EP0285437A2 - Improved cationic-dyeable copolyester draw-texturing feed yarns - Google Patents
Improved cationic-dyeable copolyester draw-texturing feed yarns Download PDFInfo
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- EP0285437A2 EP0285437A2 EP88302937A EP88302937A EP0285437A2 EP 0285437 A2 EP0285437 A2 EP 0285437A2 EP 88302937 A EP88302937 A EP 88302937A EP 88302937 A EP88302937 A EP 88302937A EP 0285437 A2 EP0285437 A2 EP 0285437A2
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- Prior art keywords
- draw
- cationic
- filaments
- sheath
- textured
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- 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
- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
- D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
- D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
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- 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
- D01D5/34—Core-skin structure; Spinnerette packs therefor
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- 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
- D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
- D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
- D02G1/0206—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist by false-twisting
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- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
- D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
- D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
- D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
- D03D15/47—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads multicomponent, e.g. blended yarns or threads
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- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
- D03D15/49—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads textured; curled; crimped
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
- D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/14—Dyeability
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2501/00—Wearing apparel
Definitions
- This invention concerns improvements in and relating to improved cationic-dyeable copolyester draw-texturing feed yarns, and more particularly to such feed yarns that are novel on account of being concentric sheath/core bicomponent filaments, and are improved in that they are capable of being draw-textured at relatively high speeds without undesirably high numbers of broken filaments to give textured yarns having desirably high bulk, and the resulting textured yarns, and fabrics and garments containing such textured yarns.
- Synthetic polyester multifilament yarns have been known and used commercially for several decades, having been first suggested by W. H. Carothers, U.S. Patent No. 2,071,251, and then by Whinfield and Dickson, U.S. Patent No. 2,465,319.
- Most of the polyester polymer that has been manufactured and used commercially for such continuous filament yarns has been poly(ethylene terephthalate), sometimes referred to as 2G-T.
- This polymer is often referred to as homopolymer, although it is known that, in addition to the residues of ethylene, from ethylene glycol, and terephthalate residues, from dimethyl terephthalate or terephthalic acid, there are also residues from diethylene glycol.
- such commercial homopolymer is usually of intrinsic viscosity about 0.6; it can vary up to about 0.65 or even 0.67, and can also be of somewhat lower viscosity.
- Commercial homopolymer is notoriously difficult to dye.
- Such homopolymer is mostly dyed with disperse dyestuffs at high temperatures under elevated pressures, which is a relatively expensive and inconvenient process (in contrast to processes for dyeing several other commercial fibers at atmospheric pressure, e.g. at the boil), and so there have been several suggestions for improving the dyeability of polyester yarns.
- cationic-dyeable copolyesters in which the poly(ethylene terephthalate) structure is modified by inclusion of sulfonate groups that provide an affinity for cationic dyestuffs.
- Such cationic-dyeable copolyester consisting essentially of poly[ethylene terephthalate/5-(sodium sulfo) isophthalate] containing about 2 mole % of the 5-(sodium sulfo) isophthalate groups in the polymer chain has been used commercially as a basis for polyester yarns for some 20 years, and is sometimes referred to as 2G-T/SSI.
- this cationic-dyeable copolyester is significantly more expensive than the homopolymer, it has been used on a large scale for various applications, especially as staple fiber, and in heather multi-filament yarns, wherein the cationic-dyeable copolyester filaments are intermingled with homopolymer filaments.
- draw-texturing feed yarns are substantially amorphous spin-oriented multi-filament (continuous filament) yarns prepared by spinning at withdrawal speeds of the order of about 3000 ypm or more, more or less as indicated by Petrille and by Piazza and Reese. These withdrawal speeds are used to obtain the spin-orientation that is required for the feed yarns to be stable (in storage and to heat, so that they may be draw-textured).
- the feed yarns be substantially amorphous, i.e. of relatively low crystallinity. It is this low crystallinity that distinguishes DTFY from drawn polyester yarns that are used in fabric formation, e.g. by weaving or knitting.
- the present invention is concerned with DTFY, i.e. with feed yarns that are spin-oriented, but of low crystallinity, as distinguished from crystalline yarns such as have been used directly in fabrics.
- Most commercial DTFY at this time has a crystallinity of the order of 10%, and relatively high boil-off shrinkage; such shrinkages have generally been of the order of about 40%.
- commercial polyester yarns that are drawn have generally had crystallinity of more than 30%, and shrinkages of 15% or less.
- crystalline spin-oriented yarns by spinning under different conditions, including very high speeds, e.g. as disclosed by Frankfort and Knox in U.S. Patent Nos. 4,134,882 and 4,195,051, and these yarns may be subjected to draw-texturing.
- such crystalline yarns are not contemplated and it is preferred to use spin-oriented yarns of low crystallinity, as shown by a boil-off shrinkage of at least 15%, and preferably at least 25%.
- U.S. Patent No. 4,059,949 discloses composite yarns exhibiting heather dyeing capability, comprised of two groups of filaments composed of two differently dyeable polymers, wherein filaments of one group are homofilaments of one polymer, and filaments of the other group are of a substantially concentric sheath/core structure with the sheath being of the other polymer and the core being of the same polymer as the homofilaments.
- the yarn dyes to give a heather appearance which is different from the appearance expected based on the polymer composition of the yarn.
- Lee makes no reference to DTFY, nor to draw-texturing.
- Example I shows the preparation of heather yarns from molten 2G-T of 22 HRV and molten 2G-T/SSI of 14 HRV to provide yarns of 34 filaments, 7 of which are single component filaments of 2G-T/SSI, whereas 27 of which are substantially concentric sheath/core bicomponent filaments of which the core is 2G-T/SSI and the sheath is 2G-T, by a process of spinning, quenching and drawing in a continuous operation. These drawn heather yarns are then false-twist textured without drawing. Most of the dependent claims are directed to this combination, which is obviously preferred, as can be seen from the majority of the description.
- Claim 10 is directed to the feature wherein the homofilaments are composed of 2G-T and the sheath/core filaments are composed of a 2G-T core and a sheath of 2G-T/SSI.
- column 4 There is also a reference in column 4, starting at line 28, to a reverse case with a basic dyeing component in the sheath and a disperse dyeable core component.
- the 2G-T/SSI sheath takes up both disperse dyes and basic dyes, and the 2G-T core is dyed only with the disperse dyes.
- both the sheath and core are dyed with disperse dyes, but neither sheath nor core is dyed with basic dyes (column 4, lines 16-28).
- an improved cationic-dyeable copolyester draw-texturing feed yarn wherein the cationic-dyeable copolyester consists essentially of poly[ethylene terephthalate/5-(sodium sulfo) isophthalate] containing about 2 mole % of the 5-(sodium sulfo) isophthalate groups in the polymer chain, and the feed yarn is a substantially amorphous spin-oriented multi-filament yarn prepared by spinning at a withdrawal speed of the order of about 3000 ypm or more, the improvement characterized in that the filaments are concentric sheath/core bicomponent filaments, wherein the sheath consists essentially of the cationic-dyeable copolyester, and the core consists essentially of poly(ethylene terephthalate) of intrinsic viscosity about 0.6.
- the bicomponent filaments preferably consist essentially of approximately equal amounts by weight of sheath and of core.
- the Figure is a photomicrograph of cross-sections of filaments of the bicomponent yarns of the invention.
- 4,059,949 discloses the preparation of mixed yarns including drawn concentric bicomponent filaments (as well as monocomponent drawn filaments), and not of DTFY.
- the preparation of bicomponent filaments for polyester DTFY is disclosed in Mirhej, U.S. Patent No. 4,157,419, it being recognized that Mirhej discloses the preparation of eccentric bicomponent filaments that are intended to break during draw-texturing and provide a helical crimp, on account of the excentric nature, whereas the bicomponent filaments according to the present invention are concentric, and are primarily intended to resist breaking during normal draw-texturing operations. Further details for preparing preferred concentric bicomponent filaments and DTFY according to the present invention are given in the following Example, as are details of their texturing.
- the preparation of fabrics and garments from the resulting textured yarns may be carried out by conventional techniques.
- the advantage of the improved (reduced) BFC is quite significant, as is the increased bulk obtained in comparison with monocomponent 2G-T/SSI copolymer filament yarns.
- a further advantage of the DTFY according to the invention is that the cost of the homopolymer, that provides the core of the novel bicomponent filaments, is considerably cheaper than for the 2G-T/SSI copolymer, so the cost of the raw materials for the bicomponent filaments is considerably less than for monocomponent filaments of 2G-T/SSI.
- NDR and NDF are determined from a stress-strain curve measured on an Instron tensile testing machine at 70°F and 65% RH using a sample length of five inches and a rate of elongation of 400% per minute.
- Crimp Contraction (CCA5) was measured essentially as in U.S. Patent No. 4,134,882. The method for determining LRV is disclosed in Most, U.S. Patent No. 4,444,710.
- a 240/68 bicomponent feed yarn was prepared at a withdrawal speed of 3315 ypm, with 50/50 by weight of 2G-T of 19.4 LRV (intrinsic viscosity 0.61) in the core and with 98/2 2G-T/SSI copolyester of 12.8 LRV (intrinsic viscosity 0.49) in the concentric sheath, using a block temperature of 286°C, but otherwise essentially as described and illustrated in Lee U.S. Patent No. 4,059,949.
- the filaments were treated with a commercial draw-texturing finish and interlaced.
- the resulting yarns had the following properties, Tenacity 1.3 g/d, Elongation 117%, Modulus 24 g/d, Natural Draw Ratio 1.4, Natural Draw Force 150 g, Shrinkage 45%, Density 1.347 and Birefringence 0.02. Cross-sections of filaments are shown in the photomicrograph in the Figure.
- This yarn was draw-textured on a Murata machine under conventional conditions and compared with a control yarn prepared essentially similarly except that it was monocomponent, consisting only of the 2G-T/SSI copolyester.
- the bicomponent feed yarn of the invention gave significantly fewer broken filaments and better crimp, as can be seen from the Table.
- These textured yarns may be processed into fabrics by conventional techniques, such as knitting, or weaving if desired, and dyed to attractive shades with cationic and/or disperse dyes, despite the presence of a homopolymer core.
- the sheath/core (DTFY) filaments of the invention contain about 50/50 by weight of homopolymer/copolymer, and correspondingly about equal amounts by area of cross-section, since the densities are approximately equal.
- the diameter of the core (which is the same as the internal diameter for the sheath) is about 10.5 microns, whereas the external diameter of the sheath (and of the total filament) is about 15 microns.
- the thickness of the sheath (on either side) is only about 2 microns. A decrease in the thickness of the sheath in the feed yarn may lead to more bulk in the textured product, and possibly lower broken filaments and lighter dyeing.
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- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
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- Multicomponent Fibers (AREA)
Abstract
Description
- This invention concerns improvements in and relating to improved cationic-dyeable copolyester draw-texturing feed yarns, and more particularly to such feed yarns that are novel on account of being concentric sheath/core bicomponent filaments, and are improved in that they are capable of being draw-textured at relatively high speeds without undesirably high numbers of broken filaments to give textured yarns having desirably high bulk, and the resulting textured yarns, and fabrics and garments containing such textured yarns.
- Synthetic polyester multifilament yarns have been known and used commercially for several decades, having been first suggested by W. H. Carothers, U.S. Patent No. 2,071,251, and then by Whinfield and Dickson, U.S. Patent No. 2,465,319. Most of the polyester polymer that has been manufactured and used commercially for such continuous filament yarns has been poly(ethylene terephthalate), sometimes referred to as 2G-T. This polymer is often referred to as homopolymer, although it is known that, in addition to the residues of ethylene, from ethylene glycol, and terephthalate residues, from dimethyl terephthalate or terephthalic acid, there are also residues from diethylene glycol. For textile (apparel) purposes, such commercial homopolymer is usually of intrinsic viscosity about 0.6; it can vary up to about 0.65 or even 0.67, and can also be of somewhat lower viscosity. Commercial homopolymer is notoriously difficult to dye. Such homopolymer is mostly dyed with disperse dyestuffs at high temperatures under elevated pressures, which is a relatively expensive and inconvenient process (in contrast to processes for dyeing several other commercial fibers at atmospheric pressure, e.g. at the boil), and so there have been several suggestions for improving the dyeability of polyester yarns.
- Accordingly, Griffing and Remington, U.S. Patent No. 3,018,272, suggested the use of cationic-dyeable copolyesters, in which the poly(ethylene terephthalate) structure is modified by inclusion of sulfonate groups that provide an affinity for cationic dyestuffs. Such cationic-dyeable copolyester consisting essentially of poly[ethylene terephthalate/5-(sodium sulfo) isophthalate] containing about 2 mole % of the 5-(sodium sulfo) isophthalate groups in the polymer chain has been used commercially as a basis for polyester yarns for some 20 years, and is sometimes referred to as 2G-T/SSI. Although this cationic-dyeable copolyester is significantly more expensive than the homopolymer, it has been used on a large scale for various applications, especially as staple fiber, and in heather multi-filament yarns, wherein the cationic-dyeable copolyester filaments are intermingled with homopolymer filaments.
- A very large amount of homopolymer has been used to make draw-texturing feed yarns. This concept was first suggested by Petrille in U.S. Patent No. 3,771,307 and Piazza and Reese in U.S. Patent No. 3,772,872. These draw-texturing feed yarns (DTFY) are substantially amorphous spin-oriented multi-filament (continuous filament) yarns prepared by spinning at withdrawal speeds of the order of about 3000 ypm or more, more or less as indicated by Petrille and by Piazza and Reese. These withdrawal speeds are used to obtain the spin-orientation that is required for the feed yarns to be stable (in storage and to heat, so that they may be draw-textured). It is also desirable, however, that the feed yarns be substantially amorphous, i.e. of relatively low crystallinity. It is this low crystallinity that distinguishes DTFY from drawn polyester yarns that are used in fabric formation, e.g. by weaving or knitting. The present invention is concerned with DTFY, i.e. with feed yarns that are spin-oriented, but of low crystallinity, as distinguished from crystalline yarns such as have been used directly in fabrics. Most commercial DTFY at this time has a crystallinity of the order of 10%, and relatively high boil-off shrinkage; such shrinkages have generally been of the order of about 40%. In contrast, commercial polyester yarns that are drawn have generally had crystallinity of more than 30%, and shrinkages of 15% or less. It is also possible to obtain crystalline spin-oriented yarns by spinning under different conditions, including very high speeds, e.g. as disclosed by Frankfort and Knox in U.S. Patent Nos. 4,134,882 and 4,195,051, and these yarns may be subjected to draw-texturing. However, according to the present invention, such crystalline yarns are not contemplated and it is preferred to use spin-oriented yarns of low crystallinity, as shown by a boil-off shrinkage of at least 15%, and preferably at least 25%.
- As indicated, conventional homopolymer DTFY has been manufactured in large quantities and has been draw-textured. Hitherto, however, although 2G-T/SSI copolymer has been used satisfactorily for other types of polyester yarns, customers have complained that 2G-T/SSI DTFY has given unacceptably high broken filament counts (BFC) in contrast to conventional homopolymer DTFY. This has been particularly true, for instance, when it has been desired to prepare a 150/68 (denier/number of filaments) textured 2G-T/SSI copolyester yarn by draw-texturing a 250-68 DTFY at a draw ratio of about 1.6X on a Barmag FK6 machine at speeds of 500-600 m/min., which texturing conditions have been desirable commercially for several years, and have long been attainable with regular homopolymer DTFY with acceptable BFC levels of about 0.5/lb. or less (counted by examining the ends of the packages of textured yarn). Despite many efforts, hitherto, we have not found it practical to improve 2G-T/SSI copolyester DTFY by varying its process of manufacture so as to meet customer requirements in this regard at an economic price.
- It is an object of the invention to provide a cationic-dyeable copolyester DTFY that meets such requirements.
- It was suggested by Barmag (Schippers) in German DE OS 23 35 946 to manufacture crimped filaments by heating and simultaneous false-twisting with more than 2,000 turns per meter of filament length using multi-component filaments, in which at least one component had properties that affected its length or its length-behavior that differed from those of the other component or components. The bicomponent construction could be any made of usual and known materials. Example II shows the spinning of nylon 6 and a polyester component at 3 km/min. to provide concentric sheath/core filaments, and their draw-texturing using a draw ratio of 1:1.25 (1.25X), using a single heater at 220°C (the second heater was by-passed). The other Examples show side-by-side bicomponent filaments that are wholly polyamide. Barmag does not disclose the specific combination of a 2G-T/SSI copolyester in any bicomponent combination.
- Lee, U.S. Patent No. 4,059,949 discloses composite yarns exhibiting heather dyeing capability, comprised of two groups of filaments composed of two differently dyeable polymers, wherein filaments of one group are homofilaments of one polymer, and filaments of the other group are of a substantially concentric sheath/core structure with the sheath being of the other polymer and the core being of the same polymer as the homofilaments. The yarn dyes to give a heather appearance which is different from the appearance expected based on the polymer composition of the yarn. Lee makes no reference to DTFY, nor to draw-texturing. Example I shows the preparation of heather yarns from molten 2G-T of 22 HRV and molten 2G-T/SSI of 14 HRV to provide yarns of 34 filaments, 7 of which are single component filaments of 2G-T/SSI, whereas 27 of which are substantially concentric sheath/core bicomponent filaments of which the core is 2G-T/SSI and the sheath is 2G-T, by a process of spinning, quenching and drawing in a continuous operation. These drawn heather yarns are then false-twist textured without drawing. Most of the dependent claims are directed to this combination, which is obviously preferred, as can be seen from the majority of the description. Claim 10, however, being dependent on Claim 1, is directed to the feature wherein the homofilaments are composed of 2G-T and the sheath/core filaments are composed of a 2G-T core and a sheath of 2G-T/SSI. There is also a reference in column 4, starting at line 28, to a reverse case with a basic dyeing component in the sheath and a disperse dyeable core component. In this reverse case, the 2G-T/SSI sheath takes up both disperse dyes and basic dyes, and the 2G-T core is dyed only with the disperse dyes. However, in the preferred case, both the sheath and core are dyed with disperse dyes, but neither sheath nor core is dyed with basic dyes (column 4, lines 16-28).
- According to the invention, there is provided an improved cationic-dyeable copolyester draw-texturing feed yarn, wherein the cationic-dyeable copolyester consists essentially of poly[ethylene terephthalate/5-(sodium sulfo) isophthalate] containing about 2 mole % of the 5-(sodium sulfo) isophthalate groups in the polymer chain, and the feed yarn is a substantially amorphous spin-oriented multi-filament yarn prepared by spinning at a withdrawal speed of the order of about 3000 ypm or more, the improvement characterized in that the filaments are concentric sheath/core bicomponent filaments, wherein the sheath consists essentially of the cationic-dyeable copolyester, and the core consists essentially of poly(ethylene terephthalate) of intrinsic viscosity about 0.6. The bicomponent filaments preferably consist essentially of approximately equal amounts by weight of sheath and of core. The advantages of the DTFY of the invention are particularly noted for filaments of lighter denier, being about 5 dpf or less.
- There is also provided a process for preparing a textured cationic-dyeable polyester yarn, wherein such feed yarn is subjected to draw-false-twist-texturing, and the resulting textured polyester yarns, and fabrics and garments containing at least 10% by weight of such textured polyester yarns, and preferably consisting essentially of such textured polyester yarns.
- The Figure is a photomicrograph of cross-sections of filaments of the bicomponent yarns of the invention.
- The preparation of monocomponent polyester DTFY has been amply described in the prior art, e.g. in the aforesaid U.S. Patent Nos. 3,771,307 and 3,772,872, the disclosures of which are hereby incorporated by reference, and these conventional techniques need only be modified by providing for the spinning of concentric bicomponent filaments, e.g. using a spinneret as disclosed on the left hand side of Figure 1 of aforesaid U.S. Patent No. 4,059,949, the disclosure of which is also hereby incorporated by reference, it being recognized that U.S. Patent No. 4,059,949 discloses the preparation of mixed yarns including drawn concentric bicomponent filaments (as well as monocomponent drawn filaments), and not of DTFY. The preparation of bicomponent filaments for polyester DTFY is disclosed in Mirhej, U.S. Patent No. 4,157,419, it being recognized that Mirhej discloses the preparation of eccentric bicomponent filaments that are intended to break during draw-texturing and provide a helical crimp, on account of the excentric nature, whereas the bicomponent filaments according to the present invention are concentric, and are primarily intended to resist breaking during normal draw-texturing operations. Further details for preparing preferred concentric bicomponent filaments and DTFY according to the present invention are given in the following Example, as are details of their texturing. The preparation of fabrics and garments from the resulting textured yarns may be carried out by conventional techniques. The advantage of the improved (reduced) BFC is quite significant, as is the increased bulk obtained in comparison with monocomponent 2G-T/SSI copolymer filament yarns. A further advantage of the DTFY according to the invention is that the cost of the homopolymer, that provides the core of the novel bicomponent filaments, is considerably cheaper than for the 2G-T/SSI copolymer, so the cost of the raw materials for the bicomponent filaments is considerably less than for monocomponent filaments of 2G-T/SSI. In view of these economic incentives, and the many prior suggestions of using bicomponent filaments for various other purposes, it is quite surprising that no one has previously suggested the present invention.
- The invention is further described in the following Example. Reference may be made to Knox, U.S. Patent No. 4,156,071 for most of the various test measurements. For the tensile properties, however, there was used a six-inch sample length, without twist at a 200% per minute rate of extension. "Natural Draw Ratio "(NDR) is determined from a stress-strain curve as described by Ludewig in Polyester Fibres, Section 5.4.1 (pages 174-177), John Wiley & Sons, Ltd., 1971. "Natural Draw Force" (NDF) is the value of the tensile stress on the yarn taken from the straight-line portion of the stress-strain curve located in the yield zone below the natural draw ratio. As reported here, NDR and NDF are determined from a stress-strain curve measured on an Instron tensile testing machine at 70°F and 65% RH using a sample length of five inches and a rate of elongation of 400% per minute. Crimp Contraction (CCA₅) was measured essentially as in U.S. Patent No. 4,134,882. The method for determining LRV is disclosed in Most, U.S. Patent No. 4,444,710.
- A 240/68 bicomponent feed yarn was prepared at a withdrawal speed of 3315 ypm, with 50/50 by weight of 2G-T of 19.4 LRV (intrinsic viscosity 0.61) in the core and with 98/2 2G-T/SSI copolyester of 12.8 LRV (intrinsic viscosity 0.49) in the concentric sheath, using a block temperature of 286°C, but otherwise essentially as described and illustrated in Lee U.S. Patent No. 4,059,949. The filaments were treated with a commercial draw-texturing finish and interlaced. The resulting yarns had the following properties, Tenacity 1.3 g/d, Elongation 117%, Modulus 24 g/d, Natural Draw Ratio 1.4, Natural Draw Force 150 g, Shrinkage 45%, Density 1.347 and Birefringence 0.02. Cross-sections of filaments are shown in the photomicrograph in the Figure.
- This yarn was draw-textured on a Murata machine under conventional conditions and compared with a control yarn prepared essentially similarly except that it was monocomponent, consisting only of the 2G-T/SSI copolyester. The bicomponent feed yarn of the invention gave significantly fewer broken filaments and better crimp, as can be seen from the Table.
- It was also found that there was consistent improvement in crimp contraction measured over various loadings (from 0.5 to 10 mg/denier) which could be of advantage in providing a combination of greater bulk and/or less broken filaments, as desired, by using more or less rigorous texturing conditions.
- These textured yarns may be processed into fabrics by conventional techniques, such as knitting, or weaving if desired, and dyed to attractive shades with cationic and/or disperse dyes, despite the presence of a homopolymer core.
- As indicated in the foregoing Example, the sheath/core (DTFY) filaments of the invention contain about 50/50 by weight of homopolymer/copolymer, and correspondingly about equal amounts by area of cross-section, since the densities are approximately equal. The diameter of the core (which is the same as the internal diameter for the sheath) is about 10.5 microns, whereas the external diameter of the sheath (and of the total filament) is about 15 microns. In other words, the thickness of the sheath (on either side) is only about 2 microns. A decrease in the thickness of the sheath in the feed yarn may lead to more bulk in the textured product, and possibly lower broken filaments and lighter dyeing. Increased dyeing capability could possibly be achieved by increasing the proportion of SSI in the copolyester used for the sheath, if desired. Thus, although this description has emphasized the 2G-T/SSI copolymer that has been preferred for many years and has been available commercially, it will be understood that variations of the precise compositions and proportions of the polymers and of their conditions of preparation can be made without departing from the essence of the invention, both for the copolymer sheath and for the homopolymer core of the bicomponent filaments and yarns, according to the present invention. For instance, the viscosity of the homopolymer may vary from about 0.6 to about 0.67. It is also conventional to use additives, such as pigments or delustering agents, such as titanium dioxide, if desired.
Claims (9)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US3442987A | 1987-04-03 | 1987-04-03 | |
PCT/US1993/006450 WO1995002719A1 (en) | 1987-04-03 | 1993-07-13 | Preparing cationic-dyeable textured yarns |
US34429 | 1998-03-03 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0285437A2 true EP0285437A2 (en) | 1988-10-05 |
EP0285437A3 EP0285437A3 (en) | 1989-11-29 |
EP0285437B1 EP0285437B1 (en) | 1991-10-23 |
Family
ID=21876356
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP88302937A Expired - Lifetime EP0285437B1 (en) | 1987-04-03 | 1988-03-31 | Improved cationic-dyeable copolyester draw-texturing feed yarns |
Country Status (9)
Country | Link |
---|---|
EP (1) | EP0285437B1 (en) |
JP (1) | JPS6414333A (en) |
KR (1) | KR880012806A (en) |
CN (1) | CN1024573C (en) |
CA (1) | CA1289708C (en) |
DE (1) | DE3865719D1 (en) |
IN (1) | IN169982B (en) |
MX (1) | MX168794B (en) |
TR (1) | TR27091A (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0525628A2 (en) * | 1991-07-25 | 1993-02-03 | Kuraray Co., Ltd. | Composite fiber containing inorganic fine powder |
US5242640A (en) * | 1987-04-03 | 1993-09-07 | E. I. Du Pont De Nemours And Company | Preparing cationic-dyeable textured yarns |
US5294488A (en) * | 1987-04-03 | 1994-03-15 | E. I. Du Pont De Nemours And Company | Preparing cationic-dyeable textured yarns |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2010035640A1 (en) * | 2008-09-26 | 2010-04-01 | 東レ株式会社 | Polyester monofilament, method for producing same, and method for producing screen gauze using same |
CN108215165A (en) * | 2018-01-25 | 2018-06-29 | 清华大学 | Intelligent pattern of skin-core structure fiber and printing method and application thereof |
CN109722738B (en) * | 2018-12-27 | 2020-07-07 | 江苏恒力化纤股份有限公司 | Semi-dull polyester drawn yarn and preparation method thereof |
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DE2335946A1 (en) * | 1973-07-14 | 1975-01-30 | Barmag Barmer Maschf | Crimping process for multi-component filaments - having a continuous and combined heating and false twisting system |
US4059949A (en) * | 1974-02-15 | 1977-11-29 | E. I. Du Pont De Nemours And Company | Sheath-core cospun heather yarns |
US4115989A (en) * | 1977-05-02 | 1978-09-26 | E. I. Du Pont De Nemours And Company | Product and process |
WO1979000149A1 (en) * | 1977-09-16 | 1979-03-22 | Du Pont | Polyester feed yarn for draw-texturing |
US4233363A (en) * | 1979-03-02 | 1980-11-11 | E. I. Du Pont De Nemours And Company | Polyester draw-texturing feed yarns |
Family Cites Families (3)
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JPS55116827A (en) * | 1979-03-01 | 1980-09-08 | Unitika Ltd | Production of special polyester modified yarn |
JPS5721518A (en) * | 1980-07-16 | 1982-02-04 | Toray Ind Inc | Extremely fine conjugate fiber and its bundle |
JPS6071729A (en) * | 1983-09-29 | 1985-04-23 | 東レ株式会社 | Silk-like polyester filament yarn and its production |
-
1988
- 1988-03-28 IN IN255/CAL/88A patent/IN169982B/en unknown
- 1988-03-29 CA CA000562810A patent/CA1289708C/en not_active Expired - Lifetime
- 1988-03-30 MX MX010945A patent/MX168794B/en unknown
- 1988-03-30 CN CN88101834A patent/CN1024573C/en not_active Expired - Fee Related
- 1988-03-31 JP JP63076631A patent/JPS6414333A/en active Pending
- 1988-03-31 EP EP88302937A patent/EP0285437B1/en not_active Expired - Lifetime
- 1988-03-31 DE DE8888302937T patent/DE3865719D1/en not_active Expired - Lifetime
- 1988-04-01 TR TR00251/88A patent/TR27091A/en unknown
- 1988-04-02 KR KR1019880003719A patent/KR880012806A/en not_active Application Discontinuation
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2335946A1 (en) * | 1973-07-14 | 1975-01-30 | Barmag Barmer Maschf | Crimping process for multi-component filaments - having a continuous and combined heating and false twisting system |
US4059949A (en) * | 1974-02-15 | 1977-11-29 | E. I. Du Pont De Nemours And Company | Sheath-core cospun heather yarns |
US4115989A (en) * | 1977-05-02 | 1978-09-26 | E. I. Du Pont De Nemours And Company | Product and process |
WO1979000149A1 (en) * | 1977-09-16 | 1979-03-22 | Du Pont | Polyester feed yarn for draw-texturing |
US4233363A (en) * | 1979-03-02 | 1980-11-11 | E. I. Du Pont De Nemours And Company | Polyester draw-texturing feed yarns |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5242640A (en) * | 1987-04-03 | 1993-09-07 | E. I. Du Pont De Nemours And Company | Preparing cationic-dyeable textured yarns |
US5294488A (en) * | 1987-04-03 | 1994-03-15 | E. I. Du Pont De Nemours And Company | Preparing cationic-dyeable textured yarns |
WO1995002719A1 (en) * | 1987-04-03 | 1995-01-26 | E.I. Du Pont De Nemours And Company | Preparing cationic-dyeable textured yarns |
EP0525628A2 (en) * | 1991-07-25 | 1993-02-03 | Kuraray Co., Ltd. | Composite fiber containing inorganic fine powder |
EP0525628A3 (en) * | 1991-07-25 | 1993-07-21 | Kuraray Co., Ltd. | Composite fiber containing inorganic fine powder |
US5464695A (en) * | 1991-07-25 | 1995-11-07 | Kuraray Company Limited | Composite fiber containing inorganic fine powder |
Also Published As
Publication number | Publication date |
---|---|
JPS6414333A (en) | 1989-01-18 |
CN1024573C (en) | 1994-05-18 |
EP0285437B1 (en) | 1991-10-23 |
IN169982B (en) | 1992-01-25 |
DE3865719D1 (en) | 1991-11-28 |
EP0285437A3 (en) | 1989-11-29 |
CA1289708C (en) | 1991-10-01 |
MX168794B (en) | 1993-06-08 |
KR880012806A (en) | 1988-11-29 |
TR27091A (en) | 1994-10-18 |
CN88101834A (en) | 1988-10-19 |
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