EP0496734A1 - Verfahren zur herstellung von bikomponent fasern - Google Patents
Verfahren zur herstellung von bikomponent fasernInfo
- Publication number
- EP0496734A1 EP0496734A1 EP19900913042 EP90913042A EP0496734A1 EP 0496734 A1 EP0496734 A1 EP 0496734A1 EP 19900913042 EP19900913042 EP 19900913042 EP 90913042 A EP90913042 A EP 90913042A EP 0496734 A1 EP0496734 A1 EP 0496734A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fiber
- fibers
- polymer
- ethylene polymer
- bicomponent
- 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.)
- Granted
Links
- 239000000835 fiber Substances 0.000 title claims abstract description 193
- 238000000034 method Methods 0.000 title claims abstract description 37
- 229920000573 polyethylene Polymers 0.000 claims abstract description 58
- 229920000642 polymer Polymers 0.000 claims abstract description 39
- KDYFGRWQOYBRFD-UHFFFAOYSA-N succinic acid Chemical compound OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 claims abstract description 39
- 239000000203 mixture Substances 0.000 claims abstract description 21
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 18
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 18
- 239000001384 succinic acid Substances 0.000 claims abstract description 17
- RINCXYDBBGOEEQ-UHFFFAOYSA-N succinic anhydride Chemical group O=C1CCC(=O)O1 RINCXYDBBGOEEQ-UHFFFAOYSA-N 0.000 claims abstract description 14
- 229920006258 high performance thermoplastic Polymers 0.000 claims abstract description 11
- 238000004519 manufacturing process Methods 0.000 claims abstract description 5
- 239000011230 binding agent Substances 0.000 claims description 45
- -1 polyethylene terephthalate Polymers 0.000 claims description 21
- 229920002959 polymer blend Polymers 0.000 claims description 21
- 238000002844 melting Methods 0.000 claims description 20
- 230000008018 melting Effects 0.000 claims description 20
- 239000004744 fabric Substances 0.000 claims description 16
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 16
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 16
- 238000002156 mixing Methods 0.000 claims description 13
- 229920006253 high performance fiber Polymers 0.000 claims description 9
- 229920000728 polyester Polymers 0.000 claims description 9
- 239000004952 Polyamide Substances 0.000 claims description 7
- 229920002647 polyamide Polymers 0.000 claims description 7
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 7
- 125000002091 cationic group Chemical group 0.000 claims description 4
- 210000002268 wool Anatomy 0.000 claims description 4
- 239000002998 adhesive polymer Substances 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 238000004043 dyeing Methods 0.000 claims description 2
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 abstract description 14
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 abstract description 10
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 abstract description 9
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 abstract description 9
- 239000011976 maleic acid Substances 0.000 abstract description 9
- 239000002253 acid Substances 0.000 abstract description 6
- 239000004677 Nylon Substances 0.000 abstract description 4
- 229920001778 nylon Polymers 0.000 abstract description 4
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 abstract description 2
- 239000000470 constituent Substances 0.000 abstract description 2
- 235000012830 plain croissants Nutrition 0.000 abstract 1
- 239000000306 component Substances 0.000 description 38
- 229920001903 high density polyethylene Polymers 0.000 description 26
- 239000004700 high-density polyethylene Substances 0.000 description 26
- 229920000092 linear low density polyethylene Polymers 0.000 description 24
- 239000004707 linear low-density polyethylene Substances 0.000 description 24
- 239000000975 dye Substances 0.000 description 11
- 229920002544 Olefin fiber Polymers 0.000 description 9
- 150000001336 alkenes Chemical group 0.000 description 9
- 239000004767 olefin fiber Substances 0.000 description 9
- 229920001577 copolymer Polymers 0.000 description 8
- 239000004745 nonwoven fabric Substances 0.000 description 8
- 239000004743 Polypropylene Substances 0.000 description 7
- 238000001125 extrusion Methods 0.000 description 7
- 229920000578 graft copolymer Polymers 0.000 description 7
- 229920001155 polypropylene Polymers 0.000 description 7
- 229920001684 low density polyethylene Polymers 0.000 description 6
- 239000004702 low-density polyethylene Substances 0.000 description 6
- 239000004698 Polyethylene Substances 0.000 description 5
- 229920000297 Rayon Polymers 0.000 description 5
- 239000000155 melt Substances 0.000 description 5
- 238000002074 melt spinning Methods 0.000 description 5
- 239000002964 rayon Substances 0.000 description 5
- 238000005520 cutting process Methods 0.000 description 4
- 229920000742 Cotton Polymers 0.000 description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 3
- 239000005977 Ethylene Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 150000008064 anhydrides Chemical group 0.000 description 3
- 239000011324 bead Substances 0.000 description 3
- 239000012141 concentrate Substances 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 239000002657 fibrous material Substances 0.000 description 3
- 239000003999 initiator Substances 0.000 description 3
- 150000002978 peroxides Chemical class 0.000 description 3
- 229920000098 polyolefin Polymers 0.000 description 3
- 150000003254 radicals Chemical class 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 238000007711 solidification Methods 0.000 description 3
- 230000008023 solidification Effects 0.000 description 3
- 238000009987 spinning Methods 0.000 description 3
- 229920002994 synthetic fiber Polymers 0.000 description 3
- 239000012209 synthetic fiber Substances 0.000 description 3
- 239000002759 woven fabric Substances 0.000 description 3
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 2
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 239000012736 aqueous medium Substances 0.000 description 2
- 239000000981 basic dye Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000003490 calendering Methods 0.000 description 2
- 238000010622 cold drawing Methods 0.000 description 2
- 239000008358 core component Substances 0.000 description 2
- 230000007794 irritation Effects 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229920013683 Celanese Polymers 0.000 description 1
- RUPBZQFQVRMKDG-UHFFFAOYSA-M Didecyldimethylammonium chloride Chemical compound [Cl-].CCCCCCCCCC[N+](C)(C)CCCCCCCCCC RUPBZQFQVRMKDG-UHFFFAOYSA-M 0.000 description 1
- 229920010126 Linear Low Density Polyethylene (LLDPE) Polymers 0.000 description 1
- 235000009421 Myristica fragrans Nutrition 0.000 description 1
- 239000012963 UV stabilizer Substances 0.000 description 1
- 238000005411 Van der Waals force Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 1
- 125000002843 carboxylic acid group Chemical group 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 238000009960 carding Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 239000012967 coordination catalyst Substances 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- 239000012792 core layer Substances 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 229960004670 didecyldimethylammonium chloride Drugs 0.000 description 1
- 238000000113 differential scanning calorimetry Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 229920006240 drawn fiber Polymers 0.000 description 1
- 238000005108 dry cleaning Methods 0.000 description 1
- 238000005538 encapsulation Methods 0.000 description 1
- 238000007765 extrusion coating Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 238000007757 hot melt coating Methods 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 150000002432 hydroperoxides Chemical class 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 125000003010 ionic group Chemical group 0.000 description 1
- 239000010410 layer Substances 0.000 description 1
- 229920004889 linear high-density polyethylene Polymers 0.000 description 1
- 125000005647 linker group Chemical group 0.000 description 1
- 239000001115 mace Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000002609 medium Substances 0.000 description 1
- 229920001179 medium density polyethylene Polymers 0.000 description 1
- 239000004701 medium-density polyethylene Substances 0.000 description 1
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000019612 pigmentation Effects 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- 238000004448 titration Methods 0.000 description 1
- 238000002604 ultrasonography Methods 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
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
- 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
- D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
-
- 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
- D01F8/12—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyamide as constituent
-
- 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
Definitions
- the present invention pertains to dyeable thermoplastic bicomponent fibers and a method of
- bicomponent fibers are characterized by contacting under thermally bonding conditions (a) a first component comprising at least one high performance thermoplastic polymer, and (b) a second component comprising at least one grafted linear ethylene polymer having pendant succinic acid or succinic anhydride groups.
- the bicomponent fibers can be prepared by coextruding (a) and (b) into fiber having a round, oval, trilobal, triangular, dog-boned, flat or hollow shape and a sheath/core or side-by-side configuration.
- the bicomponent fiber can be coextruded using melt blown, spunbond or staple fiber manufacturing process
- the present invention also pertains to a method of bonding high performance fibers using the dyeable thermoplastic bicomponent fibers of the present invention as binder fibers.
- Various olefin fibers i.e., fibers in which the fiber-forming substance is any long chain, synthetic polymer of at least 85 weight percent ethylene,
- propylene, or other olefin units are known from the prior art.
- the mechanical properties of such fibers are generally related in large part to the morphology of the polymer, especially molecular orientation and
- polypropylene fibers and filaments are items of commerce and have been used in making products such as ropes, non-woven fabrics, and woven fabrics.
- Polypropylene is known to exist as atactic (largely amorphous), syndiotactic (largely crystalline), and isotactic (also largely crystalline).
- poly.olefins which have been suitably formed into fibers include linear ethylene polymers, such as linear high density polyethylene
- HDPE high density polyethylene
- LLDPE linear low density polyethylene
- LDPE low density polyethylene
- LLDPE linear medium density polyethylene
- the densities of the linear ethylene polymers are measured in accordance with ASTM D-792 and defined as in ASTM 0-1248. These polymers are prepared using coordination catalysts and are generally known as linear polymers because of the substantial absence of branched chains of polymerized monomer pendant from the main polymer backbone.
- LLDPE is a linear low density ethylene polymer wherein ethylene has been polymerized along with minor amounts of ⁇ , ⁇ -ethylenically
- unsaturated alkenes having from three to twelve carbon (C 3 -C 12 ) atoms per alkene molecule, and more typically four to eight (C 4 -C 8 ).
- LLDPE contains short chain branching due to the pendant side groups introduced by the alkene comonomer and exhibits
- low density polyethylene such as toughness and low modulus, it generally retains much of the strength, crystallinity, and extensibility normally found in HDPE homopolymers.
- polyethylene prepared with the use of a free radical initiator, such as peroxide gives rise to highly branched polyethylenes known as low density polyethylene (LDPE) and sometimes as high pressure polyethylene (HPPE) and ICI-type polyethylenes.
- LDPE low density polyethylene
- HPPE high pressure polyethylene
- ICI-type polyethylenes ICI-type polyethylenes.
- fibers such as, for example, polyvinyl chloride, low melting polyester and polyvinylacetate
- binder fibers by blending the binder fiber with high performance natural and/or synthetic fibers such as polyesters (e.g., polyethylene terephthalate (PET) or polybutylene terephthalate (PBT)), polyamides,
- PET polyethylene terephthalate
- PBT polybutylene terephthalate
- Olefin fibers are inherently difficult to dye, because there are no sites for the specific attraction of dye molecules, i.e., there are no hydrogen bonding or ionic groups, and dyeing can only take place by virtue of weak van der Waals forces.
- dyeing can only take place by virtue of weak van der Waals forces.
- fibers are colored by adding pigments to the polyolefin melt before
- Bicomponent fibers are typically fabricated commercially by melt spinning.
- a die e.g., a spinnerette
- Melt spinning may also include cold drawing, heat treating, texturizing and/or cutting.
- An important aspect of melt spinning is the orientation of the polymer molecules by drawing the polymer in the molten state as it leaves the spinnerette.
- a “monofilament” refers to an individual strand of denier greater than 15, usually greater than 30;
- a “fine denier fiber or "filament” refers to a strand of denier less than 15:
- multi-filament refers to simultaneously formed fine denier filaments spun in a bundle of fibers, generally containing at least 3, preferably at least 15-100 fibers and can be several hundred or several thousand;
- extruded strand refers to an extrudate formed by passing polymer through a forming-orifice, such as a die;
- a "bicomponent fiber” refers to a fiber comprising two polymer components, each in a continuous phase, e.g. side-by-side or sheath/core;
- a "bicomponent staple fiber” refers to a fine denier strand which have been formed at, or cut to, staple lengths of generally one to eight inches (2.5 to 20 cm).
- the shapes of these bicomponent fibers, extruded strands and bicomponent staple fibers can be any which is convenient to the producer for the intended end use, e.g., round, trilobal, triangular, dog-boned, flat or hollow.
- the configuration of these bicomponent fibers or bicomponent staple fibers can be symmetric (e.g., sheath/core or side-by-side) or they can be asymmetric (e.g., a crescent/moon configuration within a fiber having an overall round shape).
- European Patent Application No. 87304728.6 which describes a non ⁇ woven fabric formed of heat bonded bicomponent filaments having a sheath of LLDPE and a core of polyethylene terephthalate.
- CA 91:22388p (1979) there is described a fiber comprising polypropylene and ethylene-maleic anhydride graft copolymer spun at a 50:50 ratio and drawn 300 percent at 100°C, and a blend of the drawn fibers and rayon at a 40:60 weight ratio carded and heated at 145°C to give a bulky non-woven fabric.
- polypropylene is disadvantageous in some applications because of its relatively high melting point (145°C), and because of the relatively poor hand or feel imparted to fabrics made thereof. Poor hand is manifested in a relatively rough and inflexible fabric, as opposed to a smooth and flexible fabric.
- U.S. Patent No. 4,684,576 describes the use of olends of HDPE grafted with maleic acid or maleic anhydride to give rise to succinic acid or succinic anhydride groups along the polymer chain with other olefin polymers as an adhesive, for example, in
- thermoplastic bicomponent fibers by contacting under thermally bonding conditions (a) a first component being at least one high performance thermoplastic polymer, and (b) a second component which is olefinic and which forms at least a portion of the fiber's surface characterized by (b) including at least one grafted linear ethylene polymer having pendant succinic acid or succinic anhydride groups; whereby the fiber is dyeable.
- a first component being at least one high performance thermoplastic polymer
- a second component which is olefinic and which forms at least a portion of the fiber's surface characterized by (b) including at least one grafted linear ethylene polymer having pendant succinic acid or succinic anhydride groups; whereby the fiber is dyeable.
- the bicomponent fiber can be prepared by coextruding (a) and (b) into a fiber having a symmetrical or asymmetrical sheath/core or side-by-side configuration and a round, oval, trilobal, triangular, dog-boned, flat or hollow shape.
- Component (a) can be a polyester (such as polyethylene
- Component (b) can be a polymer blend of a grafted linear ethylene polymer having pendant succinic acid or succinic anhydride groups and at least one ungrafted linear ethylene polymer.
- the bicomponent fiber can be formed under melt blown, spunbond or staple manufacturing process
- a method of bonding high performance natural and/or synthetic fibers such as polyester (e.g., PET or PBT), polyamides (e.g., nylon), cellulosics (e.g., cotton), modified cellulosics (e.g., rayon), wool or the like, by blending dyeable thermoplastic bicomponent fibers of the present invention used as binder fibers with the high performance fibers and heating the fibrous mixture to thermally weld the binder fiber to the high performance fibers.
- the invention provides a fabric comprising dyeable thermoplastic bicomponent fibers.
- the invention provides a fabric comprising dyeable thermoplastic bicomponent fibers as binder fiber blended with performance fibers, wherein the bicomponent binder fibers are bonded to the performance fibers.
- an adhesive polymer blend for use as a component in making the dyeable thermoplastic
- the polymer blend comprises (a) at least one grafted linear ethylene polymer having pendant succinic acid or succinic anhydride groups and (b) at least one ungrafted linear ethylene polymer.
- thermoplastic bicomponent fiber characterized by (a) a first component comprising at least one high performance thermoplastic polymer, and (b) a second component comprising at least one grafted linear
- succinic anhydride groups which have been contacted under thermally bonding conditions.
- the linear ethylene polymers used for grafting can be linear HDPE and/or LLDPE.
- the density of linear HDPE before grafting can be about 0.94 to 0.97 g/cc, but is typically between about 0.945 and 0.965 g/cc, while that of LLDPE before grafting can be about 0.88 to
- linear HDPE and LLDPE will have about the same density before and after grafting, but this can vary depending on the particular linear ethylene polymer properties, graft level, grafting conditions and the like.
- the linear ethylene polymer before grafting has a melt index (MI) measured at 190°C/2.16 kg from about 0,1 to about 1000 grams/10 minutes, but typically less after grafting.
- MI melt index
- linear HDPE with a 25 MI and a 0.955 g/cc density grafted to a level of about 1 weight percent maleic anhydride (MAH) has a MI after grafting of about 16-18 grams/10 minutes.
- MI melt index
- the MI of the ungrafted linear ethylene polymer used for grafting is selected depending on the specific melt spinning procedure employed and whether or not the grafted linear ethylene polymer is employed alone or in a blend with another linear ethylene polymer.
- the grafting of succinic acid or succinic anhydride groups may be done by methods described in the art which generally involve reacting maleic acid or maleic anhydride in admixture with heated polymer, generally using a peroxide or free radical initiator to accelerate the grafting.
- the maleic acid and maleic anhydride compounds are known in these relevant arts as having their olefin unsaturation sites conjugated to the acid groups. Fumaric acid, an isomer of maleic acid which is also conjugated, gives off water and rearranges to form maleic anhydride when heated, and thus is operable in the present invention.
- Grafting may be effected in the presence of oxygen, air hydroperoxides, or other free radical initiators, or in the essential absence of these materials when the mixture of monomer and polymer is maintained under high shear and heat conditions.
- a convenient method for producing the graft polymer is extrusion machinery, although Brabender mixers or Banbury mixers, roll mills and the like may also be used for forming the graft polymer. It is preferred to employ a twin-screw devolatilizing extruder (such as a Werner-Pfleiderer twin-screw extruder) wherein maleic acid or maleic anhydride is mixed and reacted with the linear ethylene polymer(s) at molten temperatures to produce and extrude the grafted polymer.
- twin-screw devolatilizing extruder such as a Werner-Pfleiderer twin-screw extruder
- the anhydride or acid groups of the grafted polymer generally comprise from about 0.001 to about 10 weight percent, preferably from about 0.01 to about 5 weight percent, and especially from 0.1 to about 1 weight percent of the grafted polymer.
- the grafted polymer is characterized by the presence of pendant succinic acid or anhydride groups along the polymer chain, as opposed to the carboxylic acid groups obtained by the bulk copolymerization of ethylene with an
- Grafted linear HDPE is the preferred grafted linear ethylene polymer.
- the grafted linear ethylene polymer(s) can be employed singly or as a component in a polymer blend with other linear ethylene polymers.
- the polymer blend preferably contains from about 0.5 to about 99.5 weight percent of the grafted linear ethylene polymer, more preferably from about 1 to 50 weight percent grafted linear ethylene polymer, and especially from about 2 to 15 weight percent grafted linear ethylene polymer.
- the polymer blend may also include conventional additives, such as dyes, pigments, antioxidants, UV stabilizers, spin finishes, and the like and/or relatively minor proportions of other fiber forming polymers which do not significantly alter the melting properties of the blend or the improved hand obtained in fabrics containing fibers employing LLDPE as a polymer blend component.
- the LLDPE employed either as the grafted linear ethylene polymer component or as the. ungrafted component in the dyeable thermoplastic bicomponent fiber,
- olefinically unsaturated alkene preferably a C 4 -C 8 olefinically unsaturated alkene, and 1-octene is
- the alkene may constitute from about 0.5 to about 35 percent by weight of the LLDPE, preferably from about 1 to about 20 weight percent, and most preferably from about 2 to about 15 weight percent.
- grafted linear HDPE. grafted linear HDPE.
- ungrafted linear ethylene polymer such as ungrafted LLDPE
- dry blending of pellets of the grafted linear ethylene polymer and the ungrafted linear ethylene polymer prior to extrusion is generally adequate where the melt indices of the blend components are similar, and there will generally be no advantage in melt blending such blend constituents prior to
- melt blending may be desired, as in the case of grafted linear HDPE and LLDPE or dissimilar melt indices, melt blending may be
- the high performance thermoplastic polymer useful as such as the second component of the dyeable thermoplastic bicomponent fiber of the present invention can be a polyester (e.g., PET or PBT) or a polyamide (e.g., nylon).
- the high performance thermoplastic polymer can be used as one component of the bicomponent fiber by contacting it with the grafted linear ethylene polymer(s) under thermally bonding conditions, such as that encountered when coextruding bicomponent fiber using a bicomponent staple fiber die.
- performance polymer can either component of a
- the high performance thermoplastic polymer can be chosen to provide stiffness in the bicomponent fiber, especially when the grafted linear ethylene polymer is a polymer blend of grafted linear HDPE blended with ungrafted LLDPE. Additionally, the high performance thermoplastic polymer used in making the bicomponent fiber of the present invention can be the same polymer as that used for making high performance fiber which is blended with the bicomponent fiber.
- Extrusion of the polymer through a die to form a fiber is effected using conventional equipment such as, for example, extruders, gear pumps and the like. It is preferred to employ separate extruders, which feed gear pumps to supply the separate molten polymer streams to the die.
- the grafted linear ethylene polymer or polymer blend is preferably mixed in a mixing zone of the extruder and/or in a static mixer, for example, upstream of the gear pump in order to obtain a more uniform dispersion of the polymer components.
- the fiber is taken up in solid form on a godet or another take-up surface.
- the fibers are taken up oh a godet which draws down the fibers in proportion to the speed of the take-up godet.
- the fibers are collected in a jet, such as, for example, an air gun, and blown onto a take-up surface such as a roller or moving belt.
- a jet such as, for example, an air gun
- blown onto a take-up surface such as a roller or moving belt.
- air is ejected at the surface of the spinnerette which serves to simultaneously draw down and cool the fibers as they are deposited on a take-up surface in the path of the cooling air.
- melt drawdowns of up to about 1:1000 may be employed depending upon spinnerette die diameter and spinning velocity, preferably from about 1:10 to about 1:200, and especially 1:20 to 1:100.
- the strands may also be heat treated or
- the strands may further be texturized, such as, for example, by crimping and cutting the strand or strands to form staple.
- texturizing is effected in the air jet and by impact on the take-up surface, respectively.
- Similar texturizing is effected in the melt blown process by the cooling fluid which is in shear with the molten polymer strands, and which may also randomly delinearize the fibers prior to their solidification.
- the bicomponent fibers so formed by the above-described process also constitute a part of the present invention.
- the bicomponent fibers are generally fine denier filaments of 15 denier or less down to fractional deniers, preferably in the range of from 1 to 10 denier, although this will depend on the desired properties of the fibers and the specific application in which they are to be used.
- the bicomponent fibers of the present invention have a wide variety of potential applications.
- the bicomponent fibers may be formed into a batt and heat treated by calendaring on a heated, embossed roller to form a fabric.
- the batts may also be heat bonded, for example, by infrared light, ultrasound or the like, to obtain a high loft fabric.
- the fibers may also be employed in conventional textile processing such as carding, sizing, weaving and the like. Woven fabrics made from the bicomponent fibers of the present invention may also be heat treated to alter the
- a preferred embodiment of the invention resides in the employment of the bicomponent fibers formed according to the process of the invention in binder fiber applications with high performance natural and/or synthetic fibers such as, for example, polyamides, polyesters, silk, cellulosics (e.g. cotton), wool, modified cellulosics such as rayon and rayon acetate. and the like.
- the bicomponent fibers of the present invention find particular advantage as binder fibers owing to their adhesion to performance fibers and dyeability thereof which is enhanced by the presence of the acid groups in the grafted linear ethylene polymer component and the relatively lower melting temperature or range of the grafted linear ethylene polymer
- the relative proportions of the binder fiber of the present invention employed in admixture with performance fibers in a fiber blend will depend on the desired application and capabilities of the resulting fiber mixture and/or fabric obtained thereby. It is preferred to employ from about 5 to about 95 parts by weight of the binder fiber per 100 parts by weight of the binder fiber/performance fiber mixture, more preferably from about 5 to about 50 parts by weight binder fiber, and especially 5 to 15 parts by weight binder fiber.
- the binder fibers are in staple form, there should be no fusing of the fibers when they are cut into staple, and the crimp imparted to the binder fibers should be sufficient for blending with the performance fibers to obtain good distribution of the fibers.
- the ability of the component comprising at least one grafted linear ethylene polymer having pendant succinic acid or anhydride groups to adhere to the other component of at least one high performance thermoplastic polymer is an important consideration in cutting of bicomponent staple fiber.
- the fiber When bicomponent staple fiber is cut and one of the components (e.g., the core of a bicomponent fiber) protrudes from the cut edge, the fiber will create an irritation when worn next to the skin. The irritation is especially pronounced when the core component is a high performance thermoplastic such as PET.
- ungrafted linear ethylene polymer and PET are made, respectively, into a sheath/core bicomponent fiber and cut into short staple fiber. the core of PET protrudes beyond the cut edge.
- the enhanced adhesion of the grafted linear ethylene polymer component to the PET component used in making the dyeable thermoplastic bicomponent fiber of the present invention reduces PET protrusion beyond the fiber after cutting and thus enables fabrics and fiber blends to be mace which can be more comfortably worn next to the skin.
- the ability of the bicomponent binder fibers to adhere to the performance fibers is another important consideration. Adhesion and dyeability can generally be controlled by varying the acid content of the binder fiber, either by the level of graft of maleic acid or anhydride in the grafted linear ethylene polymer, or by the proportion of the grafted linear ethylene polymer blended with the ungrafted linear ethylene polymer in the bicomponent binder fibers. In typical non-woven fabrics obtained by thermally bonding the performance fibers with a bicomponent binder fiber, the ability of the binder fibers to bond together the performance fibers depends largely on the thermal bonding of the performance fibers together by the binder fibers.
- the binder fiber thermally bonds performance fibers together by at least partially melting to form globules or beads which encapsulate the performance fibers.
- the binder fibers of the present invention enhance the non-woven fabric by providing great adhesion of the binder fiber to the performance fiber.
- Employing the binder fibers of the present invention it is also possible to obtain thermal bonding of the binder fiber to a performance fiber by partial melting and contact adhesion in which the bicomponent binder fibers largely retain their fibrous form, and the resulting non-woven fabric is characterized by a reduced number of globules or beads formed by the melting of the lower melting component of the bicomponent binder fibers.
- melting point range or thermal bonding window is the difference between the Vicat softening point and the peak melting point determined by differential scanning calorimetry (DSC). Narrow melting point ranges present a difficult target for process bonding equipment such as a calendar roll, and even slight variations in the temperature of bonding
- the bicomponent binder fibers will not be
- a melting point range of at least 7.5oC is desired for proper thermal bonding, and preferably a sufficiently broad melting point range that a minimum 10°C bonding window is obtained.
- bicomponent binder fibers Another important characteristic of bicomponent binder fibers is that when they are melted in equipment such as a calendar roll, one of the components will have a sufficient melt viscosity to be retained in the fiber matrix and not readily flow therefrom.
- An important advantage of the bicomponent binder fibers of the present invention is that one component has generally higher melt viscosity than fibers consisting of
- bonding of the present binder fibers can also be obtained using other bonding techniques, e.g. with hot air, infrared heaters, and the like.
- thermoplastic bicomponent fibers of the invention can be dyed by contacting them with a water soluble ionic dye, preferably a water soluble cationic dye, in a suitable aqueous medium.
- a water soluble ionic dye preferably a water soluble cationic dye
- the aqueous medium can contain surfactants, if desired, to promote contact.
- a linear HDPE ethylene/propylene copolymer (the "base” polymer), having a MI of about 25 grams/10 minutes and density of 0.955 g/cc, is extruded with maleic anhydride (3.0 pounds per hour) and dicumyy peroxide (0.3 pounds per hour) at an average melt temperature of 225°C (the temperature ranged from about 180° to about 250°C) using a Werner-Pfleiderer twin-screw devolatization extruder.
- concentration of maleic anhydride is about 1 % by weight (as determined by titration) and has a MI of about
- compositions ranging from 5% MAH-grafted linear HDPE concentrate to 50% MAH-grafted linear HDPE concentrate in various LLDPE resins at a melt temperature of 170°C.
- the blends are useful as at least one component in a bicomponent fiber, wherein at least one other component is a performance polymer component, such as PBT or PET.
- Example 3 (ethylene/propylene copolymer, MI of 25 grams/10 minutes before grafting, density of 0.955 g/cc before grafting) having about 1 % by weight succinic acid groups is blended with about 90% by weight of an ungrafted LLDPE (ethylene/octene copolymer, MI of 18 grams/10 minutes, 0.930 g/cc density) to form a polymer blend having about 0.1% by weight succinic acid groups.
- the polymer blend is then used as a sheath component in a bicomponent staple fiber spinning operation, with the core component being PET.
- the sheath/core bicomponent fibers are blended with other performance fibers such as PET or cellulosics, formed into batts and oven bonded. The batts are found to be well-bonded and have good physical integrity.
- Example 3 Example 3
- Linear HDPE ethylene-propylene copolymer, MI of 25 grams/10 minutes, 0.955 g/cc density
- MI ethylene-propylene copolymer
- 0.955 g/cc density ethylene-propylene copolymer
- Portions of the grafted linear HDPE are then blended with amounts of ungrafted LLDPE
- Linear HDPE ethylene-propylene copolymer, MI of 25 grams/10 minutes, 0.955 g/cc density
- MI ethylene-propylene copolymer
- maleic anhydride to provide about 1% by weight succinic anhydride groups along the polymer chain.
- Portions of the grafted linear HDPE are blended with amounts of ungrafted LLDPE (ethylene-octene copolymer. MI of 18 grams/10 minutes, 0.930 g/cc density) to produce polymer blends containing 0.05%, 0.1%, 0.15%, 0.2%, and 0.5% by weight of the succinic acid groups.
- Polymer blends of the grafted linear HDPE with the ungrafted LLDPE can be coextruded as the sheath layer in a bicomponent spunbond system using a PET as the core layer.
- the resultant thermally bonded fabric has a bonded fabric strength higher than that obtained using ungrafted linear ethylene polymer alone as the sheath resin.
- LLDPE ethylene-octene copolymer, MI of 18 grams/10 minutes, 0.930 g/cc density
- Basic Violet III a basic dye also known as Crystal Violet
- the resulting polymer blend when treated in the same manner as immediately above, became dyed to a blue/purple color.
- the dye does not readily leach out, even when placed in boiling water for 10-15 minutes.
- Other water soluble cationic dyes i.e., dyes which are typically referred to as "basic dyes" in the industry
- basic dyes can be similarly used to dye the novel bicomponent fibers.
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Multicomponent Fibers (AREA)
- Artificial Filaments (AREA)
- Nonwoven Fabrics (AREA)
- Inorganic Fibers (AREA)
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US1990/004410 WO1992002669A1 (en) | 1990-08-07 | 1990-08-07 | Method for making biocomponent fibers |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0496734A1 true EP0496734A1 (de) | 1992-08-05 |
EP0496734A4 EP0496734A4 (en) | 1993-06-16 |
EP0496734B1 EP0496734B1 (de) | 1999-01-07 |
Family
ID=22220986
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP90913042A Expired - Lifetime EP0496734B1 (de) | 1990-08-07 | 1990-08-07 | Thermisch gebundene fasererzeugnisse mit bikomponentfasern als haftfasern |
Country Status (8)
Country | Link |
---|---|
EP (1) | EP0496734B1 (de) |
JP (1) | JP2920567B2 (de) |
KR (1) | KR0154969B1 (de) |
AU (1) | AU645264B2 (de) |
BR (1) | BR9007727A (de) |
DE (1) | DE69032885T2 (de) |
ES (1) | ES2127717T3 (de) |
WO (1) | WO1992002669A1 (de) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2019190705A1 (en) | 2018-03-29 | 2019-10-03 | Dow Global Technologies Llc | Bicomponent fiber and polymer composition thereof |
US12104050B2 (en) | 2018-03-29 | 2024-10-01 | Dow Global Technologies Llc | Bicomponent fiber and polymer composition thereof |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5904982A (en) * | 1997-01-10 | 1999-05-18 | Basf Corporation | Hollow bicomponent filaments and methods of making same |
JP4350258B2 (ja) * | 2000-03-14 | 2009-10-21 | 株式会社クラレ | 染色性に優れた軽量繊維 |
DE10244778B4 (de) | 2002-09-26 | 2006-06-14 | Trevira Gmbh | Exzentrische Polyester-Polyethylen-Bikomponentenfaser |
NL1035682C2 (nl) * | 2008-07-10 | 2010-01-12 | Desseaux H Tapijtfab | Kunstgrasveld. |
CN103339304B (zh) * | 2011-02-02 | 2016-04-06 | 大和纺控股株式会社 | 显现卷曲性复合短纤维及其制造方法、纤维集合物及卫生物品 |
CN110461806A (zh) | 2017-11-20 | 2019-11-15 | 株式会社Lg化学 | 分解苯酚生产工艺中的副产物的方法 |
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US4230830A (en) * | 1979-03-30 | 1980-10-28 | E. I. Du Pont De Nemours And Company | Adhesive blends containing thermally grafted ethylene polymer |
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US4500384A (en) * | 1982-02-05 | 1985-02-19 | Chisso Corporation | Process for producing a non-woven fabric of hot-melt-adhered composite fibers |
US4684576A (en) * | 1984-08-15 | 1987-08-04 | The Dow Chemical Company | Maleic anhydride grafts of olefin polymers |
WO1990001504A1 (en) * | 1988-08-09 | 1990-02-22 | The Dow Chemical Company | Maleic anhydride graft copolymer products having low yellowness index and preparation |
WO1990005152A1 (en) * | 1988-11-02 | 1990-05-17 | The Dow Chemical Company | Maleic anhydride-grafted polyolefin fibers |
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EP0434448A2 (de) * | 1989-12-21 | 1991-06-26 | Hoechst Celanese Corporation | Vorrichtung und Verfahren zum Spinnen von Bikomponentfasern und damit hergestellte Produkte |
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US423830A (en) * | 1890-03-18 | Two-wheeled vehicle | ||
CA920316A (en) * | 1968-02-29 | 1973-02-06 | Kanegafuchi Boseki Kabushiki Kaisha | Multi-component mixed filament with nebular configuration |
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DE3544523A1 (de) * | 1984-12-21 | 1986-06-26 | Barmag Barmer Maschinenfabrik Ag, 5630 Remscheid | Verfahren zur herstellung von bikomponentenfasern, daraus hergestellte fasern und deren verwendung |
EP0248598B1 (de) * | 1986-05-31 | 1992-10-21 | Unitika Ltd. | Vliesstoff aus Polyolefin und Verfahren zur Herstellung desselben |
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1990
- 1990-08-07 BR BR909007727A patent/BR9007727A/pt not_active IP Right Cessation
- 1990-08-07 ES ES90913042T patent/ES2127717T3/es not_active Expired - Lifetime
- 1990-08-07 WO PCT/US1990/004410 patent/WO1992002669A1/en active IP Right Grant
- 1990-08-07 JP JP2511881A patent/JP2920567B2/ja not_active Expired - Lifetime
- 1990-08-07 AU AU62781/90A patent/AU645264B2/en not_active Expired
- 1990-08-07 KR KR1019920700786A patent/KR0154969B1/ko not_active IP Right Cessation
- 1990-08-07 DE DE69032885T patent/DE69032885T2/de not_active Expired - Lifetime
- 1990-08-07 EP EP90913042A patent/EP0496734B1/de not_active Expired - Lifetime
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US4230830A (en) * | 1979-03-30 | 1980-10-28 | E. I. Du Pont De Nemours And Company | Adhesive blends containing thermally grafted ethylene polymer |
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Publication number | Priority date | Publication date | Assignee | Title |
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WO2019190705A1 (en) | 2018-03-29 | 2019-10-03 | Dow Global Technologies Llc | Bicomponent fiber and polymer composition thereof |
US12104050B2 (en) | 2018-03-29 | 2024-10-01 | Dow Global Technologies Llc | Bicomponent fiber and polymer composition thereof |
Also Published As
Publication number | Publication date |
---|---|
DE69032885T2 (de) | 1999-05-27 |
ES2127717T3 (es) | 1999-05-01 |
EP0496734A4 (en) | 1993-06-16 |
JPH05500394A (ja) | 1993-01-28 |
BR9007727A (pt) | 1992-07-21 |
JP2920567B2 (ja) | 1999-07-19 |
EP0496734B1 (de) | 1999-01-07 |
KR927003891A (ko) | 1992-12-18 |
KR0154969B1 (ko) | 1998-12-01 |
WO1992002669A1 (en) | 1992-02-20 |
DE69032885D1 (de) | 1999-02-18 |
AU645264B2 (en) | 1994-01-13 |
AU6278190A (en) | 1992-03-02 |
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