EP0675215B1 - A process for preparing a thermal bondable fiber - Google Patents

A process for preparing a thermal bondable fiber Download PDF

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Publication number
EP0675215B1
EP0675215B1 EP95104015A EP95104015A EP0675215B1 EP 0675215 B1 EP0675215 B1 EP 0675215B1 EP 95104015 A EP95104015 A EP 95104015A EP 95104015 A EP95104015 A EP 95104015A EP 0675215 B1 EP0675215 B1 EP 0675215B1
Authority
EP
European Patent Office
Prior art keywords
fibers
molten polymer
fiber
spinneret
filament
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP95104015A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0675215A1 (en
Inventor
Eric J. Evain
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.)
Basell North America Inc
Original Assignee
Montell North America Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US08/331,319 external-priority patent/US5507997A/en
Application filed by Montell North America Inc filed Critical Montell North America Inc
Publication of EP0675215A1 publication Critical patent/EP0675215A1/en
Application granted granted Critical
Publication of EP0675215B1 publication Critical patent/EP0675215B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • D01F6/06—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins from polypropylene
    • 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
    • D01D10/00—Physical treatment of artificial filaments or the like during manufacture, i.e. during a continuous production process before the filaments have been collected

Definitions

  • This invention relates to a process of preparing fibers, in particular, an improved process of preparing thermal bondable fibers of fiber grade material.
  • Fibers of certain thermoplastic materials are used widely in the manufacturing of thermally bonded products, such as nonwoven textiles, by various processes. Said processes, such as calendering and spun bonding, require that the fibers have the capability of thermally bonding at temperatures lower than the melting point of the particular polymer(s) from which they are made, and that the fibers and articles manufactured therefrom be resistant to aging, yellowing and color variations caused by gas fading and oxidation.
  • Another approach is to add to the fiber grade polymer a low melting material, such as oligomers and waxes.
  • a low melting material such as oligomers and waxes.
  • the disadvantage of this approach is that the process must be modified to ensure adequate mixing of the materials so that gels are not formed in the fiber.
  • one component of the fiber has a lower melting point than the other, and covers the surface of the other component which has a higher melting point.
  • These fibers are generally referred to as a "sheath-core" or “side-by-side” bicomponent fibers.
  • the lower melting component enables thermal bonding at a temperature below the melting point of the fiber core.
  • fibers typically contain only one fiber grade polymer, such as "skin fiber". Modification of the fiber surface can be obtained using various methods, such as irradiation, plasma treatment, ozone treatment, corona discharge treatment or chemical treatment.
  • the polymer is heated in an extruder to the melting point and the molten polymer is pumped at a constant rate under pressure through a spinneret containing one or more orifices of desired diameter, thereby producing filaments of the molten polymer.
  • the molten polymer filaments are fed downward from the face of the spinneret into a cooling stream of gas, generally air.
  • the filaments of molten polymer are solidified as a result of cooling to form fibers.
  • the fibers are spread to form a fiber web and bonded directly, like in the spun bond method.
  • the fibers are gathered together and, if desired, drawn to orient the macromolecular structure of the fibers, and are then wound on bobbins. Bonding or calendering is then performed in a separate step.
  • the modification of the filaments or fibers takes place after the molten polymer filaments have solidified as a result of cooling to form the fiber, or on the preformed fiber itself.
  • the thermal bondability of fibers can be enhanced by treating the fiber grade polymer during the formation of the filaments, instead of treating the filaments or fibers after they are formed.
  • the process of the present invention is not limited to any specific fiber preparation technique where a resin is melted and formed into a fiber, such as long spin, short spin, spun bond and melt blown fiber production methods.
  • the spinning process limited to being carried out in any particular spinning environment, e.g. the presence or absence of oxygen or nitrogen.
  • Applicant has found that fibers having improved thermal bondability can be produced at lower spinning temperatures and increased spinning speeds by irradiating the molten fiber grade polymer filaments as soon as the filaments exit the orifices of the spinneret with electromagnetic radiation.
  • the present invention provides an improved process for the production of thermal bondable fibers comprising exposing the molten polymer filaments to from 1 x 10 -2 to 50 W/cm 2 of electromagnetic energy at the spinneret face.
  • Figure 1 is a schematic representation of a melt spinning arrangement used in the process of the present invention.
  • spinneret face is intended to include the upper portion of the spin line and the exit point of the molten material from one or more orifices, having any desired diameter, of the spinneret.
  • fiber grade polymer means any polymer that is capable of being spun into filaments to produce a fiber.
  • the fiber grade polymer is charged into a hopper 1 , and fed into an extruder 2 of known or conventional type, containing single or multiple screws and equipped with controls for regulating the temperature of the barrel in various zones along the length of the barrel, where the polymer is heated to its melting point.
  • the molten polymer is then fed to a metering pump 3 , which delivers the molten polymer at a constant rate to a heated spinneret 4 containing one or more orifices.
  • the fluid molten polymer filaments emerging in a downward direction from the face of the spinneret are exposed to electromagnetic radiation from a radiation source 5 .
  • the radiation source is positioned whereby the source encompasses the spinneret face.
  • the molten polymer filaments are then solidified by cooling to form fibers 6 .
  • the filaments produced by the process of this invention are typically combined into one or more fibers of varying thickness. Fibers made up of one filament are generally referred to as monofilament fibers and fibers made up of more than one filament are generally referred to as multifilament fibers.
  • the spun denier of the fibers produced accordinq to the method of this invention range from less than 1.1 dtex to at least 55.6 dtex (1 to at least 50 dpf, denier) per filament. (Denier is the weight in grams of 9000 meters of fiber).
  • the fiber forming polymers useful in the present invention can be any polymer typically used to prepare fibers.
  • the fiber grade polymer is polyethylene, polypropylene, random copolymer of propylene and ethylene, polyisobutylene, polyamide, polyester, polystyrene, polyvinyl chloride, polyacrylate and mixtures thereof.
  • Most preferred is polypropylene and random copolymers of propylene and ethylene.
  • the electromagnetic radiation can be ultraviolet, visible or infrared radiation.
  • the total amount of electromagnetic energy that reaches the filament(s), referred to as irradiance, can be adjusted by changing the distance between the source of the radiation and the filament(s), changing the wavelength emitted by the source, and by changing the power, intensity, of the source.
  • the total amount of electromagnetic energy that reaches the filament(s) is from 1 x 10 -2 to 50 M/cm 2 and from 1 x 10 -1 to 10 W/cm 2.
  • additives may be blended with the fiber forming polymer used to produce the thermal bondable fibers of the present invention.
  • additives include, stabilizers, antioxidants, antislip agents, antistatic agents, flame retardants, nucleating agents, pigments, antisoiling agents, photosensitizers and the like.
  • the molten polymer is fed to the meter pump, and pumped at a constant rate under pressure to a spinneret, containing one orifice with a diameter of 0.05cm (0.020 inches).
  • the molten polymer filament emerging downward from the orifice of the spinneret is exposed to 0.88 W/cm 2 ultraviolet radiation.
  • the filament of molten polymer is solidified as a result of cooling to form a monofilament fiber, and is collected on the godet.
  • the processing conditions are as follows: Extruder Feed Zone Temp. 220°C Metering Pump Temp. 300°C Spinneret Temp. 300°C Fiber Spun Denier 2.2 dtex (2 g/9000 m) Godet Take-up Speed 1000 m/min
  • the monofilament fibers prepared above were then tested for bond strength according to the following procedure.
  • the fibers were cut into 400 mm lengths.
  • the samples weighed between 0.160 and 0.170 grams.
  • the fibers were then mechanically twisted eighty times and folded in half.
  • the bundle was hand twisted six times and allowed to wrap around itself.
  • the sample was bonded in a Sentinel Model 1212 heat sealer at 2.812 kg/cm 2 (40 psi) for 1.50 seconds at the desired temperature.
  • the force required to separate the bonded segments was recorded on an Instron Model 114 universal testing machine.
  • Fibers were prepared according to the procedure of Example 1 using the same ingredients and processing conditions, except that the molten polymer filament emerging downward from the face of the spinneret was not exposed to the ultraviolet radiation.
  • the bonding strength of the fibers of the present invention is substantially higher than the bonding strength of the fibers of the Comparative Example 1 at the same bonding temperature.
  • Irgafos 168 tris(2,4-di-tert-butylphenyl)phosphite stabilizer and 1000 ppm wt.
  • calcium stearate are prepared by according to the process of Example 1, except the processing conditions were as follows: Extruder Feed Zone Temp. 220°C Metering Pump Temp. 275°C Spinneret Temp. 275°C Fiber Spun Denier 9.9 dtex (9 g/9000 m) Godet Take-up Speed 1000 m/min Ultraviolet radiation 2.8 W/cm 2
  • Fibers were prepared according to the procedure of Example 2 using the same ingredients and processing conditions, except that the molten polymer filament emerging downward from the face of the spinneret was not exposed to the ultraviolet radiation.
  • the fibers of the present invention demonstrate better bonding strength as compared to the fibers of Comparative Example 2.
  • Irgafos 168 tris-(2,4-di-tert-butylphenyl)phosphite stabilizer and 1000 ppm wt.
  • calcium stearate were prepared by according to the process of Example 1, except the processing conditions were as follows: Extruder Feed Zone Temp. 220°C Metering Pump Temp. 300°C Spinneret Temp. 300°C Fiber Spun Denier 2.2 dtex (2 g/9000 m) Godet Take-up Speed 4000 m/min Ultraviolet radiation 0.88 W/cm 2
  • Fibers were prepared according to the procedure of Example 4 using the same ingredients and processing conditions, except that the molten polymer filament emerging downward from the face of the spinneret was not exposed to the ultraviolet radiation.
  • the fibers of the present invention demonstrate better bonding strength as compared to the fibers of Comparative Example 3.
  • Fibers were prepared according to the procedure of Example 4 using the same ingredients and processing conditions, except that the molten polymer filament emerging downward from the face of the spinneret was not exposed to the ultraviolet radiation.
  • the fibers of the present invention demonstrate better bonding strength as compared to the fibers of Comparative Example 4.
  • the thermal bondable fibers prepared according to the process of the present invention can be used in the manufacturing of nonwovens, by spun bonded and melt blown processes.
  • Nonwovens are useful in the production of personal hygiene products, for example, infant care and adult incontinence products, protective covering, for example surgical gowns and shoe covers and other disposable medical and clothing products.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Artificial Filaments (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Inorganic Fibers (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Multicomponent Fibers (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Adhesives Or Adhesive Processes (AREA)
EP95104015A 1994-03-31 1995-03-18 A process for preparing a thermal bondable fiber Expired - Lifetime EP0675215B1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US22130594A 1994-03-31 1994-03-31
US221305 1994-03-31
US331319 1994-10-28
US08/331,319 US5507997A (en) 1994-03-31 1994-10-28 Process for preparing a thermal bondable fiber

Publications (2)

Publication Number Publication Date
EP0675215A1 EP0675215A1 (en) 1995-10-04
EP0675215B1 true EP0675215B1 (en) 1998-09-30

Family

ID=26915667

Family Applications (1)

Application Number Title Priority Date Filing Date
EP95104015A Expired - Lifetime EP0675215B1 (en) 1994-03-31 1995-03-18 A process for preparing a thermal bondable fiber

Country Status (15)

Country Link
EP (1) EP0675215B1 (ru)
JP (1) JP3693374B2 (ru)
CN (1) CN1058063C (ru)
AT (1) ATE171733T1 (ru)
AU (1) AU691569B2 (ru)
BR (1) BR9501291A (ru)
CA (1) CA2144934A1 (ru)
DE (1) DE69505033T2 (ru)
EG (1) EG20572A (ru)
ES (1) ES2124927T3 (ru)
FI (1) FI951556A (ru)
NO (1) NO306911B1 (ru)
PH (1) PH31402A (ru)
RU (1) RU2139189C1 (ru)
TR (1) TR28851A (ru)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6787066B2 (en) * 2001-11-16 2004-09-07 Sunoco Inc (R&M) Stabilization system for improving the melt viscosity of polypropylene during fiber processing
ATE505583T1 (de) * 2009-03-18 2011-04-15 Baumhueter Extrusion Gmbh Polymerfaser, deren verwendung und verfahren zu deren herstellung
CN106835375A (zh) * 2017-03-26 2017-06-13 响水县永泰纺织制衣有限公司 一种用于熔融纺织和冷却多根合成长丝装置
EP3608742B1 (en) 2018-08-07 2021-10-06 ABB Schweiz AG Apparatus for alarm information determination

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS54138076A (en) * 1978-04-19 1979-10-26 Toray Ind Inc Surface modification of plastic molded article
EP0013538B1 (de) * 1979-01-03 1983-04-06 Manahl, Robert, Dipl.-Ing. Einrichtung zur Gewinnung von Methangas aus organischen Abfällen
DE4113524A1 (de) * 1991-04-25 1992-10-29 Abb Patent Gmbh Verfahren zur behandlung von oberflaechen

Also Published As

Publication number Publication date
EP0675215A1 (en) 1995-10-04
DE69505033T2 (de) 1999-03-18
FI951556A0 (fi) 1995-03-31
TR28851A (tr) 1997-07-17
AU691569B2 (en) 1998-05-21
BR9501291A (pt) 1995-10-31
ATE171733T1 (de) 1998-10-15
AU1618895A (en) 1995-10-26
NO951227L (no) 1995-10-02
FI951556A (fi) 1995-10-01
NO951227D0 (no) 1995-03-30
RU2139189C1 (ru) 1999-10-10
CA2144934A1 (en) 1995-10-01
ES2124927T3 (es) 1999-02-16
JP3693374B2 (ja) 2005-09-07
JPH07278944A (ja) 1995-10-24
RU95105024A (ru) 1997-01-27
CN1111294A (zh) 1995-11-08
NO306911B1 (no) 2000-01-10
DE69505033D1 (de) 1998-11-05
CN1058063C (zh) 2000-11-01
PH31402A (en) 1998-10-29
EG20572A (en) 1999-08-30

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