EP3724380A1 - Fibers including an alkylene oxide-containing nonionic surfactant, articles, and methods - Google Patents
Fibers including an alkylene oxide-containing nonionic surfactant, articles, and methodsInfo
- Publication number
- EP3724380A1 EP3724380A1 EP18829490.4A EP18829490A EP3724380A1 EP 3724380 A1 EP3724380 A1 EP 3724380A1 EP 18829490 A EP18829490 A EP 18829490A EP 3724380 A1 EP3724380 A1 EP 3724380A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- nonionic surfactant
- fibers
- fiber
- containing nonionic
- alkylene oxide
- 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.)
- Withdrawn
Links
- 239000000835 fiber Substances 0.000 title claims abstract description 270
- 239000002736 nonionic surfactant Substances 0.000 title claims abstract description 128
- 125000002947 alkylene group Chemical group 0.000 title claims abstract description 111
- 238000000034 method Methods 0.000 title claims description 75
- 229920005601 base polymer Polymers 0.000 claims abstract description 59
- 229920000728 polyester Polymers 0.000 claims abstract description 39
- 229920002292 Nylon 6 Polymers 0.000 claims abstract description 32
- 125000003118 aryl group Chemical group 0.000 claims abstract description 30
- 238000002844 melting Methods 0.000 claims abstract description 21
- 230000008018 melting Effects 0.000 claims abstract description 21
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 42
- -1 polyethylene terephthalate Polymers 0.000 claims description 38
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 claims description 30
- 238000012360 testing method Methods 0.000 claims description 28
- 239000000203 mixture Substances 0.000 claims description 26
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 26
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 26
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 claims description 24
- 229920002215 polytrimethylene terephthalate Polymers 0.000 claims description 20
- 239000000758 substrate Substances 0.000 claims description 20
- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 claims description 13
- 238000010521 absorption reaction Methods 0.000 claims description 11
- 238000004043 dyeing Methods 0.000 claims description 11
- 239000000454 talc Substances 0.000 claims description 11
- 229910052623 talc Inorganic materials 0.000 claims description 11
- 238000002156 mixing Methods 0.000 claims description 8
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000004744 fabric Substances 0.000 description 67
- 239000004094 surface-active agent Substances 0.000 description 34
- 239000000654 additive Substances 0.000 description 29
- 125000000217 alkyl group Chemical group 0.000 description 29
- 239000000975 dye Substances 0.000 description 25
- 230000000996 additive effect Effects 0.000 description 17
- 239000004750 melt-blown nonwoven Substances 0.000 description 11
- 230000008569 process Effects 0.000 description 10
- 125000004432 carbon atom Chemical group C* 0.000 description 9
- 239000007788 liquid Substances 0.000 description 9
- 238000010998 test method Methods 0.000 description 7
- 229920000642 polymer Polymers 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- 239000004743 Polypropylene Substances 0.000 description 4
- 150000001412 amines Chemical class 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- 238000000354 decomposition reaction Methods 0.000 description 4
- 230000002209 hydrophobic effect Effects 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000004745 nonwoven fabric Substances 0.000 description 4
- 229920001778 nylon Polymers 0.000 description 4
- 239000002952 polymeric resin Substances 0.000 description 4
- 229920001155 polypropylene Polymers 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- 229920000742 Cotton Polymers 0.000 description 3
- 239000004594 Masterbatch (MB) Substances 0.000 description 3
- 239000004677 Nylon Substances 0.000 description 3
- 239000012298 atmosphere Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 238000009998 heat setting Methods 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 229920003002 synthetic resin Polymers 0.000 description 3
- 239000004753 textile Substances 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 150000001335 aliphatic alkanes Chemical class 0.000 description 2
- 239000004599 antimicrobial Substances 0.000 description 2
- 239000003963 antioxidant agent Substances 0.000 description 2
- 239000002216 antistatic agent Substances 0.000 description 2
- 125000002619 bicyclic group Chemical group 0.000 description 2
- 238000009960 carding Methods 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 125000004122 cyclic group Chemical group 0.000 description 2
- 239000008367 deionised water Substances 0.000 description 2
- 229910021641 deionized water Inorganic materials 0.000 description 2
- 239000003814 drug Substances 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000010348 incorporation Methods 0.000 description 2
- 125000001449 isopropyl group Chemical group [H]C([H])([H])C([H])(*)C([H])([H])[H] 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 238000002074 melt spinning Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 238000005453 pelletization Methods 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000004580 weight loss Effects 0.000 description 2
- 125000004955 1,4-cyclohexylene group Chemical group [H]C1([H])C([H])([H])C([H])([*:1])C([H])([H])C([H])([H])C1([H])[*:2] 0.000 description 1
- 101000583175 Homo sapiens Prolactin-inducible protein Proteins 0.000 description 1
- 102100030350 Prolactin-inducible protein Human genes 0.000 description 1
- 239000012963 UV stabilizer Substances 0.000 description 1
- 239000002250 absorbent Substances 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 239000004596 additive masterbatch Substances 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 229920005603 alternating copolymer Polymers 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- WPYMKLBDIGXBTP-UHFFFAOYSA-N benzoic acid Chemical class OC(=O)C1=CC=CC=C1 WPYMKLBDIGXBTP-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 230000036760 body temperature Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
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- 230000001143 conditioned effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000009945 crocheting Methods 0.000 description 1
- 125000000582 cycloheptyl group Chemical group [H]C1([H])C([H])([H])C([H])([H])C([H])([H])C([H])(*)C([H])([H])C1([H])[H] 0.000 description 1
- 125000000113 cyclohexyl group Chemical group [H]C1([H])C([H])([H])C([H])([H])C([H])(*)C([H])([H])C1([H])[H] 0.000 description 1
- 125000001511 cyclopentyl group Chemical group [H]C1([H])C([H])([H])C([H])([H])C([H])(*)C1([H])[H] 0.000 description 1
- 230000009699 differential effect Effects 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
- 229920000578 graft copolymer Polymers 0.000 description 1
- 239000008240 homogeneous mixture Substances 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 125000000959 isobutyl group Chemical group [H]C([H])([H])C([H])(C([H])([H])[H])C([H])([H])* 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 238000009940 knitting Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 125000004108 n-butyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 125000003136 n-heptyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 125000000740 n-pentyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 238000001579 optical reflectometry Methods 0.000 description 1
- 125000001820 oxy group Chemical group [*:1]O[*:2] 0.000 description 1
- 230000037081 physical activity Effects 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920005644 polyethylene terephthalate glycol copolymer Polymers 0.000 description 1
- 229920002959 polymer blend Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000003825 pressing 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
- 238000005086 pumping Methods 0.000 description 1
- 229920005604 random copolymer Polymers 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- YGSDEFSMJLZEOE-UHFFFAOYSA-N salicylic acid Chemical group OC(=O)C1=CC=CC=C1O YGSDEFSMJLZEOE-UHFFFAOYSA-N 0.000 description 1
- 230000035807 sensation Effects 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- FVEFRICMTUKAML-UHFFFAOYSA-M sodium tetradecyl sulfate Chemical compound [Na+].CCCCC(CC)CCC(CC(C)C)OS([O-])(=O)=O FVEFRICMTUKAML-UHFFFAOYSA-M 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 125000000547 substituted alkyl group Chemical group 0.000 description 1
- 210000000106 sweat gland Anatomy 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 230000037303 wrinkles Effects 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
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/10—Other agents for modifying properties
-
- 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
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/60—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyamides
-
- 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
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/02—Material containing basic nitrogen
- D06P3/04—Material containing basic nitrogen containing amide groups
- D06P3/24—Polyamides; Polyurethanes
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/34—Material containing ester groups
- D06P3/52—Polyesters
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/82—Textiles which contain different kinds of fibres
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/82—Textiles which contain different kinds of fibres
- D06P3/854—Textiles which contain different kinds of fibres containing modified or unmodified fibres, i.e. containing the same type of fibres having different characteristics, e.g. twisted and not-twisted fibres
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
- D06P3/00—Special processes of dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form, classified according to the material treated
- D06P3/82—Textiles which contain different kinds of fibres
- D06P3/8204—Textiles which contain different kinds of fibres fibres of different chemical nature
- D06P3/8276—Textiles which contain different kinds of fibres fibres of different chemical nature mixtures of fibres containing ester groups
Definitions
- Thermal comfort depends upon the heat release from the human body. Moisture release is one mechanism of heat loss. An average human can lose 1200 milliliters (mL) perspiration per hour in heavy activity from the Apocrine and Eccrine sweat glands during vigorous physical activity. Cotton can absorb such perspiration (e.g., moisture regain is 7.0-8.5% moisture at 65% Relative Humidity (RH)), whereas polyester and nylon, which are more hydrophobic in nature, cannot. For example, polyester fabrics can only retain 0.4% moisture at 65% RH.
- RH Relative Humidity
- the rate at which water vapor moves through a fabric plays an important role in determining a person’s comfort, as it influences the cool/warmth sensation and aids in regulating body temperature. This process is called moisture vapor transmission or wicking.
- a vast majority of active wear apparel is made of polyester or nylon, which do not allow moisture on its surface, because of their hydrophobic natures, and do not pass vapor easily through the pores of the fabrics, resulting in limited wicking capability across fabrics made of polyester or nylon fibers. This can lead to either accumulation of moisture at the surface of the fabric or outright repulsion of moisture back to the surface of the skin, thereby impeding the flow of moisture through and across the fabric. Therefore, a person may experience or perceive discomfort when wearing polyester garments. Cotton absorbs better, but it does not wick efficiently either, leading to discomfort.
- Attempts to improve water absorbency/wicking of a polyester fabric involve the following approaches: (1) use of a different spinning nozzle to make a differently shaped fiber; (2) use of hollow microporous fibers; (3) incorporation of two or three layers of hydrophilic fabric (e.g., cotton) with hydrophobic polyester fabric in a construction; and (4) applying a hydrophilic agent to the surface of hydrophobic fiber.
- hydrophilic fabric e.g., cotton
- the present disclosure provides fibers, articles including such fibers, and methods of making and using such fibers.
- the fibers include an alkylene oxide-containing nonionic surfactant.
- the present disclosure provides a fiber including: a base polymer that includes an aromatic polyester or nylon-6; and an alkylene oxide-containing nonionic surfactant mixed within the base polymer; wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10.
- the present disclosure provides a plurality of fibers as described herein, which may be in the form of a yarn or a web, for example.
- an article is provided that includes a plurality of fibers as described herein, wherein a first portion of the plurality of fibers include: a base polymer including an aromatic polyester or nylon-6; an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10; and a dye; wherein the dye is present in a greater amount in the first portion of the fibers than in other portions of the fibers of the article.
- the present disclosure provides a method of making fibers as described herein, the method including: providing a base polymer comprising an aromatic polyester or nylon-6; providing an alkylene oxide-containing nonionic surfactant, wherein the alkylene oxide- containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10; melt mixing the alkylene oxide-containing nonionic surfactant with the base polymer; and forming a plurality of fibers, each of which includes the alkylene oxide- containing nonionic surfactant mixed within the base polymer.
- the present disclosure also provides a method of differentially dyeing a fibrous substrate, the method including: providing a fibrous substrate including a first portion of fibers and a second portion of fibers; applying the same type and amount of dye under the same conditions to the first and second portions of the fibrous substrate; wherein the first and second portions of the fibrous substrate differentially absorb the dye.
- the fibrous substrate includes: a first portion of fibers including: a base polymer including an aromatic polyester or nylon-6; and an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10; and a second portion of fibers including: a base polymer that is the same as in the first portion; and optionally an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the amount (including no such surfactant) and/or type of the alkylene oxide-containing nonionic surfactant is different than that in the first portion.
- alkylene oxide refers to a divalent group that is an oxy group bonded directly to an alkylene group
- the term“alkylene” refers to a divalent group that is a radical of an alkane and includes groups that are linear, branched, cyclic, bicyclic, or a combination thereof.
- the alkylene group typically has 1 to 30 carbon atoms. In some embodiments, the alkylene group has 1 to 20 carbon atoms, 1 to 10 carbon atoms, 1 to 6 carbon atoms, or 1 to 4 carbon atoms.
- Examples of“alkylene” groups include methylene, ethylene, propylene, 1, 4-butylene, 1,4- cyclohexylene, and l,4-cyclohexyldimethylene.
- alkyl refers to a monovalent group that is a radical of an alkane and includes straight-chain, branched, cyclic, and bicyclic alkyl groups, and combinations thereof, including both unsubstituted and substituted alkyl groups. Unless otherwise indicated, the alkyl groups typically contain from 1 to 72 carbon atoms. In some embodiments, the alkyl groups contain 1 to 45 carbon atoms, 1 to 30 carbon atoms, 1 to 10 carbon atoms.
- alkyl groups include, but are not limited to, methyl, ethyl, n- propyl, n-butyl, n-pentyl, isobutyl, t-butyl, isopropyl, n-octyl, n-heptyl, ethylhexyl, cyclopentyl, cyclohexyl, cycloheptyl, and the like.
- polymer and“polymeric material” include, but are not limited to, organic homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof.
- polymer shall include all possible geometrical configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic symmetries.
- the phrase“consisting essentially of’ indicates that the listed elements are required or mandatory, but that other elements are optional and may or may not be present depending upon whether or not they materially affect the activity or action of the listed elements.
- phrases such as“a,”“an,” and“the” are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration.
- the terms“a,”“an,” and“the” are used interchangeably with the term“at least one.”
- the phrases“at least one of’ and“comprises at least one of’ followed by a list refers to any one of the items in the list and any combination of two or more items in the list.
- room temperature refers to a temperature of 20°C to 25°C or 22°C to 25°C.
- each group is“independently” selected, whether specifically stated or not.
- each R group is independently selected.
- subgroups contained within these groups are also independently selected.
- the present disclosure provides fibers, articles including such fibers, and methods of making and using such fibers.
- the fibers include an alkylene oxide-containing nonionic surfactant mixed within (i.e., incorporated within) a base polymer that includes an aromatic polyester or nylon-6. Due to the incorporation of the surfactant, the fibers are capable of absorbing liquid (e.g., water). In certain embodiments, the fibers are capable of wicking liquid as exemplified by water or an 80/20 (by weight) water/isopropanol mixture. This makes the fibers, as well as yarns, threads, webs, and other articles that include such fibers capable of absorbing moisture, and, preferably, wicking perspiration away from a body (e.g., a perspiring human body).
- a body e.g., a perspiring human body
- a meltblown web of a plurality of the fibers demonstrates absorption of a water drop within 5 minutes, within 1 minute, within 30 seconds, within 10 seconds, or instantaneously, according to the Water Drop Test of the Examples Section.
- a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test of the Examples Section. In certain embodiments, a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test to a distance of at least 5 cm, at least 6 cm, at least 7 cm, at least 8 cm, at least 9 cm, or at least 10 cm after 5 minutes.
- the present disclosure provides a fiber including: an aromatic polyester (e.g., polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), or mixtures thereof), or nylon-6 (as the base polymer); and an alkylene oxide-containing nonionic surfactant mixed within (e.g., as a result of melt blending) the aromatic polyester or nylon-6.
- an aromatic polyester e.g., polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), or mixtures thereof
- nylon-6 as the base polymer
- an alkylene oxide-containing nonionic surfactant mixed within e.g., as a result of melt blending
- the base polymer for making the fibers include aromatic polyesters and nylon-6.
- polyester fiber a manufactured fiber in which the fiber forming substance is any long-chain synthetic polymer composed of at least 85% by weight of an ester of a substituted aromatic carboxylic acid,” including but not restricted to substituted terephthalic units, p(-R-0-C0-C6H 4 -C0-0-)x, and parasubstituted hydroxy-benzoate units, p(-R-0-C0-C6H 4 -0-)x.
- the aromatic polyester is selected from polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polypropylene terephthalate, and
- the aromatic polyester is selected from polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), and combinations thereof.
- the aromatic polyester is selected from polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), and combinations thereof.
- Commercially available sources of aromatic polyesters include Nan Ya Plastics Corp. (Wharton, TX), Eastman Chemical Co. (Kingsport, TN), Einifi (Greensboro, NC).
- Commercially available sources of nylon-6 include BASF (Ludwigshafen,
- each fiber or a plurality of fibers in a major amount (i.e., in an amount of greater than 50 wt-%).
- each fiber or a plurality of fibers includes at least 90 percent by weight (wt-%), at least 95 wt- %, at least 97 wt-%, or at least 98 wt-%, of the base polymer, based on the total weight of the fiber (or plurality of fibers).
- each fiber (or a plurality of fibers) includes up to 99.9 wt-%, up to 99.5 wt-%, up to 99.0 wt-%, or up to 98.5 wt-% of the base polymer, based on the total weight of the fiber (or plurality of fibers).
- Surfactant includes up to 99.9 wt-%, up to 99.5 wt-%, up to 99.0 wt-%, or up to 98.5 wt-% of the base polymer, based on the total weight of the fiber (or plurality of fibers).
- alkylene oxide-containing nonionic surfactant that has a hydrophile lipophile balance (HLB) of at least 10.
- HLB hydrophile lipophile balance
- the alkylene oxide-containing nonionic surfactant has an HLB of at least 11, at least 12, at least 13, at least 14, or at least 15.
- the alkylene oxide-containing nonionic surfactant has an HLB of up to 20.
- the HLB Hydrophilic-Lipophilic Balance
- M is the molecular mass of the entire molecule.
- the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C. In certain embodiments, the alkylene oxide-containing nonionic surfactant has a melting point of at least 30°C, or at least 40°C, or at least 50°C. In certain embodiments, the alkylene oxide-containing nonionic surfactant has a decomposition temperature of at least 250°C, which is the temperature at which 5% of the weight of the surfactant is lost. There is no upper limit for the decomposition temperature.
- the alkylene oxide-containing nonionic surfactant has an average molecular weight of at least 900 grams/mole, at least 1000 grams/mole, or at least 4000 grams/mole. In certain embodiments, the alkylene oxide-containing nonionic surfactant has an average molecular weight of up to 5000 grams/mole.
- the alkylene oxide-containing nonionic surfactant includes an ethylene oxide-containing nonionic surfactant, an ethylene oxide/propylene oxide- containing nonionic surfactant, or a combination thereof. In certain embodiments, the alkylene oxide-containing nonionic surfactant does not include propylene oxide moieties.
- the alkylene oxide-containing nonionic surfactant includes an ethylene oxide-containing nonionic surfactant.
- the ethylene oxide-containing nonionic surfactant has the following Formula (I):
- R 1 (Cl2-C72)alkyl (preferably, a linear or branched alkyl);
- each r is independently 0 or 1 (preferably, 0);
- R 2 H or a (Cl-ClO)alkyl.
- the alkylene oxide-containing nonionic surfactant includes an ethylene oxide/propylene oxide-containing nonionic surfactant.
- the ethylene oxide/propylene oxide-containing nonionic surfactant has the following Formula (II) or (III):
- each R 3 is independently H or a (Cl-C72)alkyl (preferably, a linear or branched alkyl);
- each r is independently 0 or 1 (preferably, 0);
- each n2 is independently 10- 100;
- each m is independently 5-65.
- the alkylene oxide-containing nonionic surfactant includes an ethylene oxide-containing amine nonionic surfactant having the following Formula (IV):
- R 4 (C8-C22)alkyl (preferably, a linear or branched alkyl);
- R 5 H or a (Cl-72)alkyl.
- a mixture of alkylene oxide-containing nonionic surfactants can be used if desired.
- each fiber (or plurality of fibers) includes at least 0.1 wt- %, at least 0.5 wt-%, at least 1.0 wt-%, or at least 1.5 wt-%, of the alkylene oxide- containing nonionic surfactant, based on the total weight of the fiber (or plurality of fibers). In certain embodiments, each fiber (or plurality of fibers) includes up to 5.0 wt-% (or up to 2.0 wt-%) of the alkylene oxide-containing nonionic surfactant, based on the total weight of the fiber (or plurality of fibers).
- the fibers further include talc mixed within the bulk of each fiber.
- each fiber (or plurality of fibers) includes at least 0.5 wt-% talc, based on the total weight of the fiber (or plurality of fibers).
- each fiber (or plurality of fibers) includes up to 3.0 wt-% talc, based on the total weight of the fiber (or plurality of fibers).
- the fibers further include one or more additives such as antioxidants (e.g., hindered light amine stabilizers, etc.), flame retardants, UV stabilizers, colorants (e.g., pigments or dyes), softeners, antimicrobial agents, antistatic agents, optical brighteners, and combinations thereof.
- antioxidants e.g., hindered light amine stabilizers, etc.
- flame retardants e.g., UV stabilizers
- colorants e.g., pigments or dyes
- softeners e.g., antimicrobial agents, antistatic agents, optical brighteners, and combinations thereof.
- Such optional additives are mixed within the bulk of each fiber. These optional additives could also be applied to the surface of the fibers and/or fabric.
- any fiber, or plurality of fibers the sum of all components equals 100 % by weight.
- the fibers of the present disclosure can be made using a variety of techniques.
- a plurality of such fibers may be used to make yarns or threads.
- Such fibers, yarns, and/or threads may be incorporated into a fabric (e.g., textile or cloth), which may be formed by knitting, weaving, crocheting, knotting, or pressing (e.g., felt).
- a plurality of the fibers may be bonded together in at least point locations. Typical fabrics are knitted, woven, or non woven webs.
- Fiber forming methods typically include melt extrusion.
- melt extrusion In accordance with known technology, such as continuous filament spinning for yam or fibers, and nonwoven processes such as spunbond production and meltblown production, the fibers are formed by extrusion of the molten polymer through small orifices. In general, the fibers thus formed are then drawn or elongated to induce molecular orientation and affect
- the fibers are directly deposited onto a foraminous surface, such as a moving flat conveyor and are at least partially consolidated by any of a variety of bonding means.
- Preferred fiber forming methods include melt spinning. Exemplary melt spinning techniques are described in the Handbook of Fiber Chemistry, Second Edition, M. Lewin and
- Nonwoven fabrics of the present disclosure may have a carded fiber structure or comprise a mat in which the fibers are distributed in a random array.
- the fabric may be formed and bonded by any one of numerous known processes including
- hydroentanglement or spun-lace techniques or by air-laying or melt-blowing fibers, batt drawing, stitchbonding, etc., depending upon the end use of the article to be made from the fabric.
- such methods involve melt mixing (i.e., melt blending) with extrusion temperatures for preparation of the fibers in a range of 285°C to 300°C.
- the method involves: providing a base polymer that includes an aromatic polyester or nylon-6; providing an alkylene oxide-containing nonionic surfactant, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10; melt mixing the alkylene oxide- containing nonionic surfactant with the base polymer; and forming a plurality of fibers, each of which includes the alkylene oxide-containing nonionic surfactant mixed within the base polymer.
- the fibers of the present disclosure may be continuous or staple fibers.
- a plurality of fibers of the present disclosure may be formed into a web (nonwoven or woven), a yarn, or other articles that include a plurality of fibers.
- Such articles may be in the form of fabrics suitable for use in making active wear apparel with desirable absorption and moisture wicking performance, as described herein.
- fibers of the present disclosure can be used in methods of differential dyeing, and articles that result therefrom. That is, while differential dyeing techniques of fibers (e.g., as used to dye carpets) conventionally use different polymers in the fibers of the various regions of a fibrous substrate, fibers of the present disclosure allow for the use of the same base polymer in the fibers of the various regions of a fibrous substrate mixed with different amounts (including no alkylene oxide- containing nonionic surfactant) and/or different types of alkylene oxide-containing nonionic surfactants.
- differential dyeing techniques of fibers e.g., as used to dye carpets
- fibers of the present disclosure allow for the use of the same base polymer in the fibers of the various regions of a fibrous substrate mixed with different amounts (including no alkylene oxide- containing nonionic surfactant) and/or different types of alkylene oxide-containing nonionic surfactants.
- a method of differentially dyeing a fibrous substrate includes: providing a fibrous substrate including: a first portion of fibers including: a base polymer including an aromatic polyester or nylon-6; and an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10; and a second portion of fibers including: a base polymer that is the same as in the first portion; and optionally an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the amount and/or type of the alkylene oxide-containing nonionic surfactant is different than that in the first portion. In this second portion, there may be no alkylene oxide-containing nonionic surfactant.
- the method of differential dyeing further includes applying the same type and amount of dye under the same conditions to the first and second portions of the fibrous substrate, wherein the first and second portions of the fibrous substrate differentially absorb the dye.
- a fibrous substrate can include numerous portions of fibers with differing types and/or amounts of alkylene oxide-containing nonionic surfactants (including no such surfactant).
- the present disclosure also provides an article that includes a plurality of fibers as described herein, wherein a first portion (of any desired number of portions, e.g., two, three, four, etc.) of the plurality of fibers includes: an aromatic polyester or nylon-6; and an alkylene oxide-containing nonionic surfactant mixed within the aromatic polyester or nylon-6; wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10; and a dye; wherein the dye is present in a greater amount in the first portion of the fibers than in other portions of the fibers of the article.
- the fibers can be formed in a variety of lengths and widths. They may also be referred to as filaments. They typically have a circular cross-section, but may also have a non-circular cross-section, such as multilobal (e.g., trilobal or pentalobal), hexagonal, or irregular shape. Such fibers may be continuous or staple fibers.
- an individual fiber has a fiber size of at least 1 Denier (D), or at least 5 D. In certain embodiments, an individual fiber has a fiber size of up to 100 D, up to 65 D, up to 50 D, or up to 30 D.
- D Denier
- an individual fiber has a median fiber diameter or an effective fiber diameter of at least 5 microns (i.e., micrometers), at least 10 microns, or at least 20 microns. In certain embodiments, an individual fiber has a median fiber diameter of up to 125 microns, up to 100 microns, up to 80 microns, or up to 70 microns. The values of the median and effective fiber diameters are often within ⁇ 25%.
- the term“median fiber diameter” means fiber diameter determined by producing one or more images of the fiber structure, such as by using a scanning electron
- x is greater than 20, more preferably greater than 50, and desirably ranges from 50 to 200.
- the term“effective fiber diameter” or“EFD” is the apparent diameter of the fibers in a fiber web based on an air permeation test in which air at 1 atmosphere and room temperature is passed through a web sample at a specified thickness and face velocity (typically 5.3 cm/sec), and the corresponding pressure drop is measured. Based on the measured pressure drop, the Effective Fiber Diameter is calculated as set forth in C.N. Davies, The Separation of Airborne Dust and Particulates, Institution of Mechanical Engineers , London Proceedings, IB (1952).
- Embodiment l is a fiber comprising: a base polymer comprising an aromatic polyester or nylon-6; and an alkylene oxide-containing nonionic surfactant mixed within the base polymer; wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10.
- Embodiment 2 is the fiber of embodiment 1 wherein the alkylene oxide-containing nonionic surfactant has a melting point of at least 30°C (or at least 40°C, or at least 50°C).
- Embodiment 3 is the fiber of embodiment 1 or 2 wherein the alkylene oxide- containing nonionic surfactant has an average molecular weight of at least 900 grams/mole (or at least 1000 grams/mole, or at least 4000 grams/mole).
- Embodiment 4 is the fiber of any one of the previous embodiments wherein the alkylene oxide-containing nonionic surfactant has an average molecular weight of up to 5000 grams/mole.
- Embodiment 5 is the fiber of any one of the previous embodiments wherein the alkylene oxide-containing nonionic surfactant has a decomposition temperature of at least 250°C (temperature at which 5% weight loss occurs).
- Embodiment 6 is the fiber of any one of the previous embodiments wherein the alkylene oxide-containing nonionic surfactant has an HLB of at least 11 (at least 12, at least 13, at least 14, or at least 15).
- Embodiment 7 is the fiber of any one of the previous embodiments wherein the alkylene oxide-containing nonionic surfactant has an HLB of up to 20.
- Embodiment 8 is the fiber of any one of the previous embodiments wherein the alkylene oxide-containing nonionic surfactant comprises an ethylene oxide-containing nonionic surfactant, an ethylene oxide/propylene oxide-containing nonionic surfactant, or a combination thereof.
- Embodiment 9 is the fiber of embodiment 8 wherein the alkylene oxide-containing nonionic surfactant comprises an ethylene oxide-containing nonionic surfactant.
- Embodiment 10 is the fiber of any one of the previous embodiments wherein the alkylene oxide-containing nonionic surfactant does not include propylene oxide moieties.
- Embodiment 11 is the fiber of any one of embodiments 8 through 10 wherein the alkylene oxide-containing nonionic surfactant is an ethylene oxide-containing nonionic surfactant having the following Formula (I):
- R 1 (Cl2-C72)alkyl (preferably, a linear or branched alkyl);
- each r is independently 0 or 1 (preferably, 0);
- R 2 H or a (Cl-ClO)alkyl.
- Embodiment 12 is the fiber of embodiment 8 wherein the alkylene oxide- containing nonionic surfactant is an ethylene oxide/propylene oxide-containing nonionic surfactant having the following Formula (II) or (III):
- each R 3 is independently H or a (Cl-C72)alkyl (preferably, a linear or branched alkyl);
- each r is independently 0 or 1 (preferably, 0);
- each n2 is independently 10- 100;
- Embodiment 13 is the fiber of embodiment 8 wherein the alkylene oxide- containing nonionic surfactant includes an ethylene oxide-containing amine nonionic surfactant having the following Formula (IV):
- R 4 (C8-C22)alkyl (preferably, a linear or branched alkyl);
- nl 3-100
- R 5 H or a (Cl-C72)alkyl.
- Embodiment 14 is the fiber of any one of the previous embodiments comprising at least 0.1 wt-% (or at least 0.5 wt-%, or at least 1.0 wt-%, or at least 1.5 wt-%) of the alkylene oxide-containing nonionic surfactant, based on the total weight of the fiber.
- Embodiment 15 is the fiber of any one of the previous embodiments comprising up to 5.0 wt-% (or up to 2.0 wt-%) of the alkylene oxide-containing nonionic surfactant, based on the total weight of the fiber.
- Embodiment 16 is the fiber of any one of the previous embodiments further comprising talc.
- Embodiment 17 is the fiber of embodiment 16 comprising at least 0.5 wt-% talc, based on the total weight of the fiber.
- Embodiment 18 is the fiber of embodiment 16 or 17 comprising up to 3.0 wt-% talc, based on the total weight of the fiber.
- Embodiment 19 is the fiber of any of the previous embodiments further comprising one or more antioxidants, flame retardants, ETV stabilizers, colorants, softeners, antimicrobial agents, antistatic agents, optical brighteners, or combinations thereof.
- Embodiment 20 is the fiber of any one of the previous embodiments wherein a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test of the Examples Section.
- Embodiment 21 is the fiber embodiment 20 wherein a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test to a distance of at least 5 cm (or at least 6 cm, or at least 7 cm, or at least 8 cm, or at least 9 cm, or at least 10 cm).
- Embodiment 22 is the fiber of any one of the previous embodiments wherein a meltblown web of a plurality of the fibers demonstrates absorption of a water drop within 5 minutes (or within 1 minute, or within 30 seconds, or within 10 seconds, or
- Embodiment 23 is the fiber of any one of the previous embodiments having a median fiber diameter or an effective fiber diameter of at least 5 microns (or at least 10 microns, or at least 20 microns).
- Embodiment 24 is the fiber of any one of the previous embodiments having a median fiber diameter or an effective fiber diameter of up to 125 microns (up to 100 microns, up to 80 microns, or up to 70 microns).
- Embodiment 25 is the fiber of any one of the previous embodiments having a fiber size of at least 1 Denier (or at least 5 D).
- Embodiment 26 is the fiber of any one of the previous embodiments having a fiber size of up to 100 Denier (up to 65 D, up to 50 D, or up to 30 D).
- Embodiment 27 is the fiber of any one of the previous embodiments which is a continuous or staple fiber.
- Embodiment 28 is the fiber of any of the previous embodiments wherein the base polymer comprises an aromatic polyester selected from polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), and mixtures thereof.
- PET polyethylene terephthalate
- PTT polytrimethylene terephthalate
- Embodiment 29 is a plurality of fibers of any one of the previous embodiments.
- Embodiment 30 is the plurality of fibers of embodiment 29 which is in the form of a yam.
- Embodiment 31 is the plurality of fibers of embodiment 29 which is in the form of a web.
- Embodiment 32 is an article comprising a plurality of fibers of any one of embodiments 1 through 28, wherein a first portion of the plurality of fibers comprises: a base polymer comprising an aromatic polyester or nylon-6; an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10; and a dye; wherein the dye is present in a greater amount in the first portion of the fibers than in other portions of the fibers of the article.
- Embodiment 33 is a method of making fibers of any one of embodiments 1 through 28, the method comprising: providing a base polymer comprising an aromatic polyester or nylon-6; providing an alkylene oxide-containing nonionic surfactant, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10; melt mixing the alkylene oxide-containing nonionic surfactant with the base polymer; and forming a plurality of fibers, each of which comprises the alkylene oxide-containing nonionic surfactant mixed within the base polymer.
- Embodiment 34 is the method of embodiment 33 wherein a meltblown web of a plurality of the fibers demonstrates absorption of a water drop within 5 minutes (or within 1 minute, or within 30 seconds, or within 10 seconds, or instantaneously) according to the Water Drop Test of the Examples Section.
- Embodiment 35 is the method of embodiment 33 or 34 wherein a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test of the Examples Section.
- Embodiment 36 is the method of embodiment 35 wherein a meltblown web of a plurality of the fibers wicks an 80/20 water/isopropanol mixture according to the Vertical Wicking Test to a distance of at least 5 cm (or at least 6 cm, or at least 7 cm, or at least 8 cm, or at least 9 cm, or at least 10 cm).
- Embodiment 37 is a method of differentially dyeing a fibrous substrate, the method comprising: providing a fibrous substrate comprising: a first portion of fibers comprising: a base polymer comprising an aromatic polyester or nylon-6; and an alkylene oxide- containing nonionic surfactant mixed within the base polymer, wherein the alkylene oxide-containing nonionic surfactant has a melting point of greater than 25°C and an HLB of greater than 10; and a second portion of fibers comprising: a base polymer comprising an aromatic polyester or nylon-6 that is the same as in the first portion; and optionally an alkylene oxide-containing nonionic surfactant mixed within the base polymer, wherein the amount (including no alkylene oxide-containing nonionic surfactant) and/or type of the alkylene oxide-containing nonionic surfactant is different than that in the first portion.
- the method further includes applying the same type and amount of dye under the same conditions to the first and second portions of the fibrous substrate; wherein the first and second portions of the fibrous substrate differentially absorb the dye.
- Embodiment 38 is the method of embodiment 37 wherein the alkylene oxide- containing nonionic surfactant has a melting point of at least 30°C (or at least 40°C, or at least 50°C).
- Embodiment 39 is the method of embodiment 37 or 38 wherein the alkylene oxide- containing nonionic surfactant has an average molecular weight of at least 900 grams/mole (or at least 1000 grams/mole, or at least 4000 grams/mole).
- Embodiment 40 is the method of any one of embodiments 37 through 39 wherein the alkylene oxide-containing nonionic surfactant has an average molecular weight of up to 5000 grams/mole.
- Embodiment 41 is the method of any one of embodiments 37 through 40 wherein the alkylene oxide-containing nonionic surfactant has a decomposition temperature of at least 250°C (temperature at which 5% weight loss occurs).
- Embodiment 42 is the method of any one of embodiments 37 through 41 wherein the alkylene oxide-containing nonionic surfactant has an HLB of at least 11 (at least 12, at least 13, at least 14, or at least 15).
- Embodiment 43 is the method of any one of embodiments 37 through 42 wherein the alkylene oxide-containing nonionic surfactant has an HLB of up to 20.
- Embodiment 44 is the method of any one of embodiments 37 through 43 wherein the alkylene oxide-containing nonionic surfactant comprises an ethylene oxide-containing nonionic surfactant, an ethylene oxide/propylene oxide-containing nonionic surfactant, or a combination thereof.
- Embodiment 45 is the method of embodiment 44 wherein the alkylene oxide- containing nonionic surfactant comprises an ethylene oxide-containing nonionic surfactant.
- Embodiment 46 is the method of any one of embodiments 37 through 45 wherein the alkylene oxide-containing nonionic surfactant does not include propylene oxide moieties.
- Embodiment 47 is the method of any one of embodiments 44 through 46 wherein the alkylene oxide-containing nonionic surfactant has the following Formula (I):
- R 1 (Cl2-C72)alkyl (preferably, a linear or branched alkyl);
- EO Ethylene Oxide;
- each r is independently 0 or 1 (preferably, 0);
- R 2 H or a (Cl-ClO)alkyl.
- Embodiment 48 is the method of embodiment 44 wherein the alkylene oxide- containing nonionic surfactant is an ethylene oxide/propylene oxide-containing nonionic surfactant having the following Formula (II) or (III):
- each R 3 is independently H or a (Cl-C72)alkyl (preferably, a linear or branched alkyl);
- each n2 is independently 10- 100;
- each r is independently 0 or 1 (preferably, 0);
- each m is independently 5-65.
- Embodiment 49 is the method of embodiment 44 wherein the alkylene oxide- containing nonionic surfactant includes an ethylene oxide-containing amine nonionic surfactant having the following Formula (IV):
- R 4 (C8-C22)alkyl (preferably, a linear or branched alkyl);
- nl 3-100
- R 5 H or a (Cl-C72)alkyl.
- Embodiment 50 is the method of any one of embodiments 37 through 49 wherein the fibers comprise at least 0.1 wt-% (or at least 0.5 wt-%, or at least 1.0 wt-%, or at least 1.5 wt-%) of the alkylene oxide-containing nonionic surfactant, based on the total weight of the fiber.
- Embodiment 51 is the method of any one of embodiments 37 through 50 wherein the fibers comprise up to 5.0 wt-% (or up to 2.0 wt-%) of the alkylene oxide-containing nonionic surfactant, based on the total weight of the fiber.
- Embodiment 52 is the method of any one of embodiments 37 through 51 wherein the fibers further comprise talc.
- Embodiment 53 is the method of embodiment 52 wherein the fibers comprise at least 0.5 wt-% talc, based on the total weight of the fiber.
- Embodiment 54 is the method of embodiment 52 or 53 wherein the fibers comprise up to 3.0 wt-% talc, based on the total weight of the fiber.
- Embodiment 55 is the method of any one of embodiments 37 through 54 wherein the fibers have a median fiber diameter or an effective fiber diameter of at least 5 microns (or at least 10 microns, or at least 20 microns).
- Embodiment 56 is the method of any one of embodiments 37 through 55 wherein the fibers have a median fiber diameter or an effective fiber diameter of up to 125 microns (up to 100 microns, up to 80 microns, or up to 70 microns).
- Embodiment 57 is the method of any one of embodiments 37 through 56 wherein the fibers have a fiber size of at least 1 Denier (or at least 5 D).
- Embodiment 58 is the method of any one of embodiments 37 through 57 wherein the fibers have a fiber size of up to 100 Denier (up to 65 D, up to 50 D, or up to 30 D).
- Embodiment 59 is the method of any one of embodiments 37 through 58 wherein the fibers are continuous or staple fibers.
- Embodiment 60 is the method of any one of embodiments 37 through 59 wherein the base polymer of the fibers comprise an aromatic polyester selected from polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), and mixtures thereof.
- PET polyethylene terephthalate
- PTT polytrimethylene terephthalate
- Embodiment 61 is the method of any one of embodiments 37 through 60 wherein the base polymer of the fibers comprise nylon-6.
- This test measures the ability of a fabric to take up water. Prior to testing, the fabric samples were conditioned for 24 hours in a standard atmosphere having a relative humidity of 65% ⁇ 2% at 2l°C ⁇ l°C (70°F ⁇ 2°F). Testing was performed under the same conditions. The fabric sample was placed in an embroidery hoop or similar device to suspend the fabric. Care was taken to make sure that the fabric was free of wrinkles or creases but without stretching or distorting the fabric.
- a burette or a medicine dropper was used to dispense one drop of distilled or deionized water (41 ⁇ 3°C (105 ⁇ 5°F)) onto the surface of the fabric from a distance of 10 millimeters (mm) below the tip of the burette or medicine dropper.
- a stopwatch was used to measure the time that it takes for the water drop to completely disappear (i.e., until the water drop absorbs completely). This was indicated by a loss of light reflectivity of the water drop (i.e., when it changes to a dull wet spot due the absorbent propensity of the fabric). Absorption time was monitored for 30 minutes (rather than 60 seconds as in AATCC Test Method 79-2014).
- the reported values are an average of three tests. Shorter times indicate better absorbency. A value of“zero” in this test indicates that the water drop disappears immediately.
- This test evaluates the ability of a fabric to transport liquid and is applicable to woven, knitted, or nonwoven fabrics.
- the rate (distance per unit of time) liquid travels along and/or through a vertical fabric sample was visually observed, manually timed and recorded at specified intervals.
- Vertical wicking was tested using AATCC Test Method 197-2013,“Vertical Wicking of Textiles,” Option B, with the following modifications.
- Fabric samples were heat treated at l60°C for 2 minutes. Fabric samples were cut such that the long dimension of the fabric sample was parallel to the down-web (machine) direction of the fabric.
- the liquid used for testing was 80/20 deionized water/isopropyl alcohol having a surface tension of 32 dyne/cm.
- a small binder clip was attached to the end of the fabric sample that was submerged in the test liquid to prevent the sample from floating in the liquid. The distance that the liquid wicked after 5.0 ⁇ 0.1 minutes and 30.0 ⁇ 0.1 minutes was recorded. The reported values are an average of three tests.
- a color difference value, DE was calculated using the following equation:
- EFD is the apparent diameter of the fibers in a fiber web based on an air permeation test in which air at 1 atmosphere and room temperature is passed through a web sample at a specified thickness and face velocity (typically 5.3 cm/sec), and the corresponding pressure drop is measured. Based on the measured pressure drop, the Effective Fiber Diameter is calculated as set forth in C.N. Davies, The Separation of Airborne Dust and Particulates, Institution of Mechanical Engineers , London
- melt blown nonwoven fabrics were prepared from polyester or nylon-6 base polymer resins extruded with different types and concentrations of surfactant additives.
- melt blown nonwoven fabrics were prepared from polypropylene polymer resin extruded with different types and concentrations of surfactant additives.
- Melt blown nonwoven fabrics were prepared without any surfactant additives as control samples.
- melt blown nonwoven fabric examples were extruded on an experimental melt blown line, as taught, for example, in van Wente,“Superfine Thermoplastic Fibers,” Industrial Engineering Chemistry, Vol. 48, pages 1342 et sec (1956), or in Report No.
- the surfactant additive and base polymer were weighed individually and mixed in a 5-gallon pail for one minute using a mixer head affixed to a basic hand drill until a visually homogeneous mixture was obtained (when the base polymer used was PET, the polymer resin was dried overnight in an oven at 255° (l24°C) and mixed with the surfactant additive while the polymer resin was still hot). This mixture was then added to the extruder hopper.
- the surfactant additive was added as a side stream partway up the extruder using a heated syringe pump.
- Knit fabric was prepared from drawn texturized yarn (DTY) made from fiber grade polyethylene terephthalate (PET) or polytrimethylene terephthalate (PTT) base resin with different concentrations of surfactant additives.
- the surfactant additive was compounded into a masterbatch prior to being used to make DTY. Knit fabric was also prepared without any surfactant additives as control samples.
- the surfactant additive was compounded into a 20% weight surfactant, 80% weight polyester masterbatch. This was carried out using a fully intermeshing co-rotating twin screw extruder having conveying and kneading sections with three temperature zones that was fitted with a standard pelletizing die. Fiber grade PET or PTT resin flakes were added at the neck of the extruder and solid surfactant was added as a side-stream in temperature zone 1. The strands were run through a water bath and into a pelletizing puller, drained and dried as is known in the art.
- Neat fiber grade PET or PTT resin was combined with the additive masterbatch at letdown ratios resulting in 1.0%, 1.5%, and 2.0% surfactant additive in the final fiber.
- the mixed resins were fed into a single screw extruder containing a feed zone, compression (plasticizing) zone; and a metering (pumping) zone leading to a multi-orifice spinneret.
- Each sample of DTY was knit into a sleeve.
- the gauge of the knitted fabric was 7 stitches per inch and the basis weight of the fabric was 180-190 grams/meter 2 .
- the knit fabric Prior to heat-setting, the knit fabric was scoured in a solution of 1.5 g/L sodium carbonate and 1.0 g/L HOSTAPAL DTC surfactant for 30 minutes at 70°C followed by a rinse in room temperature water.
- the knitted fabric compositions are provided in Table 3.
- the absorbency of the melt blown nonwoven and knit fabric examples was tested according to the Water Absorbency test method described above.
- Heat setting for example, at 1 l0°C to 200°C for 1 to 20 minutes
- fabric samples may in some cases improve the effectiveness of the surfactant additive in imparting hydrophilicity, particularly for PET and PTT.
- Absorption times before and after heat setting are provided in Table 4.
- the test data shows that the melt blown nonwoven fabric samples that were prepared from PET and Nylon-6 fibers having a polyethylene alkylene-oxide type nonionic surfactant additive gave improved water absorbency and vertical wicking compared to the fabric samples prepared from PET and Nylon-6 fibers without any surfactant additive. No improvement in water absorbency was observed for the melt blown nonwoven fabric samples that were prepared from polypropylene fibers having a polyethylene alkylene-oxide type nonionic surfactant additive compared to the
- polypropylene fabric samples that were prepared without any surfactant additive. Since no absorption was observed, the polypropylene melt blown nonwoven fabric samples were not tested for vertical wicking.
- fibers of a nonwoven fabric prepared using a melt blown procedure will not have as much directionality (alignment of the fibers in the downweb direction versus the crossweb direction) compared to fabrics prepared by other methods such as, for example, knitted or woven fabrics. Fabrics having more fiber directionality would be expected to have higher vertical wicking values.
- the PET melt blown fabric samples were also dyed and tested for dye differential properties according to the Dye Differential test method described above.
- the dyed melt blown fabric samples having the surfactant additive visually appeared darker than the control melt blown fabric samples without any surfactant additive.
- Color difference values, DE are provided in Table 6.
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201762599415P | 2017-12-15 | 2017-12-15 | |
PCT/IB2018/059585 WO2019116155A1 (en) | 2017-12-15 | 2018-12-03 | Fibers including an alkylene oxide-containing nonionic surfactant, articles, and methods |
Publications (1)
Publication Number | Publication Date |
---|---|
EP3724380A1 true EP3724380A1 (en) | 2020-10-21 |
Family
ID=64902155
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP18829490.4A Withdrawn EP3724380A1 (en) | 2017-12-15 | 2018-12-03 | Fibers including an alkylene oxide-containing nonionic surfactant, articles, and methods |
Country Status (4)
Country | Link |
---|---|
US (1) | US20210189601A1 (en) |
EP (1) | EP3724380A1 (en) |
CN (1) | CN111465724A (en) |
WO (1) | WO2019116155A1 (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN113802376B (en) * | 2021-10-20 | 2023-10-24 | 广东宏昊化工有限公司 | Cotton feeling agent for chemical fiber fabric and preparation method thereof |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA986673A (en) * | 1970-07-29 | 1976-04-06 | Toray Industries, Inc. | Polyamide fiber having improved silky feel and lustre |
JPS4930684A (en) * | 1972-07-20 | 1974-03-19 | ||
DE69131915T2 (en) * | 1990-03-05 | 2000-06-29 | Kuraray Co., Ltd | Polyester fibers with permanent water absorption |
JP2870711B2 (en) * | 1990-04-26 | 1999-03-17 | 株式会社クラレ | Heat-fusible conjugate fiber with durable hydrophilicity |
JP2911068B2 (en) * | 1990-07-27 | 1999-06-23 | 株式会社クラレ | Composite fibers and nonwovens |
EP2513365A4 (en) * | 2009-12-17 | 2013-09-18 | 3M Innovative Properties Co | Dimensionally stable nonwoven fibrous webs, melt blown fine fibers, and methods of making and using the same |
JP6095798B2 (en) * | 2013-11-25 | 2017-03-15 | 旭化成株式会社 | Water absorbent fabric |
-
2018
- 2018-12-03 CN CN201880080676.2A patent/CN111465724A/en active Pending
- 2018-12-03 US US16/771,085 patent/US20210189601A1/en not_active Abandoned
- 2018-12-03 WO PCT/IB2018/059585 patent/WO2019116155A1/en unknown
- 2018-12-03 EP EP18829490.4A patent/EP3724380A1/en not_active Withdrawn
Also Published As
Publication number | Publication date |
---|---|
US20210189601A1 (en) | 2021-06-24 |
WO2019116155A1 (en) | 2019-06-20 |
CN111465724A (en) | 2020-07-28 |
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