EP0198400B1 - New synthetic water-dispersible fiber - Google Patents

New synthetic water-dispersible fiber Download PDF

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Publication number
EP0198400B1
EP0198400B1 EP86104815A EP86104815A EP0198400B1 EP 0198400 B1 EP0198400 B1 EP 0198400B1 EP 86104815 A EP86104815 A EP 86104815A EP 86104815 A EP86104815 A EP 86104815A EP 0198400 B1 EP0198400 B1 EP 0198400B1
Authority
EP
European Patent Office
Prior art keywords
fiber
water
filaments
polyester
section
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
EP86104815A
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German (de)
English (en)
French (fr)
Other versions
EP0198400A1 (en
Inventor
John Theodore Clark
Donald Albert Shiffler
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.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
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Filing date
Publication date
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Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Priority to AT86104815T priority Critical patent/ATE44786T1/de
Publication of EP0198400A1 publication Critical patent/EP0198400A1/en
Application granted granted Critical
Publication of EP0198400B1 publication Critical patent/EP0198400B1/en
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Classifications

    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D21H13/20—Organic non-cellulose fibres from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H13/24—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
    • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
    • 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
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/507—Polyesters
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/16—Synthetic fibres, other than mineral fibres
    • D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M2101/32—Polyesters

Definitions

  • This invention concerns new synthetic polymeric water-dispersible fiber, particularly of poly(ethylene terephthalate), and its preparation.
  • water-dispersible synthetic fiber especially of polyester fiber.
  • Such water-dispersible fiber is used in various non-woven applications, including paper-making and wet-laid non-woven fabrics, sometimes as part of a blend, often with large amounts of wood pulp, or fiberglass, but also in applications requiring only polyester fiber, i.e., unblended with other fiber.
  • This use, and the requirements therefor are entirely different from previous more conventional use as tow or staple fiber for conversion into textile yarns for eventual use in woven or knitted fabrics, because of the need to disperse this fiber in water instead of to convert the fiber into yarns, e.g., by processes such as carding, e.g. in the cotton system. It is this requirement for water-dispersibility that distinguishes the field of the invention from previous, more conventional polyester staple fiber.
  • water-dispersible polyester fiber is of poly(ethylene terephthalate), and is prepared in essentially the same general way as conventional textile polyester staple fiber, except that most water-dispersible polyester fiber is not crimped, whereas any polyester staple fiber for use in textile yarns is generally crimped while in the form of tow, before conversion into staple fiber.
  • water-dispersible polyester fiber has generally been prepared by melt-spinning the polyester into filaments, combining the filaments to form a tow, drawing, applying a suitable coating to impart water-dispersible properties, generally in the same way as a finish is applied to a tow of conventional textile filaments, and then, generally without any crimping (or with imparting only some mild wavy undulations in some cases to provide extra bulk and a three-dimensional matrix), converting the tow into staple.
  • Some prior polyester staple fiber has been prepared in uncrimped form, e.g. for use as flock in pile fabrics, but for such use, water-dispersibility has not been required.
  • Polyester fibers are naturally hydrophobic, so it is necessary to apply to the polyester a suitable coating, as disclosed by Ring et al. in U.S. Patent No. 4,007,083, Hawkins in U.S. Patent Nos. 4,137,181, 4,179,543 and 4,294,883, and Viscose Canal in British Patent No. 958,430 to overcome the inherent hydrophobic character of the polyester fiber without creating foam or causing the fibers to flocculate. It is this coating that has distinguished water-dispersible polyester fiber from more conventional polyester staple fiber, rather than any inherent characteristic feature of the polyester itself, or of its shape, such as the cross-section.
  • the cross-section of all commercial water-dispersible polyester fiber has been round. Indeed the cross-section of most commercial polyester staple fiber has generally been round, because this has been preferred.
  • new synthetic polymeric water-dispersible fiber especially polyester fiber, characterized in that the fibers are of scalloped-oval cross-section.
  • a scalloped-oval cross-section has been used heretofore for other polyester fibers, as described herein.
  • the water-dispersible fiber of the invention may be essentially similar to prior water-dispersible polyester or other synthetic polymer fibers, although the advantages described hereinafter may provide the opportunity for additional modifications.
  • the invention will be described hereinafter with special reference to polyester fiber, although it will be recognized that other synthetic polymers, such as polyamides and polyolefins, may also be used.
  • the fibers of the invention may be made conveniently by melt-spinning and drawing polyester filaments of appropriate denier per filament (dpf), and applying thereto a suitable coating to impart water-dispersible characteristics. The filaments are then generally cut into staple of whatever length is desired for the end-use contemplated.
  • dpf denier per filament
  • a scalloped-oval cross-section has already been used for more conventional polyester staple fiber, that has been spun into filaments and drawn, cut, converted into spun yarn, and used in woven Q r knitted fabrics. Such fiber has not had the water-dispersible characteristics required for this invention.
  • polyester filaments having a scalloped-oval cross-section are already known from Gorrafa U.S. Pat. No. 3,914,488, which suggested use in fur-like fabrics. Oriented polyester filaments of scalloped-oval cross-section have also been described by Frankfort et al. in U.S. Pat. Nos.
  • polyester filamentary substrates for making the water-dispersible fiber of the invention may be prepared by the techniques described therein, or by appropriate modifications of these or other known techniques of making polyester filaments of non-round cross-section.
  • Gorrafa U.S. Pat. No. 3,914,488 discloses parameters for a scalloped-oval cross-section and Figure 1 is essentially as shown therein.
  • a scalloped-oval is of essentially oval shape, with a significant difference between the lengths of major and minor axes, and differs significantly from prior art round and multi-lobal filaments in this respect, so that it would be misleading herein to consider all four rounded portions of the scalloped-oval as lobes (as did Gorrafa) in view of the terminology used in other prior art for symmetrical multi-lobal cross-sections.
  • dimensions, essentially as described by Gorrafa may be characterized as follows:
  • the cross-sectional configuration of fibers may be determined from a photomicrograph of the fiber cross-section.
  • the length of cross-section along the major axis X is indicated by A, which is also 2R, the circumscribing radius for the cross-section.
  • the width of the cross-section along the minor axis Y is indicated by B.
  • the ratio of length to width of the cross-section is A/B.
  • filaments of the invention have a lobe located at each end of the major cross-sectional axis, the extreme portion of the lobe being an arc of a circle, and being preferably more than a semicircle.
  • the radius of each lobe tip is indicated by r 1 .
  • a lobe tip is indicated by r 1 .
  • a minor axis Y of the cross-section there is another arc, whose radius is indicated by r 2 .
  • Figure 1 shows the centers of curvature for both arcs at the same point on the minor axis, this is not essential.
  • the centers of curvature may be separated, for example, as described by Gorrafa.
  • the tip radius ratio for the lobes on the major axis is r,/R and for the extremities of the minor axis is r 2 /R.
  • Another feature of the cross-section is the distance d which is the distance between two scallopings measured across the major axis of the fiber cross-section, as described by Gorrafa and by Franklin.
  • Dimensions are in the following proportions:-the ratio of length to width A/B of the cross-section from 1.4 to 2.4, tip radius ratio r 1 /R for the lobes on the major axis between 0.20 and 0.45, and the tip radius ratio r 2 /R on the minor axis from 0.8 to 2.1 times the tip radius ratio r 1 /R.
  • the cross-section must be properly scalloped to provide the desirable properties of the invention; for this reason, the ratio d/2r 1 , is from about 0.6 to 1.0.
  • the preparation of the polyester staple fiber is otherwise conventional, involving the steps of melt-spinning polymer into filaments, collecting the filaments into a tow, drawing the tow, and applying a suitable coating to impart water dispersible characteristics. If low shrinkage is desired, the drawn filaments are generally annealed.
  • an appropriate coating to promote water-dispersibility is important, and more of such coating is generally required than for comparable weights of fiber of round cross-section of similar denier per filament, because of the larger surface area of the periphery of the scalloped-oval cross-section. It is especially important to provide good boundary lubrication properties. For this reason, an ethoxylated coating is preferred.
  • Suitable coatings may be as disclosed in Hawkins, U.S. Pat. Nos. 4,137,181, 4,179,543 and 4,294,883 or a synthetic copolyester of poly(ethylene terephthalate) units and poly(oxyalkylene) of groups derived from a poly(oxyalkylene) glycol having an average molecular weight in the range of 300 to 6,000, as disclosed, e.g. in Mcintyre, et al. U.S. Pat. Nos. 3,416,952, 3,557,039 and 3,619,269, referred to therein; other useful segmented copolyesters are disclosed in Raynolds, U.S. Patent No. 3,981,807.
  • Such polyester fiber is generally prepared first in the form of a continuous filamentary uncrimped tow or, if extra bulk is required, and a more three-dimensional matrix, the filaments may be provided with mild wave-like undulations by a mild crimping-type process, and the uncrimped or mildly wave-like filaments are cut to the desired cut length, i.e. to form the water-dispersible fiber, which is generally sold in the form of bales, or other packages of cut fiber.
  • Suitable cut lengths are generally from about 5 to about 90 mm (1/4 to 3 inches), generally up to 60 mm (2-1/2 inches), and of length/diameter (UD) ratio from about 100:1 to about 2000:1, preferably about 150:1 to about 2000:1, it being an advantage of the invention that good performance has been obtainable with preferred water-dispersible fiber of the invention with an UD ratio higher than we have considered satisfactory with prior art water-dispersible polyester fiber. For instance, machine manufacturers have generally recommended that the L/D ratio not exceed 500:1, and many operators have considered even this figure unrealistically high.
  • a suitable denier per filament is generally from about 0.5 to about 20 (about 0.58 to about 22 dtex).
  • the coating is generally present in amount about 0.04 to about 1.0% of the weight of fiber (OWF%), it being an advantage that smaller amounts may generally be used than we have considered satisfactory according to the prior art.
  • the coating is preferably cured on the filaments by heating the coated filaments, or the resulting staple fiber, if desired, to a temperature of about 100° to about 190°C to improve durability.
  • Fiber A a comparison of round cross section
  • Fiber X a fiber of the invention of scalloped-oval cross section
  • Fiber A was spun at 1600 ypm (1463 m/min) into filaments with conventional radial air quenching using a 900 hole spinneret, with round holes 0.015 inches (0.381 mm) in diameter and capillary length of 0.030 inches (0.762 mm), a 270°C block, and polymer throughput 68.2 pounds/hour (30.9 kg/hour). Denier per filament was 3.67. Fiber A was then oriented by running over a set of feed rolls at 29.3 ypm (26.8 m/min), followed by a set of draw rolls at 80.0 ypm (73.2 m/min), and delivered to a conveyor by puller rolls at 80.1 ypm (73.24 m/min).
  • the filaments were treated in a 45°C water bath. Between feed and draw rolls the rope was sprayed with water at 98°C. Between draw and puller rolls a commercial water-dispersible coating (50/50 mixture of potassium salt of mono and diacid phosphate esters of lauryl alcohol/tallow alcohol ethoxylated with 25 moles of ethylene oxide) was applied. The filaments were then relaxed free in an oven at 150°C for 6 minutes.
  • Fiber X was produced in a similar manner to item A except that 1054 filaments of 2.98 dpf and scalloped-oval cross-section were spun through capillaries as shown in Figure 2, with block temperature 274°C, and throughput 67 pounds/hour (30.4 kg/hour). Roll speeds for the orientation were feed rolls 34.1 ypm (31.2 m/min), draw rolls 80.2 ypm (73.2 m/min) and puller rolls 79.1 ypm (72.3 m/min), and a higher level of water-dispersible coating was used to offset the scalloped oval's approximately 13% higher surface area.
  • Both types were cut to form water-dispersible fiber of 1/4, 3/8, 1/2 and 3/4 inch (6.35 mm, 9.53 mm, 12.70 mm and 19.05 mm) cut lengths and were tested on an inclined wire Fourdrinier machine. Fibers were dispersed for three minutes in a small pulper at 0.75% consistency (kg fiber per 100 kg slurry, or furnish). The cylindrical pulper was approximately 3 feet (0.91 m) in diameter by 6 feet (1.83 m) deep. Fibers were then mixed with unrefined sulphite pulp to form a 50% polyester blend and diluted to 0.1 % consistency in a 10 cubic meter stock tank.
  • This stock was further diluted in the headbox of the machine to 0.0143% consistency and formed into a 0.5 meter wide wet lay nonwoven fabric at 20 meters/minute.
  • a spray of an acrylic binder, Acronyl 240D was spray applied at the end of the Fourdrinier wire.
  • the fabric was then cured in a through air drier at 150°C. Finished fabric weight averaged 40 grams/square meter.
  • Dispersion quality can be judged by the uniformity of the fabric produced from a given sample. As cut length increases, the uniformity of the fabric can generally be expected to suffer significantly. However, great advantages can result from using a longer fiber because the fabric tear strength increases, for example. In practice, therefore, a fabric producer will generally wish to use the longest fiber that will meet his uniformity standards. Thus, a longer fiber with improved, or equivalent uniformity would be preferred. Fabric samples from Fibers A and X were independently shown to a panel of 10 persons (which was evenly divided between men and women), who were asked to rank the fabrics in terms of visual uniformity with the results shown in Table 2, the most uniform being ranked at 1, i.e. the lowest score.
  • a common defect in wet lay nonwoven fabrics is two clumps of fibers joined together by a single overlength. These defects are called dumbbells, or, if single ended, clumps. The number of such defects was determined for known weights of fabric for all cut lengths of both fibers. On the average, Item X, the scalloped-oval, had 44% fewer defects/100 grams fabric than the control. This may possibly be caused by the assymetric nature of the fiber bending modulus, which limits the freedom of the scalloped-oval long fibers to respond to swirls in the white water.
  • Fiber X had the following average properties:
  • Item X On balance, Item X exhibited advantages in the important areas of higher opacity and higher tensile strength, with minor sacrifices in tensile stretch and bulk. The fabrics of Item X also have a pleasant soft hand.
  • the scalloped-oval cross-section fiber of the invention When used with the appropriate water-dispersible coating in appropriate amount, the scalloped-oval cross-section fiber of the invention has given a fabric with exceptional dispersion uniformity, opacity and a soft hand.
  • the undispersed fiber exists in logs or clumps of many hundreds of fibers, most of which are on the inside of the logs. Therefore the undispersed surface area is negligible compared to the dispersed area, and the energy term can be expressed approximately as:
  • This energy term describes both the energy required to disperse the fiber, and the free energy driving force for reagglomeration. Therefore, for any given coating, and fiber dpf, fibers with lower area would be expected to provide a more uniform dispersion, hence more uniform fabric. The minimum surface area per unit weight for a given fiber occurs when the cross-section is round, which would be expected, therefore, to be preferred.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Artificial Filaments (AREA)
  • Polyesters Or Polycarbonates (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
EP86104815A 1985-04-09 1986-04-09 New synthetic water-dispersible fiber Expired EP0198400B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT86104815T ATE44786T1 (de) 1985-04-09 1986-04-09 Wasserdispergierbare synthesefaser.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US72134785A 1985-04-09 1985-04-09
US721347 1985-04-09

Publications (2)

Publication Number Publication Date
EP0198400A1 EP0198400A1 (en) 1986-10-22
EP0198400B1 true EP0198400B1 (en) 1989-07-19

Family

ID=24897610

Family Applications (1)

Application Number Title Priority Date Filing Date
EP86104815A Expired EP0198400B1 (en) 1985-04-09 1986-04-09 New synthetic water-dispersible fiber

Country Status (12)

Country Link
EP (1) EP0198400B1 (ko)
JP (1) JPS62502482A (ko)
KR (1) KR880002440B1 (ko)
CN (1) CN1006310B (ko)
AT (1) ATE44786T1 (ko)
CA (1) CA1280267C (ko)
DE (1) DE3664502D1 (ko)
ES (1) ES8800999A1 (ko)
FI (1) FI80077C (ko)
IE (1) IE57360B1 (ko)
NO (1) NO864926L (ko)
WO (1) WO1986006111A1 (ko)

Family Cites Families (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL125598C (ko) 1961-03-15
NL285942A (ko) * 1961-11-30
GB1088984A (en) 1963-06-05 1967-10-25 Ici Ltd Modifying treatment of shaped articles derived from polyesters
DE1635684A1 (de) * 1963-07-24 1969-10-16 Glanzstoff Ag Verfahren zur Herstellung textiler Flaechengebilde mit filzartigem Charakter
US3625754A (en) * 1970-02-02 1971-12-07 Beaunit Corp Surface-modified polyester article
US3703260A (en) * 1970-12-04 1972-11-21 John P Grabske Material spreader
DE2105681C3 (de) * 1971-02-08 1975-10-02 Bayer Ag, 5090 Leverkusen Verfahren zur Herstellung von wäßrigen Fasersuspensionen
US3914488A (en) * 1973-09-24 1975-10-21 Du Pont Polyester filaments for fur-like fabrics
US3981807A (en) 1973-09-27 1976-09-21 E. I. Du Pont De Nemours And Company Durable textile treating adducts
US4007083A (en) 1973-12-26 1977-02-08 International Paper Company Method for forming wet-laid non-woven webs
US4195051A (en) 1976-06-11 1980-03-25 E. I. Du Pont De Nemours And Company Process for preparing new polyester filaments
US4134882A (en) 1976-06-11 1979-01-16 E. I. Du Pont De Nemours And Company Poly(ethylene terephthalate)filaments
US4179543A (en) 1976-08-19 1979-12-18 Hoechst Fibers Industries, Division Of American Hoechst Corporation Staple fiber, finish therefor and process for use of same
US4294883A (en) 1976-08-19 1981-10-13 Hoechst Fibers Industries, Div. Of American Hoechst Corporation Staple fiber, finish therefor and process for use of same
US4297414A (en) * 1978-07-07 1981-10-27 Mitsui Petrochemical Industries, Ltd. Reinforcing material for hydraulic substances and method for the production thereof
JPS5725645A (en) * 1980-07-23 1982-02-10 Hitachi Ltd Method of forming fluorescent surface for color-picture tube
US4634625A (en) 1984-10-25 1987-01-06 E. I. Du Pont De Nemours And Company New fabrics, yarns and process

Also Published As

Publication number Publication date
JPS62502482A (ja) 1987-09-24
FI80077B (fi) 1989-12-29
KR880700115A (ko) 1988-02-15
EP0198400A1 (en) 1986-10-22
IE860906L (en) 1986-10-09
FI80077C (fi) 1990-04-10
CN1006310B (zh) 1990-01-03
WO1986006111A1 (en) 1986-10-23
ATE44786T1 (de) 1989-08-15
NO864926L (no) 1986-12-08
JPH0331803B2 (ko) 1991-05-08
ES553823A0 (es) 1987-12-01
FI864686A (fi) 1986-11-18
ES8800999A1 (es) 1987-12-01
IE57360B1 (en) 1992-08-12
KR880002440B1 (ko) 1988-11-12
DE3664502D1 (en) 1989-08-24
FI864686A0 (fi) 1986-11-18
CA1280267C (en) 1991-02-19
CN86102475A (zh) 1986-10-15

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