EP4050136A1 - Pbt-kraftfahrzeuggarn und verfahren zu dessen herstellung - Google Patents

Pbt-kraftfahrzeuggarn und verfahren zu dessen herstellung Download PDF

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Publication number
EP4050136A1
EP4050136A1 EP21167182.1A EP21167182A EP4050136A1 EP 4050136 A1 EP4050136 A1 EP 4050136A1 EP 21167182 A EP21167182 A EP 21167182A EP 4050136 A1 EP4050136 A1 EP 4050136A1
Authority
EP
European Patent Office
Prior art keywords
filaments
yarn
pbt
continuous filament
range
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Withdrawn
Application number
EP21167182.1A
Other languages
English (en)
French (fr)
Inventor
Abhishek Rajesh Mandawewala
Khushboo Abhishek Mandawewala
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aym Syntex Ltd
Original Assignee
Aym Syntex Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aym Syntex Ltd filed Critical Aym Syntex Ltd
Publication of EP4050136A1 publication Critical patent/EP4050136A1/de
Withdrawn legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—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
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/24—Bulked yarns or threads, e.g. formed from staple fibre components with different relaxation characteristics
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/08—Melt spinning methods
    • D01D5/088—Cooling filaments, threads or the like, leaving the spinnerettes
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/12—Stretch-spinning methods
    • D01D5/16—Stretch-spinning methods using rollers, or like mechanical devices, e.g. snubbing pins
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/32—Elastic yarns or threads ; Production of plied or cored yarns, one of which is elastic
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/445—Yarns or threads for use in floor fabrics
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/446—Yarns or threads for use in automotive applications
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/01—Surface features

Definitions

  • the present disclosure generally relates to an improved multi-component yarns and methods of manufacturing the aforementioned improved multi-component yarns. Specifically, the present disclosure relates to multi-component yarns made from Polybutylene terephthalate (PBT) having good physical and aesthetic properties along with improved stain resistance, strength and hexapod rating, suitable for automotive tuft and mat application, and methods of manufacturing thereof.
  • PBT Polybutylene terephthalate
  • BCF yarns have many applications in the daily day to day life.
  • Bulk Continuous Filament (BCF) yarns are used for making carpets for various applications such as floor coverings, automobile carpets etc.
  • the Bulk Continuous Filament (BCF) yarns used for the automobile carpets must have some properties such as higher resiliency, smooth touch and feel with high shine. Further, the rugged use of carpets also requires the yarn to be strong and stain resistant.
  • tufted or woven carpets for the automobiles requires high-temperature and high-pressure withstanding capabilities for moulding.
  • nylon yarn is used for making automobile carpets as it exhibits all the required properties.
  • the nylon yarn carpets are costly as the raw material i.e., nylon, is a high-cost material.
  • the nylon yarn carpets get stained easily and it's tough to remove stains from the nylon yarn, thus making it difficult to use in light or medium colours.
  • the life of the carpet is reduced.
  • yarns from other polymers such as polypropylene, polyethylene terephthalate have been used for the purpose of making automobile carpets.
  • the yarns from such polymers lack properties such as, resiliency, smooth silky touch, shiny look, premium feel.
  • the yarns made from such polymers are not suitable for the application of making automobile carpets.
  • the carpets made from such yarn lacks high-temperature and high-pressure withstanding capabilities for moulding
  • the object of the present disclosure is to provide a high resilience and stain resistant bulked continuous filament yarn that overcomes at least partially the problems encountered in the prior art.
  • an embodiment of the present disclosure provides a high resilience and stain resistant bulked continuous filament yarn, the yarn comprising a plurality of continuous filaments of polybutylene terephthalate (PBT), wherein the polybutylene terephthalate (PBT) has intrinsic viscosity in the range of 0.8 to 1.3, wherein the yarn is obtained by a process comprising:
  • the present disclosure is advantageous in terms of providing a high resilience and stain resistant bulked continuous filament yarn having higher resiliency, high-temperature and high-pressure withstanding capabilities.
  • the drawing of the quenched filaments is performed at a draw ratio (DR) in a range of 2 - 4.5.
  • DR draw ratio
  • the texturizing of the drawn filaments is performed at a temperature in a range of 200°C - 280°C and at an air pressure in a range of 5 - 9 bar.
  • Embodiments of the present disclosure substantially eliminate or at least partially address the aforementioned problems in the prior art, and discloses a high resilience and stain resistant bulked continuous filament yarn having higher resiliency, high-temperature and high-pressure withstanding capabilities.
  • the present disclosure provides a high resilience and stain resistant bulked continuous filament yarn.
  • the yarn comprises a plurality of continuous filaments of polybutylene terephthalate (PBT), wherein the polybutylene terephthalate (PBT) has intrinsic viscosity in the range of 0.8 to 1.3.
  • the present disclosure is advantageous in terms of providing a high resilience and stain resistant bulked continuous filament yarn having higher resiliency, high-temperature and high-pressure withstanding capabilities.
  • the bulked continuous filament yarn of the present invention may have high resiliency compared to yarn of other polymers.
  • the bulked continuous filament yarn of the present invention exhibits superior and smooth feel.
  • the bulked continuous filament yarn of the present invention exhibits a shiny look.
  • the bulked continuous filament yarn of the present invention would be stain-resistant compared to yarns obtained from other polymers such as nylon and have a stain resistance rating of more than 3.
  • high resilience and stain resistant bulked continuous filament yarn refers to a yarn made up from a multiple components or materials with property of high bulk, high resilience, and stain resistance.
  • bulked continuous filament yarn is used interchangeably in place of "high resilience and stain resistant bulked continuous filament yarn”.
  • the term "bulk” refers to the property of yarn by virtue of which the yarn exhibits covering power or apparent volume higher than the conventional yarn of equal linear density and same base material with normal twist.
  • continuous filament yarn refers to yarn made up of very long continuous fibres (filaments) either twisted or grouped together.
  • the bulked continuous filament yarn is a multifilament yarn.
  • melt spinning refers to the manufacturing process for creating polymer fibres by extruding the molten polymer using a spinneret.
  • the polymer solidifies in the form of fibres by cooling after being extruded from the spinneret.
  • the term "extrusion” refers to the process of forcing thick, viscous liquid through tiny holes of spinneret to form continuous filaments.
  • the extrusion of the plurality of continuous filaments may be performed at a temperature in a range of 230°C - 300°C.
  • quenching refers to the process of cooling the extruded fibres to make bundles of the spun filaments after their discharge from the spinning machine.
  • the process of quenching may be carried out using fluids such as air, water and so forth.
  • the quenching of the extruded filaments may be performed at a temperature in a range of 2°C - 20°C.
  • the term “drawing” refers to the process of attenuating a loose assemblage of fibres (sliver) by passing the loose assemblage of fibres through a series of rollers to straighten the individual fibres and make the fibres more parallel.
  • each pair of rollers spins faster than the previous pair of rollers.
  • the drawing of the quenched filaments may be performed at a draw ratio (DR) in a range of 2 - 4.5.
  • draw ratio refers to the ratio of output roller to input roller speed. The draw ratio may also be referred as stretch ratio.
  • the term "texturizing” refers to the process of formation of crimp, loops, coils and/or crinkles in the filaments.
  • the crimp, loops, coils and/or crinkles in the filaments changes the physical form of the filaments.
  • the texturizing may affect the behaviour and feel of the yarn.
  • the texturizing of the drawn filaments may be performed at a temperature in a range of 200°C - 280°C.
  • the texturizing of the drawn filaments may be performed at an air pressure in a range of 5 - 9 bar.
  • the texturized filaments are cooled for setting of the imparted properties in the filaments.
  • the term "overfeeding" refers to the condition when input feeding in a textile process is done faster than the rate of running of process.
  • the overfeeding of the cooled-texturized filaments is performed in a range of 10 - 30%.
  • the overfeeding may cause warp yarn to retract, weft density to rise, increase gram weight.
  • winding refers to the process of yarn manufacturing wherein filaments are transferred to form big yarn packages for further processing.
  • the winding step completes the primary yarn manufacturing process.
  • the winding may be random winding.
  • the winding may be precision winding.
  • the winding of the overfeed filaments is done with or without tangling for obtaining the high resilience and stain resistant bulked continuous filament yarn.
  • the term "tangling” refers to the process of interlacing to give the property of cohesion in the synthetic filaments.
  • the tangling of the filaments may be done by running the continuous filaments under a defined tension through an air jet and applying a perpendicular or nearly perpendicular high pressure air stream to the yarn.
  • the air stream creates a turbulence, splitting the yarn bundle and then forcing individual filaments together, which creates a kind of braiding effect on the yarn.
  • cohesion between the filaments is increased by a large magnitude.
  • such yarn can be used without any further twisting in weaving and knitting.
  • Table 1 presented below, illustrates the comparison of properties such as Denier, Filaments, Tenacity, Elongation, Stain Resistance and Hexapod Rating of the yarn between regular products and bulked continuous filament yarn of the present disclosure (mentioned in bold letters).
  • the denier represents a measure for linear mass density of fibers.
  • the filament number represents number of filaments in the subject yarn.
  • the tenacity represents a measure of property of grip between fibres.
  • the tenacity is represented as grams per denier (gpd).
  • the elongation represents a measure of increase in length of the fibre.
  • the elongation is represented as a percentage of the starting length.
  • the stain resistance represents a measure of property to avoid staining of the fibres.
  • the stain resistance is tested using AATCC 175-2008 standard test method on a scale of 1 to 5.
  • the hexapod rating represents the rating achieved by the sample during the Hexapod drum test at 12000 cycles.
  • the Hexapod drum test include a rotating drum used as an instrument to test pile floor coverings. Carpet samples are placed in this rotating drum with a polyurethane studded metal ball to simulate the physical effects of traffic. This accelerated test provides a specific rating of the ability of the carpet to withstand crushing and matting.
  • Table 1 Comparison of properties between regular products and bulked continuous filament yarn of the present disclosure Denier Filaments Tenacity (gpd) Elonga tion Stain Resistance Rating (AATCC 175-2008, scale 1-5) Hexapo d rating after 12000 cycles Comparative PET 1200/120 1200 120 3.8 33% 4 1 Comparative Nylon 6 (PA6) 1200/128 1200 128 3.1 45% 2-3 3 Comparative PP 1200/120 1200 144 2.8 42% 4 1 Claimed bulked continuous filament yarn (PBT) 1200/120 1200 120 3.3 35% 5 2
  • the bulked continuous filament yarn of the present disclosure may be advantageously used over the other products for better properties.
  • the method 100 includes texturizing of the drawn filaments.
  • the method 100 includes cooling of the texturized filaments.
  • the method 100 includes overfeeding of the cooled-texturized filaments.
  • the method 100 includes winding of the overfeed filaments with or without tangling for obtaining the high resilience and stain resistant bulked continuous filament yarn, wherein the obtained high resilience and stain resistant bulked continuous filament yarn has a stain resistance rating of more than 3 and a hexapod rating of 2 or more after 12000 cycles.
  • the extrusion of the plurality of continuous filaments is performed at a temperature in a range of 230°C - 300°C.
  • the quenching of the extruded filaments is performed at a temperature in a range of 2°C - 20°C.
  • the drawing of the quenched filaments is performed at a draw ratio (DR) in a range of 2 - 4.5.
  • DR draw ratio
  • the overfeeding of the cooled-texturized filaments is performed in a range of 10 - 30%.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
EP21167182.1A 2021-02-25 2021-04-07 Pbt-kraftfahrzeuggarn und verfahren zu dessen herstellung Withdrawn EP4050136A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US17/185,473 US20220267933A1 (en) 2021-02-25 2021-02-25 Pbt automotive yarn and method of manufacturing thereof

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EP4050136A1 true EP4050136A1 (de) 2022-08-31

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EP21167182.1A Withdrawn EP4050136A1 (de) 2021-02-25 2021-04-07 Pbt-kraftfahrzeuggarn und verfahren zu dessen herstellung

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4159617A (en) * 1969-11-17 1979-07-03 Fiber Industries, Inc. Resilient polyester fibers
US4877572A (en) * 1988-07-12 1989-10-31 Davy Mckee Aktiengesellschaft Process for the production of PBT carpet yarn
EP0767846A1 (de) * 1994-06-30 1997-04-16 E.I. Du Pont De Nemours And Company Verfahren zur herstellung von endlosbauschgarnen aus polytrimetylen terephthalat, daraus hergestellte filamente und teppiche

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4159617A (en) * 1969-11-17 1979-07-03 Fiber Industries, Inc. Resilient polyester fibers
US4877572A (en) * 1988-07-12 1989-10-31 Davy Mckee Aktiengesellschaft Process for the production of PBT carpet yarn
EP0767846A1 (de) * 1994-06-30 1997-04-16 E.I. Du Pont De Nemours And Company Verfahren zur herstellung von endlosbauschgarnen aus polytrimetylen terephthalat, daraus hergestellte filamente und teppiche

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