EP1074644A1 - Elastische Mehrkomponentenfasern und daraus hergestellte Flächengebilde - Google Patents

Elastische Mehrkomponentenfasern und daraus hergestellte Flächengebilde Download PDF

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Publication number
EP1074644A1
EP1074644A1 EP00116690A EP00116690A EP1074644A1 EP 1074644 A1 EP1074644 A1 EP 1074644A1 EP 00116690 A EP00116690 A EP 00116690A EP 00116690 A EP00116690 A EP 00116690A EP 1074644 A1 EP1074644 A1 EP 1074644A1
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EP
European Patent Office
Prior art keywords
fiber
fibers
polymer
fabric
forming polymer
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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.)
Withdrawn
Application number
EP00116690A
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English (en)
French (fr)
Inventor
Franck O. Harris
August Karl Meyer
Jeffrey S. Dugan
Phillip Chris Parris
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Fiber Innovation Technology Inc
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Fiber Innovation Technology Inc
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Publication date
Application filed by Fiber Innovation Technology Inc filed Critical Fiber Innovation Technology Inc
Publication of EP1074644A1 publication Critical patent/EP1074644A1/de
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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

Definitions

  • the present invention relates to multicomponent fibers, and more particularly multicomponent fibers having a resilient polymeric component, as well as articles incorporating the fibers as a component thereof.
  • Synthetic polymers have been widely used in the manufacture of fibers, films, molded articles, and the like.
  • Common thermoplastic polymers used in the production of these and other products include polyolefins, such as polypropylene and polyethylene, polyesters, such as polyethylene terephthalate, and polyamides, among others.
  • a particular polymer is selected based upon the desired physical properties of the end product.
  • polyethylene terephthalate has excellent physical properties and is used to produce relatively low cost textile fibers of superior tensile strength, high wear resistance, and stability to heat and moisture.
  • Other polyesters, such as poly(1,4-cyclohexylene dimethylene terephthalate) also have good heat and hydrolysis resistance, among other properties such as resilience.
  • fibers made of poly(1,4-cyclohexylene dimethylene terephthalate) have resilience approaching and even superior to that exhibited by nylon fibers.
  • poly(1,4-cyclohexylene dimethylene terephthalate) is a relatively expensive polymer, thus making its use commercially impractical in many applications.
  • Fibers formed of synthetic polymers and fabrics produced therefrom are useful in a wide variety of applications, such as components in disposable absorbent articles, such as diapers, medical fabrics, such as surgical drapes and sterile wraps, filtration media, and the like.
  • Multicomponent or bicomponent fibers have been developed to impart desirable combinations of physical properties to fabrics produced using the same.
  • a bicomponent fiber may be described as a fiber having different polymeric components arranged in distinct zones across the cross section of the fibers. Typically one of the polymeric components exhibits different properties than the other so that the fibers exhibit properties of the two components.
  • conventionally bicomponent fibers include an outer polymeric sheath component, such as polyethylene, surrounding a core polymeric material, such as polyester.
  • the sheath component is formed of a polymer composition having a melting point that is lower (the "low melt” component) than the melting point of the polymer composition of the core (the “high melt” component).
  • the low melt polymer acts as a latent adhesive upon thermal treatment to bond the fibers and form a coherent textile structure.
  • bicomponent fibers include polymer domains of specific chemistries and arrangement so that the fibers develop a helical crimp.
  • the polymers of the bicomponent fibers can have differential shrink properties so as to impart a helical or spiral configuration to the fiber during formation or subsequent processing.
  • a side-by-side fiber or eccentric sheath core fiber is required for crimping.
  • Crimped fibers are considered desirable for many reasons. For example, crimped fibers exhibit increased loft imparted by the three dimensional configuration resulting from crimping.
  • the present invention provides multicomponent fibers which exhibit a number of desirable properties in a single fiber structure.
  • the fibers of the invention include a poly(1,4-cyclohexylene dimethylene terephthalate) ("PCT") polymeric component which occupies at least a portion, and preferably the entire, outer surface of the fibers.
  • PCT poly(1,4-cyclohexylene dimethylene terephthalate)
  • the fibers of the invention can exhibit desirable physical properties imparted thereto resulting from the presence of the PCT polymer, such as chemical, heat and moisture resistance, and the like.
  • PCT polymers can provide fibers having desirable resilience.
  • the fibers of the invention also include at least one other polymeric component formed of one or more fiber forming polymers.
  • the other fiber forming materials can be selected from any of the types of polymers known in the art which are capable of being formed into fibers, including polyolefins, polyesters, polyamides, and the like. Because the fibers of the invention include a polymeric component which is different from the PCT component, the cost of the fibers can be reduced, relative to fibers formed entirely of PCT polymer, because PCT polymer, which is expensive, can be replaced with a lower cost polymer. The fibers of the invention can also offer cost savings as compared to 100% polyamide fibers. Yet surprisingly the reduced amount of PCT polymer present in the fibers of the invention has been found to have minimal or essentially no impact on properties such as resilience, as compared to 100% PCT fibers or 100% nylon fibers.
  • the fibers of the invention possess substantially no latent crimpability.
  • substantially no latent crimpability refers to fibers of the invention which, when heated under relaxation, develop minimal or no crimp.
  • the fibers can also be described as "non-self crimping.”
  • the fibers of the invention develop less than or about 2 CPI (crimps per inch of the fiber).
  • the fibers of the invention have a concentric sheath/core configuration, in which the sheath is formed of PCT and the core is formed of other fiber forming materials.
  • the fibers are islands in the sea fibers in which the sea polymer is PCT and the islands are formed of other fiber forming materials.
  • the structure of the multicomponent fibers is advantageous in many regards. Because the fibers do not have substantial latent crimpability, the crimp level can be set to as specific level (number of crimps per inch and height of each crimp) when the fiber is mechanically crimped. Further, the desired crimp level can be maintained at any temperature below the melting point of the fiber. In contrast, for latent-crimpable fibers, the crimp level is a function of temperature. In addition, mechanically crimped fibers do not need the separate heating step required by self-crimping fibers.
  • the present invention also provides fabrics formed of the multicomponent fibers of the invention, articles incorporating such fabrics as a component, and processes for making the fibers.
  • FIG. 1 a transverse cross sectional view of an exemplary multicomponent fiber 10 of the invention is illustrated.
  • Figure 1 illustrates one advantageous embodiment of the invention, namely, bicomponent fibers having an inner core polymer domain 12 and surrounding sheath polymer domain 14 .
  • Figure 2 illustrates another advantageous embodiment of the invention in which the multicomponent fibers 10' of the invention are "matrix" or “islands in a sea” type fibers having an "island" polymer component 12' surrounded by a “sea” polymer component 14' .
  • Other structured fiber configurations as known in the art may potentially be used, such as but not limited to, multicomponent fibers having unconventional shapes (such as multi-lobal fibers) as known in the art
  • multicomponent fibers includes staple and continuous filaments prepared from two or more polymers present in discrete structured domains in the fiber, as opposed to blends where the domains tend to be dispersed, random or unstructured.
  • the present invention will generally be described in terms of a bicomponent fiber comprising two components. However, it should be understood that the scope of the present invention is meant to include fibers with two or more structured components.
  • the multicomponent fibers of the invention include at least two structured polymeric components arranged in substantially constantly positioned distinct zones across the cress section of the multicomponent fiber and extending continuously along the length of the multicomponent fiber.
  • At least one of the polymeric components comprises a poly(1,4-cyclohexylene dimethylene terephthalate) polymer (also referred to herein as "PCT").
  • PCT poly(1,4-cyclohexylene dimethylene terephthalate) polymer
  • the outer surface of the fibers comprises PCT polymer.
  • the entire outer surface of the fiber comprises PCT polymer.
  • PCT polymers can be generally described as polyalkylene terephthalate resins based on the reactions between 1,4-cyclohexanedimethanol and terephthalic acid or suitable synthetic equivalents.
  • PCT polymers useful in the invention typically have an inherent viscosity of about 0.5 to about 1.0 and a melting point of about 290°C.
  • the dicarboxylic acid component of the PCT polymer comprises terephthalic acid which may contain up to 10 mole percent, based on the acid component, of other aromatic dicarboxylic acids preferably having 6 to 14 carbon atoms, of aliphatic dicarboxylic acids preferably having 4 to 12 carbon atoms, or of cycloaliphatic dicarboxylic acids preferably having 8 to 12 carbon atoms.
  • dicarboxylic acids examples include phthalic acid, isophthalic acid, naphthalene-2,6-dicaroxliuc acid, cyclohexanedicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4'-dicarboxylic acid, succinic acid, sebacic acid, adipic acid, glutaric acid, azelic acid, and the like and mixtures thereof.
  • the diol component of the PCT polymer comprises 1,4-cyclohexanedimethanol which may further contain up to 10 mole percent, based on the diol component, of other cycloaliphatic diols preferably having 6 to 15 carbon atoms, or aliphatic diols preferably having 3 to 8 carbon atoms.
  • diols examples include diethylene glycol, triethylene glycol, propane-1,3-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol., 3-methylpentanediol-(2,4), 2-methylpentane diol-(1,4), 2,2,4-trimethylpentane diol-(1,3), 2-ethylhexanediol-(1,3), 2,2-diethylpropane diol (1,3), hexanediol-(1,3), 1,4-di(hydroxyethoxy)-benzene, 2,2-bis-(4-hydroxycyclohexyl)propane, 2,4-dihydroxy-1,1,3,3-tetramethyl-cyctobutane, 2,2-bis-(3-hydroxyethoxyphenyl)-propane, 2,2-bis-)4-hydroxypropoxy-phen
  • the PCT polymer may be in the cis or trans isomeric configuration or a mixture of the two.
  • PCT polymers are known in the art and are commercially available or may be prepared by processes well known in the art.
  • the PCT polymers may be prepared by direct condensation of terephthalic acid or ester interchange using dimethyl terephthalate with the selected diol. See also, for example, U.S. Patent No. 2,901,466.
  • An exemplary commercially available PCT polymer includes without limitation PCT 3879, commercially available from Eastman Chemical Co.
  • At least one other of the polymeric components comprises any of the various fiber forming polymer materials as known in the art.
  • Such materials include without limitation polyolefins including polypropylene, polyethylene (low density polyethylene, high density polyethylene, linear low density polyethylene), and polybutene, polyesters including polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, and poly(lactic acid), polyamides including nylon, polyacrylates, polystyrenes, polyurethanes, acetal resins, polyethylene vinyl alcohol, thermoplastic elastomers and copolymers, terpolymers, and mixtures thereof.
  • Each of the polymeric components of the multicomponent fibers of the invention can optionally include other components not adversely effecting the desired properties thereof.
  • Exemplary materials which could be used as additional components would include, without limitation, pigments, antioxidants, stabilizers, surfactants, waxes, flow promoters, solid solvents, particulates, and other materials added to enhance processability of the polymeric components. Such additives can be used in conventional amounts.
  • the weight ratio of the respective polymeric components of the fibers of the invention can vary.
  • the weight ratio of the polymeric components ranges from about 10:90 to 90:10, preferably from about 30:70 to about 70:30, and more preferably from about 40:60 to about 60:40.
  • the fibers of the invention possess substantially no latent crimpability, meaning that the fibers develop minimal or no crimp when heated under relaxation. Generally the fibers develop no more than about two crimps per inch (“CPI") of fiber measured using conventional techniques known in the art when heated under relaxation.
  • CPI as used herein has its conventional meaning in art and is determined using standard techniques know to the skilled artisan. Specifically, CPI refers to the number of two or three dimensional configurations per inch of a given sample of fiber under zero stress determined using ASTM D-3937.
  • the polymer domains of the fibers of the invention are selected and structured so that the fibers have substantially no latent crimpability (i.e., develop 2 or fewer CPI when heated under relaxation).
  • bicomponent fibers can take up a thee dimensional configurations, such as a helical or spiral configuration, during their formation and/or subsequent processing as a result of differences between the components of the fibers.
  • crimpable bicomponent fibers typically have either a side-by side arrangement or an eccentric sheath/core arrangement so that the resulting filaments exhibit a natural helical crimp.
  • the fibers of the invention exhibit minimal or no crimp during formation and/or subsequent processing.
  • the polymer components are arranged such that substantial crimp (i.e. more than about 2 CPI) does not develop during processing or subsequent treatments.
  • substantial crimp i.e. more than about 2 CPI
  • the multicomponent fibers are structured such that the fiber does not develop substantial crimp (i.e., less than or about 2 CPI) upon formation and/or subsequent processing.
  • the cross section of the multicomponent fiber is preferably circular, since the equipment typically used in the production of multicomponent synthetic fibers normally produces fibers with a substantially circular cross section.
  • the configuration of the first and second polymer components in a fiber of circular cross section is substantially concentric so as to provide a non-self crimping or non-latently crimpable fiber.
  • the concentric configuration is characterized by the first component having a substantially uniform thickness, such that the second component lies approximately in the center of the fiber. This is in contrast to an eccentric configuration, in which the thickness of the first component varies, and the second component therefore does not lie in the center of the fiber.
  • the fiber of the invention is a sheath/core bicomponent fiber
  • a concentric sheath/core structure is used in which the center of the core component is preferably biased by no more than about 0 to about 30 percent, preferably no more than about 0 to about 10 percent, based on the diameter of the sheath/core bicomponent fiber, from the center of the sheath component.
  • the polymeric components of the fibers can be selected so that the PCT polymer domain has a higher melting or softening temperature than other of the polymeric components. This is in contrast to conventional multicomponent fiber structures, which typically include a lower melt polymer on the outer surface of the fiber to act as a latent adhesive and to provide useful thermal bonding properties.
  • the PCT polymeric component can have a melting or softening point of at least 10°C, or more, greater than the melting point of the other polymeric component(s)
  • Methods for making multicomponent fibers arc well known and need not be described here in detail.
  • at least two polymers are extruded separately and fed into a polymer distribution system wherein the polymers are introduced into a spinneret plate.
  • the polymers follow separate paths to the fiber spinneret and are combined in a spinneret hole.
  • the spinneret is configured so that the extrudant has the desired overall fiber cross section (e.g., round, trilobal, etc.).
  • the resulting thin fluid strands, or filaments remain in the molten state for some distance before they are solidified by cooling in a surrounding fluid medium, which may be chilled air blown through the strands.
  • a surrounding fluid medium which may be chilled air blown through the strands.
  • the filaments are taken up on a godet or another take-up surface, in a continuous filament process, the strands can be taken up on a godet which draws down the thin fluid streams in proportion to the speed of the take-up godet.
  • the strands are collected in a jet, such as for example, an air attenuator, and blown onto a take-up surface such as a roller or a moving belt to form a spunbond web.
  • meltblown process air is ejected at the surface of the spinnerette which serves to simultaneously draw down and cool the thin fluid screams as they are deposited on a take-up surface in the path of cooling air, thereby forming a fiber web.
  • the thin fluid streams are melt drawn down in a molten state, i.e. before solidification occurs to orient the polymer molecules for good tenacity.
  • Typical melt draw down ratios known in the art may be utilized. The skilled artisan will appreciate that specific melt draw down is not required for meltblowing processes.
  • the continuous filaments may be mechanically crimped and cut into a desirable fiber length, thereby producing staple fiber.
  • the length of the staple fibers generally ranges from about 25 to about 50 millimeters although the fibers can be longer or shorter as desired. See, for example, U.S. Pat. No. 4,789,592 to Taniguchi et al. and U.S. Pat. No. 5,336,552 to Strack et al.
  • the multicomponent fibers of the invention can be staple fibers, continuous filaments, or meltblown fibers.
  • staple fibers, multifilament, and spunbond fibers formed in accordance with the present invention can have a fineness of about 0.5 to about 100 denier per filament.
  • Meltblown filaments can have a fineness of about 0.001 to about 10.0 denier.
  • Monofilament fibers can have a fineness of about 50 to about 10,000 denier.
  • the multicomponent fibers can be incorporated into a fabric Fibers other than the multicomponent fibers of the invention may be present as well, including any of the various synthetic and/or natural fibers known in the art.
  • Exemplary synthetic fibers include polyolefin, polyester, polyamide, acrylic, rayon, cellulose acetate, polyaramids, thermoplastic multicomponent fibers (such as conventional sheath/core fibers, for example polyethylene sheath/polyester core fibers) and the like and mixtures thereof.
  • Exemplary natural fibers include wool, cotton, wood pulp fibers and the like and mixtures thereof.
  • the multicomponent fiber of the instant invention is incorporated into a nonwoven fabric.
  • Staple fibers of the present invention may be formed into nonwoven webs by any means known in the art, including dry laid processes, such as carding or airlaying, as well as wet laid processes.
  • continuous filament may be spun directly into nonwoven webs by a spunbonding process.
  • the multicomponent fibers of the invention may also be incorporated, alone or in conjunction with other fibers, into a meltblown nonwoven fabric. The technique of meltblowing is known in the art and is discussed in various patents, e g., Buntin et al., U.S. Patent No 3,987,185; Buntin, U.S Patent No.
  • the nonwoven webs thus formed are typically subsequently bonded to transform them into nonwoven fabrics, using bonding technique known in the art, such as thermal bonding, mechanical bonding, adhesive bonding and the like.
  • bonding technique known in the art, such as thermal bonding, mechanical bonding, adhesive bonding and the like.
  • the fibers of the invention are advantageously formed into nonwoven fabrics, the present invention also includes other textile structures formed of the fibers of the invention, such as woven and knit fabrics.
  • Nonwoven fabrics which include the multicomponent fibers of the invention are useful as a component in a variety of end applications.
  • the fabrics can be used as a filter media in a broad range of applications, including use in bag filters, air filters, mist eliminators, stackhouse filters, and the like.
  • the fabrics are particularly advantageous as a filter media for severe or harsh environments because the respective polymer components can be selected to provide the desired heat, hydrolysis and chemical resistance for a particular end application.
  • the fibers of the invention in which the PCT polymer domain encapsulates the other polymer domains are particularly advantageous.
  • the filtration media fabrics of the invention can, for example, be used as a component of a bag filter as known in the art.
  • bag filters can have a variety of end uses and can generally be used in all applications in which conventional bag filters are currently being used, as well as more demanding applications in view of the superior nature of the present fibers.
  • the fabrics can be incorporated as a component of a bag filter used to filter gaseous and liquid streams.
  • the fabrics of the invention are also useful in other constructions, for example, fabric applications requiring good resilience, such as imparted by the PCT polymer component.
  • the PCT polymer can exhibit resiliency greater than nylon, which makes its use attractive in applications requiring resilience.
  • the fabrics of the invention can be useful as a component of the outer covering used in paint rollers.
  • Continuous sheath/core multi-filament melt spun fiber is produced using a bicomponent extrusion system.
  • the sheath component of the bicomponent fiber comprises a PCT polymer, commercially available under the trade name PCT 3879 from Eastman Chemical Co., and the core component comprises polypropylene, commercially available under the trade name Martex HGZ-120-04 from Philips Sumika Polypropylene Co.
  • the weight ratio of sheath/core components is 50/50.
  • the two components are subjected to sheath-and-core type conventional bicomponent melt spinning.
  • the filaments are subsequently drawn thereby yielding a 6 denier multifilament fiber.
  • a sliver knit fabric formed with the fibers is made into a paint roller cover that provides 25% higher paint take-up and 25% faster paint release than a comparable roller made with polyethylene terephthalate (PET) fibers.
  • PET polyethylene terephthalate

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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)
  • Nonwoven Fabrics (AREA)
EP00116690A 1999-08-02 2000-08-02 Elastische Mehrkomponentenfasern und daraus hergestellte Flächengebilde Withdrawn EP1074644A1 (de)

Applications Claiming Priority (2)

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US366123 1989-06-19
US36612399A 1999-08-02 1999-08-02

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1366889A3 (de) * 2002-05-16 2004-04-14 Kuraray Co., Ltd. Farbrollerstruktur und Verfahren zu ihrer Herstellung
WO2006131199A1 (de) * 2005-06-06 2006-12-14 Carl Freudenberg Kg Filterschlauch
US20090184188A1 (en) * 2008-01-17 2009-07-23 Sinykin Daniel L Methods of Manufacturing Paint Roller Covers From a Tubular Fabric Sleeve
CN102442043A (zh) * 2011-09-30 2012-05-09 江苏红运果服饰有限公司 一种耐磨保暖面料
CN102505277A (zh) * 2011-09-30 2012-06-20 江苏红运果服饰有限公司 一种具有发热功能的耐磨保暖面料
CN113039315A (zh) * 2018-09-18 2021-06-25 埃克森美孚化学专利公司 双组分纤维和由其生产的非织造材料

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1276442A (en) * 1969-08-26 1972-06-01 Du Pont Improved self-crimping polyester composite filaments
US4104439A (en) * 1977-05-31 1978-08-01 Eastman Kodak Company Textile fiber
US5518813A (en) * 1993-12-01 1996-05-21 Hoechst Aktinegesellschaft Poly (1,4-cyclohexanedimethylene terephthalate) multifilament yarns for technical applications and production thereof
WO1996039054A1 (en) * 1995-06-06 1996-12-12 Filtrona International Limited Polyethylene terephthalate sheath/thermoplastic polymer core bicomponent fibers, method of making same and products formed therefrom

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1276442A (en) * 1969-08-26 1972-06-01 Du Pont Improved self-crimping polyester composite filaments
US4104439A (en) * 1977-05-31 1978-08-01 Eastman Kodak Company Textile fiber
US5518813A (en) * 1993-12-01 1996-05-21 Hoechst Aktinegesellschaft Poly (1,4-cyclohexanedimethylene terephthalate) multifilament yarns for technical applications and production thereof
WO1996039054A1 (en) * 1995-06-06 1996-12-12 Filtrona International Limited Polyethylene terephthalate sheath/thermoplastic polymer core bicomponent fibers, method of making same and products formed therefrom

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1366889A3 (de) * 2002-05-16 2004-04-14 Kuraray Co., Ltd. Farbrollerstruktur und Verfahren zu ihrer Herstellung
WO2006131199A1 (de) * 2005-06-06 2006-12-14 Carl Freudenberg Kg Filterschlauch
US20090184188A1 (en) * 2008-01-17 2009-07-23 Sinykin Daniel L Methods of Manufacturing Paint Roller Covers From a Tubular Fabric Sleeve
US8298364B2 (en) * 2008-01-17 2012-10-30 Seamless Technologies, Llc Methods of manufacturing paint roller covers from a tubular fabric sleeve
CN102442043A (zh) * 2011-09-30 2012-05-09 江苏红运果服饰有限公司 一种耐磨保暖面料
CN102505277A (zh) * 2011-09-30 2012-06-20 江苏红运果服饰有限公司 一种具有发热功能的耐磨保暖面料
CN113039315A (zh) * 2018-09-18 2021-06-25 埃克森美孚化学专利公司 双组分纤维和由其生产的非织造材料

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