streams issuing from capillaries 22. The center sub-stream accordingly alternately strikes and bonds to one of the outer sub-streams, then buckles and strikes and bonds to the other of the outer sub-streams. The combined stream thus formed is attenuated and the various sub-streams unites side-by-side to form a stream having thick and thin regions along its length. This stream is quenched as it is accelerated to the spinning speed, i.e., the speed at which the filament travels immediately after solidification. The resulting filament has properties uniquely determined by spinning speed.
  • a spinneret having 34 combined orifices is provided, each combined orifice being constituted by a central capillary having a diameter of 0.300 mm and three satellite capillaries having diameters of 0.200 mm.
  • the satellite capillaries are equally spaced apart around the central capillary with their centers 0.400 mm from the center of the central capillary, and all capillaries have a length of 0.305 mm.
  • Polyester polymer of normal molecular weight for apparel yarns is spun through the spinneret at a melt temperature of 300°C, at a rate of 73.5 grams per minute.
  • the combined streams are conventionally quenched by transversely directed air into filaments at a spinning speed of 400 meters per minute and wound on a package.
  • the spun yarn is then conventionally drawn over a hot shoe heated to 90°C at a draw ratio of 4.0 to yield a drawn yarn having a denier of 416, 33% elongation-to-break, tenacity of 2.7 grams per denier, shrinkage of 13.4% and crimp of 1.2%.
  • the denier per filament is about 12, and fabric made from the yarn has poor cover and a harsh hand.
  • crimp is a desirable property while shrinkage is undesirable.
  • the crimp-to-shrinkage ratio is thus a measure of the general desirability of the yarn.
  • the low level of crimp, and the low value of the crimp-to-shrinkage ratio makes the yarn far less valuable than yarns made according to the present invention.
  • the shrinkage profile along a filament from the drawn yarn has the random character generally depicted in Figure 3. While successive sample numbers 42 and 43 in Figure 3 have shrinkages above 40%, this is not common in yarns spun at the low speeds of this example.
  • the spun yarn in Example 1 is similarly drawn at a draw ratio of 3.2 to produce a drawn yarn having a denier of 515, elongation of 42%, tenacity of 1.6 grams per denier, shrinkage of 16.1 %, and a crimp of 3.0%.
  • the denier per filament is about 15, and fabric made from the yarn also has poor cover and a harsh hand, as in Example 1. While the crimp level is marginally useful, the undesirably low crimp-to-shrinkage ratio makes the yarn undesirable for many end uses.
  • the shrinkage profile is again similar to Figure 3.
  • Example 1 is repeated except that the spinneret is replaced with the preferred embodiment of the Figure 1 spinneret there being 34 combined orifices.
  • the spun yarn is hot-drawn at a draw ratio of 2.80 to yield a drawn denier of 565, an elongation of 102%, tenacity of 1.85, shrinkage of 22%, and a crimp of 1.8%.
  • Figure 3 is an actual shrinkage profile of a filament produced according to this example. Fabric made from this yarn has very poor cover and a quite harsh hand.
  • Polyester polymer is melt spun at 300°C from the above preferred embodiment of the Figure 1 spinneret at a spinning speed of 3800 ypm (about 3420 meters per minute), the polymer rate being selected such that the resulting yarn has an average denier per filament (dpf) of 4.1.
  • the shrinkage profile for a filament from this yarn is illustrated in Figure 4.
  • the Figure 4 filament has a pattern of quite regularly recurring broad shrinkage peaks alternating with broad shrinkage valleys.
  • the yarn has a shrinkage of 32.9% and a crimp of 15.5% for a crimp-to-shrinkage ratio of 0.47.
  • the yarn is particularly suited for being draw- textured using a friction aggregate, downstream of the primary heater, for applying false twist, the draw ratio and aggregate speed being selected such that the filaments are broken in or after the aggregate to yield a spun-like yarn with broken filaments protruding from the yarn.
  • the regularity of recurrence of the high and low shrinkage regions permits better control of the number of broken filaments per meter of yarn by selection of the draw-texturing process conditions.
  • the breadth of the shrinkage peaks and valleys also contribute in this regard. By breadth is meant that at least two consecutive 5 cm shrinkages along an individual filament are above 40%, in the case of a shrinkage peak, or are below 20% in the case of a shrinkage valley.
  • Example 4 is repeated except that the spinning speed is increased to 5000 yards per minute (about 4500 meters per minute), and the polymer throughput is adjusted to provide an average of 3.2 denier per filament in the resulting yarn.
  • the yarn has a crimp of 4.4% and a shrinkage of 9.7%, to give a crimp-to-shrinkage ratio of 0.45.
  • Figures 5 and 6 are shrinkage profiles of two filaments from the same yarn, and illustrate the substantial regularity of occurrence of the shrinkage peaks and valleys. These figures also illustrate that the shrinkage peaks and valleys are out of phase from filament to filament, and indeed have somewhat different repetition rates. Since the yarn was spun at high speed, it is sufficiently highly oriented to be capable of direct use in fabrics, giving an unusually soft hand and excellent cover, as compared to a conventionally textured yarn of equal number of filaments and equal denier per filament.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Artificial Filaments (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Multicomponent Fibers (AREA)
EP81302448A 1980-06-06 1981-06-02 Process for production of self-crimping polyester yarn Expired EP0041820B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US15713080A 1980-06-06 1980-06-06
US157130 1980-06-06

Publications (2)

Publication Number Publication Date
EP0041820A1 EP0041820A1 (en) 1981-12-16
EP0041820B1 true EP0041820B1 (en) 1984-07-04

Family

ID=22562436

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Application Number Title Priority Date Filing Date
EP81302448A Expired EP0041820B1 (en) 1980-06-06 1981-06-02 Process for production of self-crimping polyester yarn

Country Status (6)

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EP (1) EP0041820B1 (es)
JP (1) JPS5729608A (es)
KR (1) KR830006486A (es)
BR (1) BR8103541A (es)
DE (1) DE3164556D1 (es)
ES (1) ES8203993A1 (es)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4562029A (en) * 1980-06-06 1985-12-31 Celanese Corporation Self-crimping polyester yarn
US4720314A (en) * 1980-06-06 1988-01-19 Celanese Corporation Process for producing self-crimping polyester yarn
US4522773A (en) * 1983-02-24 1985-06-11 Celanese Corporation Process for producing self-crimping polyester yarn

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5442415A (en) * 1977-08-17 1979-04-04 Monsanto Co Production of selfcrimpable filament
IT1112372B (it) * 1978-04-04 1986-01-13 Monsanto Co Procedimento per produrre un filato auto-increspante
DE2963420D1 (en) * 1978-10-02 1982-09-16 Monsanto Co Self crimping yarn, process for producing a self crimping yarn, and textured yarn having a wool-like hand

Also Published As

Publication number Publication date
BR8103541A (pt) 1982-02-24
ES502834A0 (es) 1982-04-01
JPS5729608A (en) 1982-02-17
ES8203993A1 (es) 1982-04-01
DE3164556D1 (en) 1984-08-09
EP0041820A1 (en) 1981-12-16
KR830006486A (ko) 1983-09-24

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