EP0595157A1 - Multilobalfaser mit Projektionen in jedem Schenkel für Teppichgarne und Spinndüse zu ihrer Herstellung - Google Patents

Multilobalfaser mit Projektionen in jedem Schenkel für Teppichgarne und Spinndüse zu ihrer Herstellung Download PDF

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Publication number
EP0595157A1
EP0595157A1 EP93116826A EP93116826A EP0595157A1 EP 0595157 A1 EP0595157 A1 EP 0595157A1 EP 93116826 A EP93116826 A EP 93116826A EP 93116826 A EP93116826 A EP 93116826A EP 0595157 A1 EP0595157 A1 EP 0595157A1
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EP
European Patent Office
Prior art keywords
lobe
lobes
projections
fiber
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.)
Granted
Application number
EP93116826A
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English (en)
French (fr)
Other versions
EP0595157B1 (de
Inventor
Elbert K. Warren
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.)
BASF Corp
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BASF Corp
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Filing date
Publication date
Priority claimed from US07/967,002 external-priority patent/US5263845A/en
Application filed by BASF Corp filed Critical BASF Corp
Publication of EP0595157A1 publication Critical patent/EP0595157A1/de
Application granted granted Critical
Publication of EP0595157B1 publication Critical patent/EP0595157B1/de
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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
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/445—Yarns or threads for use in floor fabrics
    • 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

Definitions

  • the present invention is directed to a multilobal fiber with projections alternating along the contour of each lobe for use on carpet yarns.
  • Another embodiment of the present invention is directed to a spinnerette plate for the manufacture of a multilobal fiber with at least one opening having a plurality of lobes radiating outwardly and each lobe having a plurality of projections alternating along the contour of each lobe, such spinnerette being suitable for the manufacture of the fiber according to the present invention.
  • Multilobal, in particular trilobal fibers and filaments and spinnerettes for their manufacture are known in the art and have been widely used, especially for carpet yarns. Such fibers show superior properties in bulk and covering power over fibers having round cross sections.
  • U.S. Pat. No. 3,194,002 discloses a multifilament yarn having a non-regular Y-shaped cross section.
  • U.S. Pat. No. 4,648,830 discloses a spinnerette for producing hollow trilobal cross-section filaments.
  • U.S. Pat. No. 5,108,838 discloses the trilobal and tetralobal filaments exhibiting low glitter and high bulk. The filaments having substantial convex curves.
  • One object of the present invention was to provide a fiber with a simple cross section, which exhibits good bulk, subdued luster, uneven surface, and good soil hiding properties.
  • Another object of the present invention was to provide a spinnerette plate with a simple geometry, which is easy to produce and which allows the manufacture of a fiber which exhibits good bulk, subdued luster, uneven surface and good soil hiding properties.
  • Still another object was to provide a carpet with subdued luster and good soil hiding properties.
  • a synthetic fiber having a multilobal cross section, each lobe of said multilobal cross section having two ends, one end being connected to the other lobes, the other end of said lobes radiating outwardly, each lobe having a plurality or projections, alternating along the contour of each lobe and by a spinnerette plate for the manufacture of such fibers comprising at least one opening having a plurality of lobes, each lobe having two ends, one end being connected to the other end of each of said lobes radiating outwardly and each lobe having a plurality of projections alternating along the contour of each lobe.
  • Figure 1 is a front view of a trilobal spinnerette capillary of the prior art.
  • Figure 1a is a cross-sectional view of a fiber spun by a spinnerette shown in Fig. 1.
  • Figure 2 is a front view of a trilobal spinnerette capillary of the present invention comprising three alternating projections along the contour of each lobe. These projections may be of a specific shape such as a rectangular, square, triangular or round shape.
  • Figure 2a is a cross-sectional view of a fiber of the present invention spun by a spinnerette shown in Fig. 2.
  • Figure 3 is a front view of a tetralobal spinnerette capillary of the present invention comprising three alternating projections along the contour of each lobe.
  • Figure 3a is a cross-sectional view of a fiber of the present invention spun by a spinnerette shown in Fig. 3.
  • the synthetic fibers of the present invention are generally prepared by melt spinning of a fiber forming polymer through a spinnerette of the present invention.
  • Suitable polymers for the production of the fibers of the present invention are all fiber forming thermoplastic materials especially polyamides, polyesters, and polyolefins.
  • Suitable polyamides are nylon 6, nylon 6/6, nylon 6/9, nylon 6/10, nylon 6/12, nylon 12, copolymers thereof and mixtures thereof.
  • Preferred polyamides are nylon 6 and nylon 6/6.
  • Preferred polyesters are polyalkyleneterephthalates and polyalkylenenaphthalates, a particularly preferred polyester is polyethylene terephthalate.
  • Suitable polyolefins are polymers of C2-C 10 ⁇ -olefins, in particular polyethylene, polypropylene and their copolymers.
  • additives may be added to the respective polymer. These include, but are not limited to, lubricants, nucleating agents, antioxidants, ultraviolet light stabilizers, pigments, dyes, antistatic agents, soil resists, stain resists, antimicrobial agents, and flame retardants.
  • the polymer usually is fed into an extruder in form of chips or granules, (indirect) melted and directed via jacketed heated polymer distribution lines (Dowtherm®, Dow Chemical, Midland Michigan) to the spinning head.
  • the polymer melt is then usually metered by a high efficiency gear pump to spin pack assembly and extruded through a spinnerette with capillaries described below.
  • the spinnerette plate of the present invention has in general at least one multilobal opening, like tris-, tetra-, penta- or hexalobal capillary, preferably tri- and tetralobal capillary.
  • the capillary of the spinnerette plate of the present invention is described with reference to Fig. 2 for a trilobal opening:
  • Lobes (1), (2) and (3) have two ends each, (4), (5); (4), (6) and (4), (7). On one end (4) the lobes are connected to each other end.
  • the angles between the lobes (1), (2) and (3) are from about 100° to about 140°, preferably about 120°.
  • the projections (8), (9), (10); (11, (12), (13); (14), (15) and (16) alternate along the contour of each lobe.
  • the number of projections per lobe is usually in the range of from 2 to 6, preferably from 2 to 4 and particularly preferably 3.
  • the projections may be different in each lobe and may have different types of shapes like rectangular, square, triangular or round. Preferred is one type of shape, preferably rectangular or square shape in the spinnerette.
  • the tetralobal opening (capillary) in the spinnerette plate according to Fig. 3 has four lobes (33), (34), (35 and (36). On one end (37) the lobes are connected to each other, the other end of each lobe (38), (39), (40) and (41) radiating outwardly.
  • the angles between the lobes (38), (39), (40) and (41) are from about 80° to 100°, preferably about 90°.
  • the projections (42), (43), (44); (45), (46), (47); (48), (49), (50) and (51), (52) and (53) alternate along the contour of each lobe.
  • the number of projections is usually in the range of from 2 to 6, preferably of from 2 to 4 and particularly preferred 3.
  • the length in mm of A and B usually satisfies the following relationship: 0.04 mm ⁇ A ⁇ 0.15 mm, preferably 0.06 mm ⁇ A ⁇ 0.12 mm and 0.06 mm ⁇ D ⁇ 3 mm, preferably 0.08 mm ⁇ D ⁇ 2.7 mm.
  • the angle zeta between the lobes of the trilobal capillary is usually from 70° to 140°, preferably from 110 to 130°, most preferred 115 to 125°, in particular 120°.
  • the angle zeta between the lobes of the tetralobal capillary is usually from 70° to 140°, preferably form 80° to 100° most preferred 85 to 95°, in particular 90°.
  • the disclosed dimensions are dependent from for example polymer type, spinning temperature, melt viscosity of the polymer and quench medium.
  • modification ratio for the resulting filaments is also an important factor.
  • modification ratio it is meant the ratio of the radius of a circle which circumscribes the filament cross-section to the radius of the largest circle which can be inscribed within the filament cross-section.
  • the two circles are shown as dotted lines in Fig. 2a and Fig. 3a.
  • the dimensions in the capillaries of the spinnerette plate are preferably such, that the MR for the cross-section of the resulting fiber is from 1.2 to 7, preferably from 2.5 to 5.
  • the respective polymer is extruded through the capillary of the spinnerette plate described in Fig. 2 or Fig. 3 to form a fiber having a cross-section described in Fig. 2a or Fig. 3a.
  • the trilobal cross-section of the fiber according to Fig. 2a has three lobes (17), (18) and (19) with two ends each (20), (21); (20), (22); and (20), (23).
  • each lobe On one end (20) the lobes are connected to each other, the other end of each lobe (21), (22) and (23) radiating outwardly.
  • the projections (24), (25), (26); (27), (28), (29) and (30), (31), (32) alternate along the contour of each lobe. According to the shape of the projections in the spinnerette, the projections of the cross section of the fiber differ slightly.
  • the tetra lobal cross-section of the fiber according to Fig. 3(a) has four lobes (54), (55), (56) and (57) with two ends each (58), (59); (58), (60); (58), (61) and (58), (62).
  • the projections (63), (64), (65); (66), (67), (68); (69), (70), (71); and (72), (73), (74) alternate along the contour of each lobe. According to the shape of the projections in the spinnerette, the projections of the cross section of the fiber differ slightly.
  • the lobes and diameters of the fiber of the present invention usually satisfy the following mathematical relationships: L1 is the narrowest width of the lobe; L2 is the widest width of the lobe; R1 is the inner fiber diameter; and R2 is the outer fiber diameter
  • L1, L2, R1 and R2 preferably satisfy the following relationship: 1.2 ⁇ R2/R1 ⁇ 7.0 more preferably 2.5 ⁇ R2/R1 ⁇ 5.0; 1.1 L1 ⁇ L2 ⁇ 5 L1 more preferably 1.3 ⁇ 1 ⁇ L2 ⁇ 4L1, and L1 ⁇ L2 ⁇ R1.
  • the spinnerette plate of the present invention has preferably from 5 to 300 openings in form of the capillaries, described above, preferably from 10 to 200 openings.
  • the fibers After being extruded, the fibers are usually quenched for example with air in order to solidify the fibers, thereafter treated with a finish comprising a lubricating oil or mixture of soils and antistatic agents and then combined to form a yarn bundle which is then wound on a suitable package.
  • the yarn can be drawn and texturized to form a bulked continuous filament (BCF) yarn suitable for tufting into carpets.
  • BCF bulked continuous filament
  • a more preferred technique involves combining the extruder or as-spun filaments into a yarn, then drawing, texturizing and winding a package, all in a single step. This one-step method of making BCF is referred to in the trade as spin-draw-texturing.
  • the BCF yarns can go through various processing steps well known to those skilled in the art.
  • the fibers of this invention are particularly useful in the manufacture of carpets for floor covering applications.
  • the BCF yarns are generally tufted into a pliable primary backing.
  • Primary backing materials are generally selected from the group comprising conventional woven jute, woven polypropylene, cellulosic nonwovens and nonwovens of nylon, polyester, and polypropylene.
  • the primary backing is then coated with a suitable latex material such as conventional styrene-butadiene latex, vinylidene chloride polymer, or vinyl chloride-vinylidene chloride copolymers. It is common practice to use fillers such as calcium carbonate to reduce latex costs.
  • the final step is to apply a secondary backing, generally a woven jute or woven synthetic such as polypropylene.
  • Nylon 6 filaments were spun using three of the modified cross-section spinnerettes. Each spinnerette had 12 capillaries of a specific design of such as that in Fig. 2A with the following dimensions:
  • the nylon 6 polymer (rel. viscosity RV 2.7) used was a bright polymer and did not contain any delusterant.
  • the molten fibers were quenched in a chimney using 80 ft/min air for cooling the fibers.
  • the filaments were pulled by feed roll rotating at a surface speed of 865 m/min through the quench zone and coated with a lubricant for drawing and crimping.
  • the yarns were combined and drawn at 1600 m/min and crimped by a process similar to that described in U.S. Pat. No. 4,095,317 to form 1100 denier 60 filament yarn.
  • the spun, drawn, and crimped yarns were cable-twisted to a 3.5 turns per inch (1.4 turns per cm) (tpi) on a cable twister and heat-set on a Superba heat-setting machine at the standard conditions for nylon 6 BCF yarns.
  • test yarns were then tufted into 32 oz/sq. yd. (1081.6 g/m2), 3/16 gauge (4.76 mm) cut pile constructions.
  • the test carpets were compared with carpets made from production running nylon 6 BCF carpet yarns in a one-step and two-step process.
  • the sidearm extruder was fed with a nylon 6 polymer blended with color concentrates to produce yarns of red, blue and green colors.
  • the polymer temperature was controlled at the pumpblock at about 265°C + 1° and the spinning throughput was 55.0 g/min per spinnerette.
  • the filaments were drawn on a drawtwister at a draw ratio of 3:10 to a final denier of 220/12 filament and combined on an air texturing machine.
  • a yarn with a denier of 200/35 filament was used as the core yarn and the green, red and blue yarns were used as accent yarns and textured to give a space-dye look in carpet.
  • the carpets were 25 oz (708.75 g) level loop and were compared to carpets made by the same process using the same blends of colors.
  • the comparative carpets were using a trilobal cross-section yarn drawn to a final denier of 220/14 filament. Results are shown in table 2. Table 2 yarns cross-section texture 1. Control round fair 2. Control 2.6 MR trilobal good 3. Example 2 4.6 MR trilobal good MR: modification ratio

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Artificial Filaments (AREA)
EP19930116826 1992-10-27 1993-10-19 Multilobalfaser mit Projektionen in jedem Schenkel für Teppichgarne und Spinndüse zu ihrer Herstellung Expired - Lifetime EP0595157B1 (de)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US96700392A 1992-10-27 1992-10-27
US967002 1992-10-27
US967003 1992-10-27
US07/967,002 US5263845A (en) 1992-10-27 1992-10-27 Spinnerette plate for the manufacture of multilobal fibers with projections on each lobe

Publications (2)

Publication Number Publication Date
EP0595157A1 true EP0595157A1 (de) 1994-05-04
EP0595157B1 EP0595157B1 (de) 1997-01-15

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EP19930116826 Expired - Lifetime EP0595157B1 (de) 1992-10-27 1993-10-19 Multilobalfaser mit Projektionen in jedem Schenkel für Teppichgarne und Spinndüse zu ihrer Herstellung

Country Status (3)

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EP (1) EP0595157B1 (de)
JP (1) JPH06192910A (de)
DE (1) DE69307456T2 (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003069031A1 (en) * 2002-02-11 2003-08-21 Honeywell International Inc. Soft hand, low luster, high body carpet filaments
WO2004016838A2 (en) * 2002-08-16 2004-02-26 Honeywell International, Inc. Fibers having dullness and products containing the same
WO2005075725A1 (en) * 2004-01-30 2005-08-18 The Procter & Gamble Company Shaped fiber fabrics
WO2013014364A1 (fr) 2011-07-28 2013-01-31 Saint-Gobain Adfors Revêtement mural absorbant acoustique renfermant une couche de fibres multilobees

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3097416A (en) * 1960-09-26 1963-07-16 Du Pont Textile filaments
US3109195A (en) * 1961-02-13 1963-11-05 Du Pont Spinneret plate
US5108838A (en) * 1991-08-27 1992-04-28 E. I. Du Pont De Nemours And Company Trilobal and tetralobal filaments exhibiting low glitter and high bulk

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH01239107A (ja) * 1988-03-15 1989-09-25 Asahi Chem Ind Co Ltd ブラシ用異形断面糸
JPH02182910A (ja) * 1989-01-06 1990-07-17 Teijin Ltd 潜在嵩高性マルチフィラメント糸
NZ233094A (en) * 1989-04-04 1992-07-28 Eastman Kodak Co Synthetic fibre with grooves spontaneously transports water on its surface
JPH05239709A (ja) * 1992-02-24 1993-09-17 Toyobo Co Ltd 極細超異形繊維

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3097416A (en) * 1960-09-26 1963-07-16 Du Pont Textile filaments
US3109195A (en) * 1961-02-13 1963-11-05 Du Pont Spinneret plate
US5108838A (en) * 1991-08-27 1992-04-28 E. I. Du Pont De Nemours And Company Trilobal and tetralobal filaments exhibiting low glitter and high bulk

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003069031A1 (en) * 2002-02-11 2003-08-21 Honeywell International Inc. Soft hand, low luster, high body carpet filaments
WO2004016838A2 (en) * 2002-08-16 2004-02-26 Honeywell International, Inc. Fibers having dullness and products containing the same
WO2004016838A3 (en) * 2002-08-16 2004-05-21 Honeywell Int Inc Fibers having dullness and products containing the same
US6841247B2 (en) 2002-08-16 2005-01-11 Honeywell International Inc. Fibers having improved dullness and products containing the same
WO2005075725A1 (en) * 2004-01-30 2005-08-18 The Procter & Gamble Company Shaped fiber fabrics
WO2013014364A1 (fr) 2011-07-28 2013-01-31 Saint-Gobain Adfors Revêtement mural absorbant acoustique renfermant une couche de fibres multilobees
US9186865B2 (en) 2011-07-28 2015-11-17 Saint-Gobain Adfors Acoustic absorbent wall coating

Also Published As

Publication number Publication date
DE69307456T2 (de) 1997-05-15
EP0595157B1 (de) 1997-01-15
JPH06192910A (ja) 1994-07-12
DE69307456D1 (de) 1997-02-27

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